Journal articles: 'Aluminium casting; Quality'

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Gaspar, Stefan, and Ján Pasko. "Analysis of Fracture Process and Common Defects in Casting Alloys EN43100 Manufactured by Die Casting Technology." Advanced Materials Research 1077 (December 2014): 39–43. http://dx.doi.org/10.4028/www.scientific.net/amr.1077.39.

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Recent research in the process of die casting production of aluminium alloys which are nowadays deeply implemented in the rapidly developing automobile, shipping and airline industry aims to increase the manufacture and quality properties of the casting in order to obtain its high mechanical properties at acceptable economic costs. In terms of ensuring the quality indicators in the production of aluminium castings it is necessary to pay close attention to internal structural quality of the castings characterized by type and extent of foundry defects (cavities, Al2O3 particles, internal cold laps). The presenting contribution deals with the analysis of the fracture process, the microorganism disturbance of test samples, the impact of casting speed on the occurrence and extent of the castings porosity and reasons for the internal foundry defects of casting alloys EN 43100 manufactured by die casting technology.

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Arulra, M., P. K. Palani, and L. Venkatesh. "Optimization of Process Parameters in Stir Casting of Hybrid Metal Matrix (LM25/SiC/B4C) Composite Using Taguchi Method." JOURNAL OF ADVANCES IN CHEMISTRY 13, no. 11 (March 29, 2017): 6038–42. http://dx.doi.org/10.24297/jac.v13i11.5774.

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Aluminium based composites exhibit many attractive material properties such as increased stiffness, wear resistance, specific strength and vibration damping and decreased co-efficient of thermal expansion compared with the conventional aluminium alloys. Aluminium Matrix Composites consist of non-metallic reinforcement which offers advantageous properties over base material. Reinforcements like SiC, B4C and Al2O3 are normally preferred to improve the mechanical properties. Here Aluminum LM25 is selected as matrix material while Silicon carbide and Boron carbide are selected as reinforcement material. The fabrication of aluminium matrix was done by stir casting method. In the present study an attempt has been made to investigate the effect of three major stir casting parameters (stir speed, stir duration and preheated temperature of reinforcement material) on stir casting of Aluminium LM25 - SiC - B4C composite. Experiments were conducted based on Taguchi methodology. Taguchi quality design concepts of L9 orthogonal array has been used to determine S/N ratio and through S/N ratio a set of optimum stir casting parameters were obtained. The experimental results confirmed the validity of Taguchi method for enhancing tensile strength of castings.

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Arulraj, M., P. K. Palani, and L. Venkatesh. "Optimization of Process Parameters in Stir Casting of Hybrid Metal Matrix (LM25/SiC/B4C) Composite Using Taguchi Method." JOURNAL OF ADVANCES IN CHEMISTRY 13, no. 9 (February 22, 2017): 6475–79. http://dx.doi.org/10.24297/jac.v13i9.5777.

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Aluminium based composites exhibit many attractive material properties such as increased stiffness, wear resistance, specific strength and vibration damping and decreased co-efficient of thermal expansion compared with the conventional aluminium alloys. Aluminium Matrix Composites consist of non-metallic reinforcement which offers advantageous properties over base material. Reinforcements like SiC, B4C and Al2O3 are normally preferred to improve the mechanical properties. Here Aluminum LM25 is selected as matrix material while Silicon carbide and Boron carbide are selected as reinforcement material. The fabrication of aluminium matrix was done by stir casting method. In the present study an attempt has been made to investigate the effect of three major stir casting parameters (stir speed, stir duration and preheated temperature of reinforcement material) on stir casting of Aluminium LM25 - SiC - B4C composite. Experiments were conducted based on Taguchi methodology. Taguchi quality design concepts of L9 orthogonal array has been used to determine S/N ratio and through S/N ratio a set of optimum stir casting parameters were obtained. The experimental results confirmed the validity of Taguchi method for enhancing tensile strength of castings.

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Korchmit, Anton Viktorovich, Nikita V. Martyushev, and Yuriy Yu Drozdov. "Casting Quality Enhancement of Bushings Made of Foundry Aluminium Bronzes." Key Engineering Materials 685 (February 2016): 459–62. http://dx.doi.org/10.4028/www.scientific.net/kem.685.459.

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The paper is devoted to the establishment of the technology of castings manufacture out of multicomponent aluminium bronzes for oil and gas producing equipment. Aluminium bronze containing iron has been chosen as a material for casting manufacture. Founding into sand mixtures has been chosen as a manufacturing method. It has been shown that this type of founding allows obtaining the castings with minimal subsequent treatment and high quality surface. The use of the coke furnace at metal melting allows obtaining the castings with high performance characteristics due to gas protection of the melt.

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Ardeleanu, Laurenţiu, Constantin Bratu, and Ioan Mărginean. "Effects of Vibration and Salts Treatments on Aluminium Alloy Properties Used in Mould Manufacture." Advanced Materials Research 1128 (October 2015): 58–63. http://dx.doi.org/10.4028/www.scientific.net/amr.1128.58.

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Metallic mould properties are influenced by the technological process used on casting. The mechanical properties of aluminium castings can be affected by dissolved gases, heterogeneous impurities or shrinkage remaining in casting after solidification. Dissolved gases and oxide inclusions in aluminium all have a deleterious effect on casting quality. The treatment of molten aluminium using vibrations and salts was found to be highly efficient in refining the microstructure of the alloy. The main objective of the paper is to understand the effects of vibrations and salts treatment on the final microstructure and changes that take place and influences aluminium alloy properties used in mould manufacture. The microstructural changes have a great significance in improving the properties of aluminium alloy castings. Understanding this effects and the modification mechanism can undoubtedly be of great significance for improving casting quality. Fluxes based on a KCl-NaCl mixture may be used to cover and protect the metal from oxidation. Most fluxes are based on a mixture of KCl and NaCl, which forms at low-temperature (665 °C) eutectic.

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Asokan, Manivannan, Sasikumar Rathinasabapathy, Shaik Dawood Abdul Khadar, and Mohammed Sadique Khan. "Novel Combined Feeding Approach to Produce Quality Al6061 Composites for Heat Sinks." High Temperature Materials and Processes 38, no. 2019 (February 25, 2019): 647–50. http://dx.doi.org/10.1515/htmp-2019-0009.

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AbstractThis elementary work aims to address agglomeration and non-uniform dispersion of reinforcement particles in stir casting using Al6061 alloy (AA 6061) as a matrix and Aluminium oxide (Al2O3) as reinforcement particles. A novel combined feeding method of Encapsulate feeding technique & Two Step Stir Casting was developed & attempted to produce good quality composites by varying weight fractions of Aluminium Oxide (0 to 5 wt.%). The wetting agent Mg (2 wt.%) added in all castings to ensure better binding between ceramics and matrix. The SEM photomicrograph ensures homogenous dispersion of reinforcement particles by combined feeding method. The thermal properties of produced good quality composites are enhanced with increase in Aluminium Oxide (Al2O3) from 0 to 5 wt.%.

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Hussainy, Syed Ferhathullah, Mohd Viquar Mohiuddin, P. Laxminarayana, S. Sundarrajan, and A. Krishnaiah. "Analysis of Shrinkage Characteristics of Aluminium Silicon Alloy." Journal for Manufacturing Science and Production 16, no. 3 (September 1, 2016): 163–71. http://dx.doi.org/10.1515/jmsp-2016-0002.

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AbstractAnalysis of shrinkage characteristics of Aluminium-Silicon alloy was studied theoretically and experimentally. The Aluminium alloys considered in the study are A413 (LM6), A360 (LM9) and A380 (LM24). Extensive literature survey has suggested that cavity filling and solidification process are two most critical aspects to produce high quality casting components. A statistical model of parameters and response to understand the influence of parameters on shrinkage and casting yield studies has been presented. Experiments were conducted in foundry in industrial environment to produce commercially treated aluminium alloy castings in sand mould. Alloy was found to be most significant factor influencing shrinkage. The yield of casting was improved using insulating and exothermic sleeves. Solidification time of exothermic riser was 10 % more than insulated riser. Thus, in order to produce radiographic quality casting a theoretical and experimental method is presented so that number of trials in foundry is reduced which leads to increased reliability and productivity. Study also shows that by using sleeves considerable metal is saved, energy saving during melting, improved quality, reduced cost and increased capacity of plant can be achieved.

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Kotus, M., E. Jankajová, and M. Petrík. "Quality control of aluminium melt in production process." Research in Agricultural Engineering 61, Special Issue (June 2, 2016): S43—S47. http://dx.doi.org/10.17221/28/2015-rae.

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The quality of aluminium alloy in the production process on the chemical composition basis was evaluated. The quality of casting alloy depends on the chemical composition of melt and on the technological process of production process. The basic elements such as Si, Cu, Fe, Mg and Al in melting were evaluated. The obtained data were compared with the guide data referred to in the standard for aluminium alloy.

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Yuksel, C., O. Tamer, E. Erzi, U. Aybarc, E. Cubuklusu, O. Topcuoglu, M. Cigdem, and D. Dispinar. "Quality Evaluation of Remelted A356 Scraps." Archives of Foundry Engineering 16, no. 3 (September 1, 2016): 151–56. http://dx.doi.org/10.1515/afe-2016-0069.

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AbstractA356 is one of the widely used aluminium casting alloy that has been used in both sand and die casting processes. Large amounts of scrap metal can be generated from the runner systems and feeders. In addition, chips are generated in the machined parts. The surface area with regard to weight of chips is so high that it makes these scraps difficult to melt. Although there are several techniques evolved to remedy this problem, yet the problem lies in the quality of the recycled raw material. Since recycling of these scrap is quite important due to the advantages like energy saving and cost reduction in the final product, in this work, the recycling efficiency and casting quality were investigated. Three types of charges were prepared for casting: %100 primary ingot, %100 scrap aluminium and fifty-fifty scrap aluminium and primary ingot mixture were used. Melt quality was determined by calculating bifilm index by using reduced pressure test. Tensile test samples were produced by casting both from sand and die moulds. Relationship between bifilm index and tensile strength were determined as an indication of correlation of melt quality. It was found that untreated chips decrease the casting quality significantly. Therefore, prior to charging the chips into the furnace for melting, a series of cleaning processes has to be used in order to achieve good quality products.

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Wang, Xiang Jie, Gang Sun, Li Juan Wang, Peng Wei Li, and Jian Zhong Cui. "A New Approach of Casting Aluminium Alloy Bar by Applying Low Frequency Electromagnetic Field." Materials Science Forum 794-796 (June 2014): 167–71. http://dx.doi.org/10.4028/www.scientific.net/msf.794-796.167.

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Aluminum is the richest metallic element in the earth, the ingots cast by DC casting process are usually extruded into aluminum bars. When the final products do not require high strength, this process appears to be low efficiency and high cost. We try to design a new technology to cast aluminum bar by horizontal direct chill (HDC) casting process directly. An electromagnetic field is applied during the horizontal continuous casting of 6061 aluminium bar with a diameter of 30mm. The experimental results show the asymmetry of the sump can be overcome by electromagnetic field. Ingot with good upper and lower surface quality is obtained. The structure of ingot is refined and the angle between growth direction and horizontal direction becomes small with increasing casting speed.

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Nadolski, M., Z. Konopka, M. Łągiewka, and A. Zyska. "The Influence of the Method of Mould Filling on the Quality of Castings Made of EN AC-44000 or EN AC-46200 Alloy." Archives of Foundry Engineering 14, no. 4 (December 1, 2014): 73–76. http://dx.doi.org/10.2478/afe-2014-0089.

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Abstract The performed examinations concerning the process of filling the plaster ceramic moulds with aluminium alloys allowed to assess the influence of various methods of introducing the metal into the mould cavity on the macro- and microstructure of the obtained experimental castings. The comparison was performed for castings with graded wall thickness made either of EN AC-44000 alloy or of EN AC-46000 alloy, produced either by gravity casting, or by gravity casting with negative pressure generated around the mould (according to the Vacumetal technology), or by counter-gravity casting. It was found that the silicon crystals grow in size with an increase in wall thickness due to the slower cooling and solidification of castings

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Erzi, Gürsoy, Yüksel, Colak, and Dispinar. "Determination of Acceptable Quality Limit for Casting of A356 Aluminium Alloy: Supplier’s Quality Index (SQI)." Metals 9, no. 9 (August 30, 2019): 957. http://dx.doi.org/10.3390/met9090957.

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Aluminium and its alloys have been widely used in the automotive industry for some time and A356 is one of the most popular aluminium alloys today in the sector. It contains approximately 7 wt.% Si and 0.3 wt.% Mg. Due to the defects that may be present in the cast parts, expected mechanical properties may not be reached and this alloy may perform in service under its potential. In a low pressure die casting, several precautions have to be taken in order to produce high quality and defect-free castings. Temperature of casting and the schemical composition of the melt is recorded continuously. Die temperature, pressure levels and their durations are optimized; degassing and fluxing operations are performed. Yet, regardless of the precautions, there could still be rejected parts. It is becoming clear that a good quality raw material is one of the most underrated points of the industry and that the starting material has a great effect on the final product and it should be taken in to account more seriously. Therefore, regarding the first rule of Campbell’s 10 Rules of Casting, in this study, the quality of the starting material of supply chains for a wheel manufacturer was investigated. Chemical compositions were compared, fluidity tests, mechanical tests and bifilm indexes of these various sources and ingots were measured and a final quality index was proposed to create a reference for the quantification of quality of supplier’s ingots. This new index was compared with the rejection rates.

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Godzsák, Melinda, and Zoltán Gácsi. "Examination of Aluminium Based Automotive Casting." Materials Science Forum 729 (November 2012): 91–96. http://dx.doi.org/10.4028/www.scientific.net/msf.729.91.

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Automotive castings have to meet more and more versatile requirements these days. One of the most important requirements towards suppliers and foundries is producing parts of better quality, higher performance but at the same time of less weight. In order to couple this small weight with high performance and excellent quality these products should meet very strict mechanical standards of automotive parts. There is a constant need for production engineering developments ranging from purity degree - that is producing molten metal with high cleanness - to grain refinement and alloy improving including heat treatment technologies.

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Dispinar, Derya, and John Campbell. "Effect of casting conditions on aluminium metal quality." Journal of Materials Processing Technology 182, no. 1-3 (February 2007): 405–10. http://dx.doi.org/10.1016/j.jmatprotec.2006.08.021.

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Švecová, Ivana, Eva Tillová, and Lenka Kuchariková. "Improving the quality of Al-Si castings by using ceramic filters." Production Engineering Archives 26, no. 1 (March 1, 2020): 19–24. http://dx.doi.org/10.30657/pea.2020.26.05.

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AbstractThe use of cast aluminium has still increased, so have the mechanical property requirements. By casting and also in other metallurgical processes, the inclusions enter to the molten aluminium alloy and it exhibits poor ductility or toughness. It can cause a variety of problems in the manufacture of aluminium alloy castings. Therefore, the purification of the molten aluminium alloy is one of the most important processes for improving the quality of Al-products. Filters have been used for many years in order to improve the quality of castings. The inclusions in molten secondary AlSi7Mg0.3 cast were removed using depth filtration by ceramic foam filters of 20 ppi porosity. Were used 4 types of ceramic filters in 2 thicknesses (15 and 22 mm); Brinell hardness and porosity were measured. Quality of microstructure (occurrence of oxidic particles and larger non-metallic inclusions) was observed. Experimental results show that the insertion of ceramic filters into the inlet system has contributed primarily to a decrease in porosity. On the microstructure, the inclusion of filters was not significantly reflected.

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Adianta, Andri Willy, Suprianto Suprianto, Arnius Daely, and Mikael F. Bangun. "Studi Fluiditas dan Karakteristik Aliran pada Pengecoran Al-Si Alloy Menggunakan Simulasi Numerik." Talenta Conference Series: Energy and Engineering (EE) 1, no. 1 (October 16, 2018): 007–12. http://dx.doi.org/10.32734/ee.v1i1.102.

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Aluminium silikon alloy merupakan paduan aluminium yang banyak digunakan dalam bidang teknik. Paduan ini memiliki kekuatan yang baik dan banyak diproduksi menjadi suatu komponen melalui proses pengecoran. Kandungan silikon dapat mengakibatkan penurunan fluiditas coran alumunium yang pada akhirnya akan menurunkan kualitas coran, fluiditas ini juga dipengaruhi temperatur pada saat penuangan alumunium cair. Penelitian ini bertujuan untuk mengetahui efek temperatur penuangan terhadap fluiditas, karakteristik aliran dan cacat coran pada pengecoran aluminium silikon alloy menggunakan cetakan pasir. Pengecoran dilakukan dengan gravity casting, analisa aliran simulasi meliputi distribusi kecepatan aliran, temperatur, tekanan, cacat permukaan dan fluiditas yang terjadi pada saat proses pengisian rongga cetak serta perbandingan fluiditas coran dan cacat permukaan pada eksperimental. Temperatur penuangan 685, 710, 735, 760 dan 785°C dengan ketebalan cetakan pola 1, 3, 5, 7, 9, dan 12 mm. Proses simulasi menggunakan software berbasis computational fluid dynamic. Hasil penelitian diperoleh temperatur tuang 785oC memiliki kecepatan aliran tertinggi yaitu sebesar ±0.145 m/s pada rongga 12 mm dan distribusi temperatur yang tinggi yaitu sebesar ±759 oC pada rongga 3 mm, sedangkan temperatur tuang 685oC memiliki distribusi tekanan yang tinggi yaitu sebesar ±107287 Pa pada rongga 6 mm. Cacat permukaan terbanyak pada temperatur tuang 785oC dan temperatur tuang 685oC paling sedikit. Fluiditas coran terbaik pada temperatur 785oC dimana rongga 12, 9, 7, 5 dan 3 mm terisi penuh dan 1 mm mencapai 181.4 mm. Aluminum silicon alloy is an aluminum alloy that is widely used in engineering. This alloy has good strength and plenty of it are produced into a component through the casting process. Silicon content could result in a decrease in fluidity of aluminum castings which in turn would reduce the quality of casting. This fluidity is also influenced by temperature at the time of pouring liquid aluminum. This study aims to determine the effect of pouring temperature on fluidity, flow characteristics and casting defects on aluminum alloy silicon casting by using sand mold. Casting was conducted by gravity casting, simulation flow analysis including flow velocity distribution, temperature, pressure, surface and fluidity defects that occured during the process of filling the mold cavity as well as the comparison of the fluidity of castings and surface defects in the experiment. Casting temperatures was 685, 710, 735, 760 and 785°C with a mold thickness of patterns 1, 3, 5, 7, 9 and 12 mm. The simulation process used software based on computational fluid dynamic. The result showed pouring temperature of 785oC had the highest flow velocity of ± 0.145 m/s in 12 mm cavity and a high temperature distribution of ± 759oC in cavity of 3 mm, while the pouring temperature of 685oC had a high pressure distribution of ± 107287 Pa in 6 mm cavity. Most surface defects occurred at pour temperature of 785oC and the least at pour temperature of 685oC. The best castings liquidity occurred at temperature of 785oC where the cavity of 12, 9, 7, 5 and 3 mm was fully filled and 1 mm reached 181.4 mm.

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Karolina, Czerwińska, and Pacana Andrzej. "Improving the Manufacturing Process of Aluminium Rims." System Safety: Human - Technical Facility - Environment 3, no. 1 (May 1, 2021): 38–46. http://dx.doi.org/10.2478/czoto-2021-0004.

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Abstract The aim of the study was to indicate the reasons for non-compliance of aluminium rim castings and, using quality management instruments (Pareto-Lorenzo diagram and 5WHy method?), elimination or reduction of non-compliant products. The object of the research was an aluminium rim, while the diagnostic process of the object of the research was based on the quality control of the chemical composition of the casting, the control of mechanical properties and the control of the continuity of the material structure by radiographic and microscopic methods. On the basis of the research carried out, it was found that a sensitive casting area is the front edge of the rim rim - a significant number of porosity clusters were identified in this area. The reason for their occurrence was also specified - too rapid flooding of moulds, which resulted in gassing of the alloy. The identified cause had its origins in human resources mismanagement, namely the lack of training of the newly recruited employee. So far, the company has not carried out analyses of quality problems with the use of a sequential quality management methodology, so the implemented corrective actions have not always led to the full achievement of quality objectives. The presented sequential method, which is a combination of diagnostic and control tests and quality management instruments, is a universal way to monitor the level of quality of products and to quickly correct nonconformities.

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Hendronursito, Yusup, and Yogi Prayanda. "POTENSI PASIR LOKAL TANJUNG BINTANG PADA ALUMINIUM SAND CASTING TERHADAP POROSITAS PRODUK HASIL COR ALUMINIUM." JURNAL KAJIAN TEKNIK MESIN 1, no. 2 (September 21, 2016): 60–68. http://dx.doi.org/10.52447/jktm.v1i2.336.

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Green sand is one of the most important components in the process of metal casting. The sand in Indonesia region is varied level of subtlety, size of sand, and shape of sand. Green sand used in the process of metal casting is possible can affect the quality of casting product. This aims to determine the potential of Tanjung Bintang sand as green sand and the quality of the product in terms of porosity defects. The research was conducted by varying sand river from Tanjung Bintang and sand from Maringgai. Composition made varying is 100%,75%, 50%, and 25% Tanjung Bintang sand compared Maringgai sand with bentonit and water is 10% and 5% constantly .The Examine of the green sand by SNI 15-0312-1989 among other water content, clay content, Grain Finnest Number (GFN), Shape of grain. The result said aluminium casting product with 50% Tanjung Bintang sand has the lowest value of porosity, 5.08% and the higher value with 75% composition of Tanjung Bintang sand, 6.98%.

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Pałyga, Ł., M. Stachowicz, and K. Granat. "Effect of Selected Parameters of Pressure Die Casting on Quality of AlSi9Cu3 Castings." Archives of Foundry Engineering 15, no. 2 (June 1, 2015): 85–90. http://dx.doi.org/10.1515/afe-2015-0044.

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Abstract This paper presents the results on the effects of die-casting process on the strength parameters of castings of the aluminium AlSi9Cu3 alloy belonging to the group of EN AB-46000, made on renovated high pressure die-casting machine. Specimens for quality testing were taken from the places of the casting most loaded during the service. The aim of a research was to prove how the new die-casting process control capabilities influence on the tensile strength of the cast material defined as a value of the breaking force of the specimens. It has been found that it is possible to specify a set of recommended settings valves of second (II) and third (III) phase, which are responsible for filling the metal mould on die-casting pressure machine. From the point of view of the finished cast element, it was noticed that exceeding the prescribed values of valve settings does not bring further benefits and even causes unnecessary overload and reduce the durability of the mold. Moreover, it was noticed that reduction of the predetermined setting of the second phase (II) valve leads to the formation of casting defects again.

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SHIM, HEE-JIN, and JUNG-KYU KIM. "EFFECT OF POROSITY ON THE FATIGUE LIFE OF CAST AC4C-T6 ALLOY FOR LCD GLASS TRANSFER ROBOT." International Journal of Modern Physics B 24, no. 15n16 (June 30, 2010): 2273–78. http://dx.doi.org/10.1142/s0217979210064782.

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Aluminium has good corrosion properties and a high strength to weight reduction which makes it favourable in many applications. The increased use of aluminium casting in the automotive industry does also imply that the need for design data for aluminium increases. Especially for castings, the influences of casting defects are always an issue. For this reason fatigue properties for as-cast sand and permanent mould specimens with different contents of porosity have been studied. The cast aluminium specimens of two different porosities were fatigue tested in cyclic axial test at R =-1. Prior to fatigue test specimens were examined by CT-scan and sorted into two quality groups depending on the porosity level. The aim of this work was to investigate the fatigue life for cast AC4C-T6 alloy with different amounts of inherent porosity. An additional aim was to predict the durability for cast components with defect constrained in a specified volume of components, by using a commercial program MSC. Fatigue.

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Patel, Jayesh B., Hu Tian Li, Ming Xu Xia, Simon Jones, Sundaram Kumar, Keyna O'Reilly, and Zhong Yun Fan. "Melt Conditioned Direct Chill Casting (MC-DC) Process for Production of High Quality Aluminium Alloy Billets." Materials Science Forum 794-796 (June 2014): 149–54. http://dx.doi.org/10.4028/www.scientific.net/msf.794-796.149.

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A novel direct chill (DC) casting process, melt conditioned direct chill (MC-DC) casting process, has been developed for production of high quality aluminium alloy billets. In the MC-DC casting process, a high shear device is submerged in the sump of the DC mould to provide intensive melt shearing, which in turn, disperses potential nucleating particles, creates a macroscopic melt flow to uniformly distribute the dispersed particles, and maintains a uniform temperature and chemical composition throughout the melt in the sump. Experimental results have demonstrated that, the MC-DC casting process can produce aluminium alloy billets with significantly refined microstructure and reduced cast defects. In this paper, we give an overview of the MC-DC casting process and report on results obtained from an industrial scale trial.

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Ji, Shou Xun, Feng Yan, and Zhong Yun Fan. "Casting Development with a High Strength Aluminium Alloy." Materials Science Forum 828-829 (August 2015): 9–14. http://dx.doi.org/10.4028/www.scientific.net/msf.828-829.9.

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In the present paper, we introduce the development of casting an industrial component with a newly developed high strength aluminium alloy for high pressure die casting, including the introduction of property requirement, and the simulation results of temperature distribution, air entrapment, air pressure and the porosity potential in the casting, overflows and gating system. The microstructure and mechanical properties of the casting with satisfied quality are described under as-cast and heat-treated conditions.

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Wang, Xiang Jie, Jiao Zhang, Yun Peng Huang, Zhi Hao Zhao, and Jian Zhong Cui. "Experimental Study on Horizontal Continuous Casting of 6061 Aluminium Alloy Bar Process." Key Engineering Materials 480-481 (June 2011): 100–103. http://dx.doi.org/10.4028/www.scientific.net/kem.480-481.100.

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The aluminium alloy bar is mainly obtained by hot extrusion in the past. In order to increase the production efficiency and reduce the cost, a new mold is designed, and horizontal continuous casting is used to produce the aluminium alloy bar in this work. The results show that aluminium alloy bar can be cast by horizontal continuous casting. The asymmetry of the sump is overcome by optimizing the design of the mold. When the temperature of the melt was 730°C, casting speed is 650 mm/min, cooling water is 15 L/min, the quality of lubricating oil is 0.5 ml/min, and the ingot with good surface quality can be cast.

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Tempiamwatcharothai, Jintana, Kumpanat Sirivedin, Pinai Mungsantisuk, and Swieng Thuanboon. "The Quality Improvement of Molten Aluminium Alloy in Melting Process by Stirring Process and the Degassing Technique." Key Engineering Materials 798 (April 2019): 17–24. http://dx.doi.org/10.4028/www.scientific.net/kem.798.17.

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The fuel-fired crucible furnace is very popular for melting of aluminium alloys. This melting technique provides good control of hydrogen gas in aluminium casting. The fuel type is LPG for convenience and low cost of production in small and medium foundry. However, the quality of the melt such as homogeneity of chemical composition is not good and stirring is normally required. In this paper, the rotary degassing system was used to improve the quality of the molten aluminium alloy. By control the homogeneity of chemical composition and reduces other impurities such as Iron (Fe). Two different inert gases, argon and nitrogen, were used to treat the melt. The combination of blade design, type of gas and rotation speed is the key success to improve the quality of molten aluminium alloy in this study. Moreover, this rotary degassing system can be used to control pouring temperature which is one of the most important parameters for the consistency of casting quality. Therefore, the rotary degassing system will be of benefit to control the homogeneity of chemical composition, control the pouring temperature, save production time and increase productivity of aluminium melting and casting.

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Znamenskij, Leonid G., O. V. Ivochkina, and Aleksey S. Varlamov. "Economical Ceramic Molds in Investment Casting." Materials Science Forum 843 (February 2016): 208–12. http://dx.doi.org/10.4028/www.scientific.net/msf.843.208.

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Ceramic corundum molds on hydrolysed ethyl silicate solution which have insufficient inertness to poured alloys are widely used in the production of castings from reactive metals alloys. This is due to the presence of free silica, which is a strong oxidant of such alloy components as aluminium and titanium in vacuum conditions, in the form of a high content. To solve the indicated problem using aluminium-borophosphate concentrate, chemically cured with periclase, as a silica free binder of ceramic corundum molds was suggested. The use of the combination of the indicated mold materials allows not only enabling chemical inertness of the molds, but also operating the process of mold forming. The developed technology provides the acceleration of the mold manufacturing cycle in 4...6 times, the increase the strength of the mold covers, the reduction in the heat-resistant alloy casting cost. It enables significant improvement of the quality and increase of the economic efficiency of manufacturing of precision casting from reactive metals and alloys.

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Senthil, P., and K. S. Amirthagadeswaran. "Experimental Study and Squeeze Casting Process Optimization for High Quality AC2A Aluminium Alloy Castings." Arabian Journal for Science and Engineering 39, no. 3 (September 7, 2013): 2215–25. http://dx.doi.org/10.1007/s13369-013-0752-5.

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Franke, Alois, and John L. Jorstad. "THINCAST^TM; Providing Strong, Lightweight Castings for Automobiles and Other Applications." Solid State Phenomena 217-218 (September 2014): 294–301. http://dx.doi.org/10.4028/www.scientific.net/ssp.217-218.294.

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Aluminium Rheinfelden has improved the competitiveness of semi solid processing by developing a casting process & alloy combination that is capable of ultra thin, ultra light parts having attractive engineering properties without need for full heat treatment. The THINCASTTM rheocasting process, together with Rheinfeldens Magsimal-59 alloy has been demonstrated capable of producing moderate sized castings with only 1-2 mm wall sections, thus providing a 30-50% reduction in traditional-process part weight. THINCASTTM can be adapted to a variety of die casting machines and will enable competitively improving the quality of conventional high pressure die castings as well as creating entirely new applications.

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Chen, Song, Da Quan Li, Fan Zhang, You Feng He, Qiang Zhu, Yi Li, and Hai Xia Cui. "Development of Semi-Solid Die Casting Process Technology for Aluminium Alloy Clamp." Materials Science Forum 850 (March 2016): 642–48. http://dx.doi.org/10.4028/www.scientific.net/msf.850.642.

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Compared with traditional liquid and solid processing methods, semi-solid die casting process can apparently overcome shrinkage cavity and porosity defects in castings and high deformation resistance and high residual stress shortcomings in forging parts. Semi-solid die casting process with advantages such as high efficiency and low cost, will become the optimal process for high quality automobile parts. In this study, using the clamp as an example, the author introduced product structure optimization and die design for semi-solid die-casting process of aluminum alloy in a new product development.The Computer Aided Engineering technology was applied to the product structure optimization according to the stress analysis. The optimal mold structure, including cavity layout, gating system, overflow and vent systems, were confirmed based on the die design criteria for traditional die casting, combining with the characteristics of semi-solid forming and the simulation results. The semi-solid aluminum alloy clamp parts with excellent performances were finally developed successfully by means of product structure optimization, die design, parameters optimization of die casting process, and the mechanical properties test of products.The existing parts were optimized to make them more suitable for semi-solid die casting processing. In addition, a reasonable die design specially for semi solid processing was an important guarantee for a successful semi solid product applied in industry. Computer numerical simulation was applied in product structure design for semi-solid die casting, die design, die-casting process optimization and other aspects, to shorten the development cycle of new product, reduce cost and improve efficiency.

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Chiesa, Franco, David Levasseur, and Jocelyn Baril. "Comparing the SEED Semi-Solid Process to Low Pressure Permanent Mould in the Production of 4mm Thick Aluminum A356 Covers." Materials Science Forum 765 (July 2013): 112–16. http://dx.doi.org/10.4028/www.scientific.net/msf.765.112.

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In order to compare the semi-solid SEED casting process to the Low Pressure Permanent Mould process (LPPM), the same part has been produced in aluminium A356 (AlSi7Mg04) using the two methods. The processes were first compared from an operational standpoint: pouring temperature, filling sequence, production rate and mould maintenance. In addition, the metallurgical quality of the castings was evaluated by measuring the tensile properties at 6 locations in the part; the metallographic structures were also compared. Filling and solidification modeling allowed the prediction of the filling sequence and local solidification times everywhere in the casting. The SEED process was generally found to deliver a finer structure, a near net shape casting and a much higher productivity. LPPM parts were more uniform in structural and mechanical properties as verified at 6 locations in the castings.

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Suraya, S., Shamsuddin Sulaiman, Mohd Khairol A. Arifin, and Mohd Sayuti. "Computer Simulation and Experimental Investigation of Solidification Casting Process." Key Engineering Materials 471-472 (February 2011): 601–5. http://dx.doi.org/10.4028/www.scientific.net/kem.471-472.601.

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Computer simulation is widely used and conventional in manufacturing as a way to improve the manufactured goods quality as at same time plummeting invention costs, development time and scrap. In this study, three-dimensional model have been developed to simulate the filling and the solidification pattern in an aluminum casting with “AnyCasting” software. Using this software, solidification of aluminium 11.8% Si alloy in sand and metal mould was simulated and the results were compared with the experimental results. The solidification time and temperature was experimentally determined from thermocouple located at diverse distances. A data logger is used in experiment to gain the temperature division contour during the process of solidification of the aluminium 11.8% Si alloy. Experiments were set up to legalize the simulation results and it is confirm that the results from the two mould methods be in good agreement and the solidification of cast aluminium alloy using copper mould was much faster compared to the one cast sand mould. From this work it is concluded that simulation using AnyCasting software can be use to initially calculate. The simulation shows result that matches with the experimental data qualitatively and therefore the validation procedure is successful.

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Gyarmati, Gábor, György Fegyverneki, Tamás Mende, and Mónika Tokár. "The Effect of Fluxes on the Melt Quality of AlSi7MgCu Alloy." International Journal of Engineering and Management Sciences 4, no. 1 (March 3, 2019): 372–80. http://dx.doi.org/10.21791/ijems.2019.1.46.

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The presence of inclusions such as oxides, carbides or refractory particles can be harmful to the mechanical and surface characteristics of castings. Inclusion-rich metals result in lower fluidity and feeding capability during casting. Nowadays, solid fluxes are widely used in foundries in order to reduce the inclusion content of aluminium melts. In this study, the effect of four different fluxes on the melt quality was studied. First, the inclusion content of the flux-treated melt, and then the properties of the fluxes (i.e. chemical composition and melting temperature) were examined.

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Gaspar, Stefan, and Ján Pasko. "Analysis of Influence of Pressing Speed, of Melt Temperature and of Casting Position in a Mold upon Ultimate Tensile Strength R_m of Die Casting from Aluminium." Advanced Materials Research 909 (March 2014): 3–7. http://dx.doi.org/10.4028/www.scientific.net/amr.909.3.

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The paper deals with analysis of influence of pressing speed, of melt temperature and of casting position in a mold upon ultimate tensile strength Rm of die casting from aluminium. The monitored parameters of die casting are very important in terms of production efficiency and quality of casting, which is positively reflected in economic indicators of the production.

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Kadhim, Mohamed Ali, Hussain Al Ali Jalal Ghuloom, Garry Martin, and Michael Jacobs. "Aluminium Bahrain - Benefits at ALBA from Use of Improved Graphite Rings for Production of Extrusion Ingots." Materials Science Forum 630 (October 2009): 251–57. http://dx.doi.org/10.4028/www.scientific.net/msf.630.251.

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Surface quality and metallurgical characteristics of extrusion ingot have a significant impact on the extrudability of the billet. Both the type of casting mould and mould maintenance significantly influences billet surface quality. ALBA, like the majority of extrusion ingot producers, uses moulds with graphite technology, where a mix of oil and gas is injected through a graphite ring into the mould to improve billet surface quality. ALBA has a policy of continual improvement in the areas of safety, product quality and productivity to enhance customer satisfaction. During 2008, an extensive campaign was conducted in ALBA’s casthouse to select the optimum type of casting rings for Airslip™ moulds supplied by Wagstaff Inc. The graphite casting rings evaluated must be suitable for the casting conditions and environment within the casthouse at ALBA. This paper details the methodology and the criteria set for the selection of the optimum graphite casting ring type as well as the results achieved. The results of the work showed a preference for L type casting rings, which enhance the quality of the extrusion ingots and extend the service life of the graphite ring.

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Kotadia, H. R., J. B. Patel, H. Tian Li, F. Gao, and Z. Fan. "Microstructure Evolution in Melt Conditioned Direct Chill (MC-DC) Casting of Fe-Rich Al-Alloy." Advanced Materials Research 1019 (October 2014): 90–95. http://dx.doi.org/10.4028/www.scientific.net/amr.1019.90.

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In order to fabricate high quality aluminium products, it is first essential to produce high quality billets/slabs. One of the key objectives associated with casting processes is to be able to control the as-cast structure. A novel direct chill (DC) casting process, the melt conditioned direct chill (MC-DC) casting process, has been developed for production of high quality aluminium billets. In the MC-DC casting process, a high shear device is submerged in the sump of the DC mould to provide intensive melt shearing, which in turn, disperses potential nucleation particles, creates a macroscopic melt flow to uniformly distribute the dispersed particles, and maintains a uniform temperature and chemical composition throughout the melt in the sump. The effect of intensive shearing on the complex microstructure evolution observed after MC-DC is explained on the basis of nucleation and growth behavior. Complete suppression of typical columnar grain growth and significant equiaxed grain refinement is observed. The solidification mechanisms responsible for the significant grain refinement by intensive shearing and the morphological evolution of Mg2Si and Fe–containing intermetallic phases are discussed.

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Zanna, Sandrine, Yakov Frayman, Bruce Gunn, and Saeid Nahavandi. "Towards a More Holistic Approach to Quality Improvements in Aluminium Die Casting." Materials Science Forum 618-619 (April 2009): 341–44. http://dx.doi.org/10.4028/www.scientific.net/msf.618-619.341.

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This work evaluates the feasibility of using a holistic approach, based on dynamical system theory, to reduce porosity defects in high pressure aluminum die casting. Quality improvements, from a dynamical system perspective mean the ability to move the die casting process out of its natural equilibrium to a more beneficial state and the ability to maintain this new process state. This more beneficial state may be achieved in several ways. One way is to increase the amount of forcing to overcome natural process resistance. This forcing approach is represented by typical continuous intervention policy, with modifications in die/part design and/or process parameters. An alternative approach is to reduce the amount of natural process resistance, in particular the amount of process disturbance, allowing the process to move out of its natural equilibrium with much less forcing. This alternative uses the self-regulating ability of dynamical systems thus decreasing the amount of human intervention required. In this respect, the influence of vacuum on time on chattering at the first stage of the casting shot was identified as a good process candidate for testing using dynamical system theory. A significant reduction in porosity defects was achieved, which also set the process on a path of slow but consistent self-improvement.

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Anastasiou, K. S. "Optimization of the aluminium die casting process based on the Taguchi method." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 216, no. 7 (July 1, 2002): 969–77. http://dx.doi.org/10.1243/09544050260174175.

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Porosity in the die casting process causes costly scrap loss and limits the use of die-cast parts in critical high-strength applications. The amount of porosity is closely related to the die casting process parameters. Consequently, the mechanisms of porosity formation in relation to die casting parameters have to be studied in detail. A considerable reduction in porosity formation can be obtained by Taguchi technique implementation in the die casting process. Through simple multifactorial experiments in the foundry, controllable factors can be isolated to provide centring and variance control for a process variable. The primary objective of this paper is to investigate the effects of process parameters on porosity formation in the pressure die casting process to improve casting quality. Examples of the off-line technique used in a Greek aluminium die casting company are given for the purpose of illustrating the practicality and ease of use by industry engineers and managers.

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Czekaj, E., J. Zych, Z. Kwak, and A. Garbacz-Klempka. "Quality Index of the AlSi7Mg0.3 Aluminium Casting Alloy Depending on the Heat Treatment Parameters." Archives of Foundry Engineering 16, no. 3 (September 1, 2016): 25–28. http://dx.doi.org/10.1515/afe-2016-0043.

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Abstract Issues connected with high quality casting alloys are important for responsible construction elements working in hard conditions. Traditionally, the quality of aluminium casting alloy refers to such microstructure properties as the presence of inclusions and intermetallic phases or porosity. At present, in most cases, Quality index refers to the level of mechanical properties – especially strength parameters, e.g.: UTS, YS, HB, E (Young’s Modulus), K1c (stress intensity factor). Quality indexes are often presented as a function of density. However, generally it is known, that operating durability of construction elements depends both on the strength and plastic of the material. Therefore, for several years now, in specialist literature, the concept of quality index (QI) was present, combines these two important qualities of construction material. The work presents the results of QI research for casting hypoeutectic silumin type EN AC-42100 (EN AC-AlSi7Mg0.3), depending on different variants of heat treatment, including jet cooling during solution treatment.

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Sayuti, Mohd, Shamsuddin Sulaiman, B. T. Hang Tuah Baharudin, Mohd Khairol A. Arifin, S. Suraya, and Gholamreza Esmaeilian. "Mechanical Vibration Technique for Enhancing Mechanical Properties of Particulate Reinforced Aluminium Alloy Matrix Composite." Key Engineering Materials 471-472 (February 2011): 721–26. http://dx.doi.org/10.4028/www.scientific.net/kem.471-472.721.

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The effects of subjecting solidifying particulate reinforced aluminium alloy matrix composite to various sources of vibration on the resulting casting quality, a mechanical vibration technique for inducing vibration resulting in enhanced mechanical properties, such as impact properties is devised. TiC particulate reinforced LM6 alloy matrix composites are fabricated by different particulate weight fraction of titanium dioxide and microstructure studies were conducted to determine the impact strength and density, respectively. Preliminary works show that the mechanical properties have been improved by using vibration mold during solidification compared to gravity castings without vibration.

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Ostermeier, Markus, Hartmut Hoffmann, and Ewald Werner. "The Effects of Hot Isostatic Pressing on Aluminium Castings." Key Engineering Materials 345-346 (August 2007): 1545–48. http://dx.doi.org/10.4028/www.scientific.net/kem.345-346.1545.

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Since the early 1960s hot isostatic pressing (HIP) was used to improve the quality of castings made of various alloys. The closure of pores, originating from the casting process, is considered as the main source of these improvements. For the aluminium alloy Al-9Si-3Cu specimens for tensile testing were machined from castings either squeeze casted and heat treated to T4 and T6 conditions or investment casted. The effect of HIP on density, roughness and mechanical properties was investigated. The density and roughness of the squeeze casted specimens did not change remarkably and their tensile strength became worse, because the initial heat-treatment-state was destroyed by HIP. The investment casted specimens became denser and roughness became worse due to closure of pores near the surface. Although roughness after HIP was higher than in the initial state, tensile strength was improved significantly by HIP, because of closure of the pores in the specimen.

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40

Hidalgo, Raquel, Jon Ander Esnaola, Miren Larrañaga, Iñigo Llavori, Nuria Herrero-Dorca, Iñaki Hurtado, Edurne Otxoa, Patxi Rodríguez, and Aitor Kortabarria. "Influence of Surface Finish and Porosity on the Fatigue behaviour of A356 Aluminium Casting Alloy." MATEC Web of Conferences 165 (2018): 14007. http://dx.doi.org/10.1051/matecconf/201816514007.

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In casting parts, due to the manufacturing process, the presence of defects such as porosity, inclusions and oxide films is unavoidable. All these irregularities have a negative effect on the component performance. Several works have demonstrated that, among them, porosity is especially detrimental to the fatigue properties. As most fatigue failures nucleate at the surface of a material, casting defects at or near the surface and surface roughness become an extremely important factor in determining the fatigue strength of cast components. Very little research has been conducted into the influence of both surface quality and porosity on the fatigue behaviour of aluminium castings parts. In the present work, the effects of two different surface qualities (machined and as-cast) on fatigue behaviour of an A356 casting alloy were studied. The S-N curves obtained showed that the cast surface had higher fatigue strength than the machined one. The failure in cast specimens initiated predominantly from valleys of the rough surface near pores or inclusions. On the other hand, in machined surfaces, the cracks initiated directly from surface pores. Thus, the improvement in fatigue life was attributed to a longer crack “initiation” period.

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41

Chiesa, Franco, Nicolas Giguère, and Bernard Duchesne. "Distribution of the Quality Index in AlSiMg Castings Produced by Different Processes: Reality vs Prediction." Materials Science Forum 690 (June 2011): 238–41. http://dx.doi.org/10.4028/www.scientific.net/msf.690.238.

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The Quality Index is a useful tool allowing to assess the metallurgical quality of aluminium AlSiMg foundry alloys (AlSi7Mg03/AlSi7Mg06, or A356/357 in North America). Its value, calculated from the ultimate tensile strength and elongation, increases with the metallurgical quality of the casting, i.e. with finer dendrites, lower microporosity, lower iron content and cleaner metal. This Quality Index does not depend on the degree of temper applied during the heat treatment (aging time and temperature). This paper will briefly explain how solidification modeling can provide the local value of the Quality Index, via the secondary dendrite arm spacing and level of microporisity calculated from the predicted values of the local solidification time and solidus velocity. The validity of the predictions has been assessed against the properties of tensile specimens excised from parts of different geometries produced by a variety of casting processes, as reported in the literature. The case study of a race car bell housing poured by two processes, namely gravity sand casting (GSC) and low pressure die casting (LPDC, or LPPM for Low Pressure Permanent Mold in North America), will be the focus of the present paper. The Quality Index has been measured and predicted at 3 locations in the castings after a T6 temper was applied which resulted in a minimum elongation of 5% for both the GDC and LPDC bell housings. Metallographic examination and image analysis allowed to quantify the superior metallurgical quality of the LPDC housings when compared to their GDC competitors.

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42

Władysiak, R. "Computer Control the Cooling Process in Permanent Mold Casting of Al-Si Alloy." Archives of Metallurgy and Materials 58, no. 3 (September 1, 2013): 977–80. http://dx.doi.org/10.2478/amm-2013-0114.

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Abstract The paper presents the test results of a computerized control system the sequential cooling process of permanent mold with use of water mist in the gravity die casting process. It describes the process for preparing high-quality casts made of AlSi7Mg alloy that achieves enhanced mechanical properties. A scheme of developed device and drivers for selected methods of sequence cooling for manufacturing of castings made in permanent steel mold was presented here. Also the microstructure and mechanical properties of received aluminium casts were described. It was shown that the use of a computer system to control the water mist cooling point of the mold not only accelerates the cooling of the cast and the gravity die casting cycle shortens, but also it has a positive effect on the microstructure and mechanical properties of castings made of unmodified AlSi7Mg alloy in a raw state.

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Mandley, Varinder, and Mamta Janagal. "Methodology to Reduce Casting Defects of Alluminium alloy using Post Heat Treatment." CGC International Journal of Contemporary Technology and Research 2, no. 1 (December 30, 2019): 77–80. http://dx.doi.org/10.46860/cgcijctr.2019.12.20.77.

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In early years with the expansion of industries and growth of technology, the usage of aluminum and its alloys is also expanding. Therefore It is additionally utilized in aviation and vehicle industries because of their low thickness, good hardness property, great mechanical properties, better consumption opposition and low coefficient of extension when compared with other metals and alloy. The initial step of assembling in the aluminum combinations begins with the throwing strategy in light of the fact that the underlying throwing structure importantly affects the achievement of thermo-mechanical properties. The initial step of manufacturing in the aluminium alloys is the casting method . The casting structure has an important effect on the success of thermo-mechanical properties. The quality of aluminum amalgams can be dictated by its size and microstructure highlights of circulation all through the throwing procedure. In this way, it is essential to characterize throwing parameters of the aluminum compounds examples for controlling the microstructure properties and throwing abandons. This paper depends on the strategy to evacuate throwing abandons and improve the hardness of the aluminum composites.

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44

Wang, L., Diran Apelian, and M. M. Makhlouf. "Optimization of Aluminium Die Casting Alloys for Enhanced Properties." Materials Science Forum 618-619 (April 2009): 601–5. http://dx.doi.org/10.4028/www.scientific.net/msf.618-619.601.

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Selecting an aluminum die casting alloy for a particular application often poses a challenge to designers and engineers. It is often difficult and sometimes not possible to find an alloy that meets all the requirements of the application; and in other times the alloy can be found, but it has a wide specified compositional range, and thus it exhibits a large variation in properties. Therefore, there is always a need to optimize existing alloys or to develop new alloys so that they meet the requirements of a given application. In order to help with the alloy selection and alloy development processes, we developed an electronic database for aluminum die casting alloys – i-Select-Al. This software can help its user to quickly select an alloy for a specific application from a comprehensive list of commercial alloys. Alternatively, it can help its user with the design of a new alloy to meet the requirements of the application. This paper presents a study in optimizing A380 alloy with the help of i-Select-Al. A380 alloy is the most commonly used die casting alloy, but it has a wide compositional range and therefore a wide range of properties. In this study, we optimized the mechanical properties of A380 alloy by optimizing its chemical composition. The Quality Index was used to quantify the changes in the alloys’ properties in response to changes in chemical composition. Two alloys were designed: one has a composition within the A380 alloy specification, and the other has a composition slightly outside the A380 alloy specification. Both alloys showed significant improvements in room temperature tensile properties and a substantial increase in the Quality Index over a commercially available A380 alloy.

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Fracchia, Elisa, Federico Simone Gobber, and Mario Rosso. "Effects of Casting-Additives on the Microstructure Evolution of Hypoeutectic Aluminium-Silicon Alloys." Metals 10, no. 5 (May 9, 2020): 618. http://dx.doi.org/10.3390/met10050618.

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Since the industries are called to produce environmentally friendly products, the research is moving toward new improved materials. In this panorama, aluminium alloys find applications for a large range of products. In the automotive, as well as in the aerospace, sector, aluminium alloys are largely adopted, thanks to their high specific properties and their light weight. Moreover, common casting techniques permit us to realize complex high-quality components. These components may be realized by using casting techniques adopting casting-additives, such as modifiers or refiners. In this work, the effect of refining and modification was studied in terms of microstructural evolution of the intermetallic phases in two aluminium-silicon alloys (EN AC 45300 and EN AC 43500). Microstructures were analyzed through micro-hardness measures, and we found a reduction in the standard deviation of the hardness with the addition of additives. Furthermore, secondary dendrites arms spacings (SDAS) were measured, evidencing a decrease in SDAS by adding casting additives. A strong correlation was found between the adding of additives and the possibility of containing the size of the silicon and of all the intermetallic phases opening up to the possibility of tailoring the microstructures.

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Barekar, Nilam S., Sanjeev Das, and Zhong Yun Fan. "Melt Conditioned Twin Roll Casting (MC-TRC) for Aluminium Alloys." Materials Science Forum 794-796 (June 2014): 1115–20. http://dx.doi.org/10.4028/www.scientific.net/msf.794-796.1115.

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Twin roll casting (TRC) has been demonstrated to be an effective route for producing Al sheet at a reduced cost. However, the quality of the Al alloys sheets produced by the TRC process is limited by the formation of centreline segregation, which hampers the downstream processing, degrade the mechanical performance of the final rolled products, limit TRC to dilute alloys with a narrow freezing range, and hence prevent its application in a wide range of engineering sectors. To improve the quality of the TRC strips, a new technology, melt conditioning twin roll casting (MC-TRC) has been developed. It has been demonstrated that the MC-TRC process is capable of producing Al-alloy strips with minimal centerline segregation which is attributed to enhanced nucleation by well dispersed naturally occurring oxides in liquid Al alloys. This work aims to investigate the upper composition limit allowed for the MC-TRC process using the binary Al-Mg alloys as model alloys. The results showed that melt conditioning increases the range of alloys (solute content up to 7%) that can be twin roll cast without severe segregation.

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P, Nagasankar, Sathiyamoorthy V, Gurusamy P, VinothKanna P, Manibharathi D, and Srikanth P. "Reduction of Blowholesin Aluminium High Pressure Die Casting Machine." International Journal of Engineering & Technology 7, no. 3.34 (September 1, 2018): 410. http://dx.doi.org/10.14419/ijet.v7i3.34.19336.

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The main objective of this research is to reduce the blowholes by analyzing the factors which are affected during the casting process. The process parameters are optimized and change is made in the design part to reduce the blowhole and to increase the efficiency of the high pressure die casting machines. Product manufactured from every manufacturing process shows some defects. For supplying quality product to the customer these defects must be reduced. In this work, an attempt is made to reduce the rejection due to the blowhole defect is found out through why-why analysis technique. Process capability of current high pressure die casting manufacturing process is checked. Manufacturing process found capable to manufacture the components. Current problem of blowhole defect is solved making an improvement in design of die which we insert. In gate directions are changed so as to obtain modified improved flow pattern. Using magma flow simulationsoftware existing and modified design has then been compared. It is found that, modified design shows superior results and using this, the defect of blowholes is minimized up to satisfactory level.

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Weiss, David, and Michael Black. "The Use of High Pressure Direct Squeeze Casting for Semi-Solid Processing of Aluminum Base Nano Composites." Solid State Phenomena 192-193 (October 2012): 72–75. http://dx.doi.org/10.4028/www.scientific.net/ssp.192-193.72.

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The production of nano-reinforced aluminium alloys in volume and quality suitable for subsequent shape casting has been problematic. Large specific surface area and high interfacial energy of the particles combined with high surface tension of the aluminium melt makes it difficult to add appreciable numbers of particles to the melt, even when later de-agglomerated by techniques such as ultrasonic cavitation. The objective of this work was to develop a technique to incorporate particles using pressure applied while the alloy was in a semi-solid state. The composites produced could be used as a master alloy to inoculate large batches of metal for subsequent casting using any suitable technique. The results show excellent distribution of 50 nm alumina particles in 2014 material. The procedure appears to have broad applicability to a full range of aluminium alloys and particle reinforcements.

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Maryani, Edna, Humiras Hardi Purba, and Sunadi. "Analysis of Aluminium Alloy Wheels Product Quality Improvement Through DMAIC Method in Casting Process: A Case Study of the Wheel Manufacturing Industry in Indonesia." Journal Européen des Systèmes Automatisés 54, no. 1 (February 28, 2021): 55–62. http://dx.doi.org/10.18280/jesa.540107.

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The global market demand for automotive wheels with alloy materials is 55%, which is quite high compared to other materials such as steel, magnesium, chromed, and carbon fiber. The high competition of the global alloy wheels market demands to be able to offer quality alloy wheels. The purpose of this research is to reduce the number of defects in the casting process step by using the Define Measure Analyze Improve Control (DMAIC) method. This study shows the systematic approach to find the root cause of major defects in aluminum castings using the defect diagnostic approach as well as cause and effect diagram. Quality improvement using quality tools, namely the Pareto diagram, fishbone diagram. The major defects for the rejections during production were identified as leak defects, porosity motive holes, and oval defects. In determining the proposed quality improvements using the FMEA tool. The results of data processing on the calculation of process capabilities and product performance show improvements after quality improvements in the casting process. Product performance from DPMO = 15.462, sigma level = 3.6 to DPMO = 8.186 and sigma level = 3.9. The effect of decreasing the percentage of defects could save production costs by IDR 413.350.000. Therefore, the application of the DMAIC method can provide a significant improvement in product quality and impact on production cost savings.

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Knych, Tadeusz, Andrzej Mamala, and Wojciech Ściężor. "Effect of Selected Alloying Elements on Aluminium Physical Properties and its Effect on Homogenization after Casting." Materials Science Forum 765 (July 2013): 471–75. http://dx.doi.org/10.4028/www.scientific.net/msf.765.471.

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Modern technology for near net shape aluminium alloy flat rolled products includes twin roll casting, cold rolling and heat treatment. The technology is most common for 1XXX, 3XXX and 8XXX aluminium alloys. In fact, this technology of cold forming is applied to materials with as cast structure which may in some cases limit formability during rolling. As a consequence, the fundamental operation for high quality products is a well chosen homogenization process of material after casting. During the homogenization of 8XXX alloys after twin roll casting, important changes in electrical conductivity of the material have been reported in the literature. Possibly, the observed effects are connected with the migration of alloying element atoms in the microstructure. This study presents the influence of selected alloying elements on the electrical conductivity and mechanical properties of aluminium. On this basis, it is possible to analyse the effect and level of diffusion of alloying elements from particles to matrix and from matrix to particles during homogenization of 8XXX alloys in as cast temper. Additional comparison of experimental results with theoretical considerations via Nordheim’s rule was also analyzed in this study.

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Journal articles on the topic 'Aluminium casting; Quality'

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