7075铝合金强度接近钢铁,被认为是实现以铝代钢的首选材料,在汽车轻量化中发挥的作用越来越大。但是该合金铸造过程极易产生组织与成份不均匀等缺陷,采用普通铸造方法很难成形完好的铸件。本文开展了7075铝合金螺旋电磁搅拌制浆及流变压铸成形工艺研究,实现短流程和低成本。采用数值模拟和试验研究相结合的方法,首先采用Magmasoft软件对7075铝合金汽车连杆铸件的充型和凝固过程进行模拟优化,在此基础上进行了流变压铸试验研究。研究结果表明:(1)现有的计算模型能够很好地反映7075合金在不同压铸参数条件下的充型和凝固过程,压射速度3 m/s、模具温度150℃时可以获得无缺陷的铸件;(2)用优化后的工艺参数进行7075铝合金连杆件流变压铸和普通压铸试验结果对比分析:流变压铸件显微组织细小均匀,平均晶粒尺寸为34μm;普通压铸件显微组织粗大不均匀,平均晶粒尺寸为59μm;与普通压铸件相比,流变压铸件合金元素(Zn、Mg、Cu)的成分偏析小,布氏硬度提高19 HB。 7075 aluminum alloy strength close to the steel, is considered to be the preferred material to achieve aluminum-steel, light-weight in the car to play an increasingly important role. However, the casting process of the alloy is extremely prone to defects such as uneven microstructure and composition. It is very difficult to form a perfect casting by ordinary casting method. In this paper, 7075 aluminum alloy spiral electromagnetic stirring pulping and rheological die-casting process research to achieve a short process and low cost. Using the method of numerical simulation and experimental research, the process of filling and solidification of 7075 aluminum alloy automotive connecting rod casting was simulated and optimized by using Magmasoft software. Based on the simulation, rheological die-casting test was carried out. The results show that: (1) The existing calculation model can well reflect the filling and solidification process of 7075 alloy under different die-casting parameters. The injection speed of 3 m / s and the mold temperature of 150 ℃ can be obtained without defects Casting; (2) With the optimized process parameters of 7075 aluminum alloy connecting rod rheo-die casting and ordinary die-casting test results of comparative analysis: rheo-die casting microstructure is small and uniform, the average grain size of 34μm; The microstructure is coarse and uneven, with an average grain size of 59μm. Compared with ordinary die-castings, the composition of the alloying elements (Zn, Mg and Cu) of the rheo-diecasting parts is small and Brinell hardness is increased by 19 HB.