Journal articles: 'Aluminum casting'

1

Midson, Stephen. "Industrial Applications for Aluminum Semi-Solid Castings." Solid State Phenomena 217-218 (September 2014): 487–95. http://dx.doi.org/10.4028/www.scientific.net/ssp.217-218.487.

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The goal of this paper is to examine industrial applications for semi-solid castings, and to develop strategies necessary for the wider commercialization of the semi-solid casting process. The performance and production techniques of semi-solid castings are reviewed, with the goal of identifying commercial niches where semi-solid castings can provide clear benefits over other casting process. A comparison of mechanical properties between semi-solid castings and other casting processes is presented. In addition, this paper provides an evaluation of the features of the optimal semi-solid casting processes, examines the characteristics of components that would benefit for production by semi-solid casting and describe the types of quality systems that casters need to have in place to make these types of castings. Cost analyses are presented suggesting that rheocasting can complete well with other casting processes.

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Rapp, Bob. "Casting aluminum." Materials Today 8, no. 7 (July 2005): 6. http://dx.doi.org/10.1016/s1369-7021(05)70961-5.

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FUJITA, Masato. "Casting and die castings of aluminum alloys." Journal of Japan Institute of Light Metals 39, no. 9 (1989): 664–83. http://dx.doi.org/10.2464/jilm.39.664.

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Vanko, Branislav, Ladislav Stanček, Michal Čeretka, Eduard Sedláček, and Roman Moravčík. "Properties of EN AW-2024 Wrought Aluminum Alloy after Casting with Crystallization under Pressure." Scientific Proceedings Faculty of Mechanical Engineering 23, no. 1 (December 1, 2015): 58–65. http://dx.doi.org/10.1515/stu-2015-0009.

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Abstract Establishing of wrought aluminum alloys casting to manufacture is now a global trend, for example due to lower production costs compare to forging or due to the ability to produce parts with thinner sections and more complex shapes. The aim of using these alloys in the foundry industry is in particular the creation of castings with higher mechanical properties than achieve castings made of standard casting aluminum alloys. Most often are cast wrought aluminum alloys of the 2xxx, 6xxx and 7xxx series. In the experiment, an alloy EN AW-2024 has been cast by modified technology of casting with crystallization under pressure. They were measured basic mechanical properties of the castings in the as-cast state and after heat treatment.

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Wang, Xue Dong, Jian He Lin, Suo Qing Yu, and Li Yong Ni. "Casting Mold Designing for Aluminum Alloy Car Holders." Applied Mechanics and Materials 378 (August 2013): 350–54. http://dx.doi.org/10.4028/www.scientific.net/amm.378.350.

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The structure and processing of car holders castings were analyzed. Die-casting molding process scheme was established. The design of mold includes three core-drawing mechanisms. the gate of the gating system was arranged on the casting bottom surface. For economy and die easy maintenance considerations, die-casting machine, mold, and mold standard parts should be standard parts. The designs of mold gating system and non-standard pieces were completed with the aid of PROE. Proved by actual production, the mold operated smoothly, without clamping stagnation, and the production of die castings meet delivery requirements.

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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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He, Li Tong, Yi Dan Zeng, and Jin Zhang. "Solidification and Microstructure Simulation of A356 Aluminum Alloy Casting." Materials Science Forum 1033 (June 2021): 18–23. http://dx.doi.org/10.4028/www.scientific.net/msf.1033.18.

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To obtain an A356 aluminum alloy casting with a uniform structure and no internal shrinkage defects, ProCAST software is used to set different filling and solidification process parameters for an A356 aluminum alloy casting with large wall thickness differences, And multiple simulations are conducted to obtain optimized casting process; then, based on the process, the microstructure of the thickest and thinnest part of the casting are simulated. The size, morphology, and distribution of the simulated microstructure of the thinnest part and the thickest part of the casting are very similar. The simulated microstructure is similar to that of the actual casting. This shows that castings with uniform structure and no internal shrinkage defects can be obtained through the optimized casting process .

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MIZUNO, Shinya. "New technologies of aluminum castings. New casting process." Journal of Japan Institute of Light Metals 47, no. 11 (1997): 580–86. http://dx.doi.org/10.2464/jilm.47.580.

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9

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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11

Xu, Yong Tao, Tian Yang Guan, Zhi Feng Zhang, Yue Long Bai, and Wei Min Mao. "Semi-Solid Rheological Squeeze Casting Process of ZL114A Aluminum Alloy Thin-Wall Complex Casting." Materials Science Forum 993 (May 2020): 248–53. http://dx.doi.org/10.4028/www.scientific.net/msf.993.248.

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High-strength aluminum alloy with large-scale and thin-walled complex castings have broad application prospects in aerospace, weapons, electronics, defense and military industries. However, due to the uneven thickness of the plate, the casting defects are inevitable by the ordinary casting method, and it is impossible to accurately control the shape and performance of the casting in the casting process. Previous studies have found that the semi-solid rheological extrusion casting technology with short process and near-end type can help solve this technical problem. Therefore, this paper studies the semi-solid rheological extrusion casting process of thin-walled complex casting of ZL114A aluminum alloy. The combination of numerical simulation and experimental research is used to simulate and optimize the filling and solidification process of thin-walled specimens. Based on this, a semi-solid rheological extrusion casting test was conducted. The result showed that, (1) The optimized model can well reflect the filling and solidification process under different rheological extrusion casting parameters, and obtain defect-free castings through process optimization. (2) The thin-walled parts of the thin plate casting produced by semi-solid rheology extrusion have excellent mechanical property and ductility.

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Kovtunov, A. I., D. A. Semistenov, Yu Yu Khokhlov, and S. V. Myamin. "The research of the processes of formation of porous non-ferrous metals." Vektor nauki Tol'yattinskogo gosudarstvennogo universiteta, no. 2 (2021): 9–17. http://dx.doi.org/10.18323/2073-5073-2021-2-9-17.

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Foamed metals are promising materials with a unique combination of mechanical and operational properties: low specific gravity, low thermal conductivity, ability to absorb acoustic and electromagnetic vibrations, and the ability to deform under a constant load. Currently, the most used methods for producing foamed aluminum and foamed magnesium are methods based on mixing gas or porophore into molten aluminum and forming a porous structure during the solidification of the aluminum melt. An alternative to this technology is the formation of a porous structure through the use of soluble granules that pre-fill the mold and after impregnating the granules with molten metal and solidifying the castings, they are leached. The work aims to determine the influence of casting modes and the size of granules on the depth of impregnation of granular filling with metal melt during the formation of porous aluminum castings. The authors proposed the technique for calculating the depth of impregnation of granular filling when producing castings of porous non-ferrous metals based on the calculation of melt cooling when moving along the thin-walled channel. The calculations made it possible to determine the depth of impregnation and establish the allowable wall thickness of the casting of porous aluminum, depending on the size of the granules used, the speed of the melt in a form, the mold temperature, and the temperature of molten aluminum. The study identified that to increase the depth of impregnation and obtain porous aluminum castings with thinner walls, it is advisable to increase the diameter of the salt granules and not the temperature and hydrodynamic modes of casting. The authors carried out calculations and identified the influence of the casting regimes and the diameter of the granules on the depth of mold impregnation to obtain porous castings from promising magnesium alloys.

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Liu, Yong Zhen, Guo Ming Cui, Jian Min Zeng, Wu Kui Gan, and Jin Bo Lu. "Prediction and Prevention of Distortion for the Thin-Walled Aluminum Investment Casting." Advanced Materials Research 915-916 (April 2014): 1049–53. http://dx.doi.org/10.4028/www.scientific.net/amr.915-916.1049.

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Investment casting is one of main precision casting processes to realize near net shape castings. For the castings with thin-walled cross section or complicated shape, it is easy to generate casting stress such as thermal stress, mechanical stress and phase transformation stress, resulting in casting deformation due to the uneven cooling and hindered contraction. Once three-dimensional deformation is formed, it is very hard to correct. In this paper the finite element method (FEM) was used to analyze the stress and deformation of thin-walled lost wax casting. The results show that the temperature and stress distributions are uneven in the casting and the tendency to deform is higher even with insulating shell mold. And based on the results, the technical measures of adding supporting ribs are adopted to restrain deformation. The practice of volume production indicates that no casting was rejected due to deformation defects.

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Gaspar, Stefan, and Jan Pasko. "Homogeneity of Aluminum Castings and Dependency on Increasing Pressure." Key Engineering Materials 669 (October 2015): 134–41. http://dx.doi.org/10.4028/www.scientific.net/kem.669.134.

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The production of die castings cast into a metal mold has in recent years achieved an expansive growth in the volume as well as the range of production and that is particularly in aviation and automobile industry. In the process of die casting the final quality of a cast is influenced by a great number of factors. The main factors of die casting are: pressing velocity, increase pressure, the melt temperature and the mold temperature. A primary criterion for achieving reliability, efficiency and quality of production is to ensure minimization of the castings defects occurrence in castings correct setting technological factors of die casting. The presented paper deals with the experimental assessment of the impact of increase pressure on the mechanical properties and homogeneity of a die cast.

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Yu, Huan, Jia Hui Wang, Bo Wen Xiong, Qing Song Yan, Zhi Feng Xu, and Guo Feng Liu. "Study on the Grade-Controlled Filling of Vacuum Counter-Pressure Casting Thin Wall Aluminum Alloy." Advanced Materials Research 337 (September 2011): 522–25. http://dx.doi.org/10.4028/www.scientific.net/amr.337.522.

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The grade-controlled filling behavior of vacuum counter-pressure casting thin wall aluminum alloy was studied by numerical simulation and experimental investigation. According to the analysis of filling behavior under fixed pressure and the casting structure, the technology of the grade-controlled filling of vacuum counter-pressure casting thin wall aluminum alloy was suggested. The result shows that the filling velocity was controlled on grade, resulting in the smoothly and sequential filling behavior, and the decreasing of defects in castings.

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Wongpreedee, Kageeporn, Panphot Ruethaitananon, and Tawinun Isariyamateekun. "Interface Layers of Ag-Al Fusing Metals by Casting Processes." Advanced Materials Research 787 (September 2013): 341–45. http://dx.doi.org/10.4028/www.scientific.net/amr.787.341.

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The materials of fusing metals commercially used in the jewelry niche marketing is seen as precious metals. An innovation of fusing metals searched for new materials to differentiate from the markets for mass production. In this research, it studied the bonding processes of silver and aluminium metals by casting processes for mass productions. The studies had been varied parameters on the types of aluminium and process temperature controls. This research had used two types of aluminium which were pure aluminium 99.99% and aluminum 5083 alloys bonding with pure silver 99.99%. The temperatures had been specified for two factors including casting temperature at X1, X2 and flasking temperature at Y1, Y2. From the results, it was found that the casting temperature at 730°C and the flasking temperature at 230 °C of pure silver-aluminum 5083 alloys bonding had the thinnest average thickness of interface at 427.29 μm. The microstructure of pure silver-aluminum 5083 alloy bonding was revealed eutectic-like structures at the interfaces. The EDS analysis showed the results of compounds at interface layers of Ag sides giving Ag2Al intermetallics on pure silver-aluminum 5083 alloy bonding unlike pure silver-pure aluminium bonding giving Ag3Al intermetallics.

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Yan, Qing Song, Zi Peng Tu, Gang Lu, Bai Ping Lu, Chang Chun Cai, and Shou Yin Zhang. "Effect of Vacuum Degree on Pinhole of Vacuum Counter-Pressure Casting Molten Aluminum Alloy." Applied Mechanics and Materials 278-280 (January 2013): 381–84. http://dx.doi.org/10.4028/www.scientific.net/amm.278-280.381.

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During vacuum counter-pressure casting, the vacuumization is an important stage for thin-wall and complicated aluminum alloy castings. Through testing and an analyzing numbers of pinhole and pinhole grade of aluminum alloy samples under different vacuum degree, the effect of vacuum degree on pinhole of vacuum counter- pressure casting molten aluminum alloy is studied. The results indicate vacuum degree has greater effect on pinhole of molten aluminum alloy in vacuumizing process. The smaller vacuum degree is, the more numbers of pinhole of the samples are, and the higher pinhole grade of the samples is. Therefore, when vacuum degree is small, pinhole of molten aluminum alloy appears easily. So the vacuum degree doesn’t choose too small, but for thin-wall and complicated aluminum alloy castings, the vacuum degree doesn’t choose too big either. Appropriate vacuum degree is from 20 KPa to 40 KPa.

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Bobba, Sujith, Sambasiva Rao Mukkollu, Z. Leman, and Harish Babu Bachina. "Experimental Investigation on the Effect Due to Mould Vibrations on Mechanical and Metallurgical Properties of Aluminum Alloy (A-1050)." International Journal of Surface Engineering and Interdisciplinary Materials Science 9, no. 1 (January 2021): 77–86. http://dx.doi.org/10.4018/ijseims.2021010105.

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In the current research work performed, the consequences caused in the casting aluminum alloy specimen due to mechanical mould vibrations are examined. Mould vibration throughout the casting provides decreased rate of shrinkage, good morphology, surface finish and lesser probability of hot tear. In this research work, the effect of mould vibration during solidification of Aluminum A-1050 alloys for dissimilar values of wavelengths at a permanent pouring temperature has been investigated to understand the modification in microstructure and mechanical properties after casting. The Al A-1050 casting has been made in a metal mould with different vibrations. The frequencies are varied from 15Hz to 50 Hz during the casting process. A casting has been made with different vibration as well to compare the results of castings with vibration frequencies. The experimental outcomes exhibited substantial grain refinement and significant increase in tensile strength and hardness of the castings with mechanical mould vibration during the duration and after solidification.

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Kim, Myoung Gyun, Gyu Chang Lee, and Joon Pyo Park. "Continuous Casting and Rolling for Aluminum Alloy Wire and Rod." Materials Science Forum 638-642 (January 2010): 255–60. http://dx.doi.org/10.4028/www.scientific.net/msf.638-642.255.

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Since the Continuous Casting & Rolling of the non-ferrous metal by Illario Properzi have invented in 1944, the various non-ferrous rod, wire and sheet are produced at present. Although there is long research and trials for producing the wire or rod of commercial the high-strength aluminum alloy, there are few companies with the success in producing commercial hard-aluminum alloys wire and rod by CC&R process. The application of the high-strength aluminum alloy rod or wire is various parts such as rivet, bolt, sports leisure supplies, high-tension power transmission wire, machinable and forgeable materials. However, it is very difficult to produce the high-strength aluminum alloy wire and rod by CC&R process because of the wide mushy zone and high strength compared with the pure or low strength aluminum alloy. Additionally, it is easy to crack and breakout in casting and rolling process due to tiny internal defects of the castings. The object of this project is to design the most suitable equipments for CC&R and optimize the experimental condition of continuous casting condition of the high-strength aluminum alloy. The facilities of CC&R process in RIST are composed of the melting furnace, the wheel casting machine, the automatic machine for moving of castings bar, the 15-step rolling machine with three rolls, the induction heater for reheating the castings bar and the coiling machine. In the present work, through the numerical computer simulation, in first, we have developed the thermal model of the solidification behavior of the casting bar. Finally, using finite element code, Marc, the temperature distribution of each rolled bar and effective strain are obtained during continuous rolling.

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FUJITA, Masato. "Casting and die casting of aluminum alloys." Journal of Japan Institute of Light Metals 44, no. 10 (1994): 574–90. http://dx.doi.org/10.2464/jilm.44.574.

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Wang, Fei Fei, Yan Wei Sui, Yao Jian Ren, Xin Zhao, and Zhi Sun. "Defects Analysis and Improvement for Electricmotorcar Aluminum Alloy Wheel by Gravity Casting." Advanced Materials Research 189-193 (February 2011): 3880–85. http://dx.doi.org/10.4028/www.scientific.net/amr.189-193.3880.

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Analysis the electricmotorcar aluminum wheels’ hole defect on macroscopic and microscopic, observed that the main defects、concentrated site and the main alloy phase. Combined with the local casting technological parameters, the filling and solidification process of aluminium alloy hub was simulated by using Anycasting software. The results showed that: castings filling smoothly, at the junction of the spoke and the rim and the hub central are easy to produce casting defects. Using the optimized process parameters that is lower pouring temperature, higher pouring height and set the vent to experiment, after comparing the results with the original process known, Shrinkage and porosity defects decreased, but there are still some degree of defects, indicating optimized process parameters have some effect.

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Gaspar, S., and J. Pasko. "Pressing Speed, Specific Pressure and Mechanical Properties of Aluminium Cast." Archives of Foundry Engineering 16, no. 2 (June 1, 2016): 45–50. http://dx.doi.org/10.1515/afe-2016-0024.

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Abstract Recent research in the process of aluminum alloy die castings production, which is nowadays deeply implemented into the rapidly growing automobile, shipping and aircraft industries, is aimed at increasing the useful qualitative properties of the die casting in order to obtain its high mechanical properties at acceptable economic cost. Problem of technological factors of high pressure die casting has been a subject of worldwide research (EU, US, Japan, etc.). The final performance properties of die castings are subjected to a large number of technological factors. The main technological factors of high pressure die casting are as follows: plunger pressing speed, specific (increase) pressure, mold temperature as well as alloy temperature. The contribution discusses the impact of the plunger pressing speed and specific (increase) pressure on the mechanical properties of the casting aluminum alloy.

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Ragab, Khaled A., Mohamed Bouazara, Amine Bouaicha, and Hatem Mrad. "Materials Performance and Design Analysis of Suspension Lower-Arm Fabricated from Al-Si-Mg Castings." Key Engineering Materials 710 (September 2016): 315–20. http://dx.doi.org/10.4028/www.scientific.net/kem.710.315.

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The diversity of physical and mechanical properties of aluminum alloys leads to develop a variety of manufacturing processes including the semi-solid casting process. Fatigue failure is considered the most common problem occurred in automotive engineering applications by which the vehicle components, mainly suspension system parts, fail under conditions of dynamic loading. It is well known that the fatigue life of aluminum castings, mainly A357, is very sensitive to casting design as well as to casting defects and microstructure constituents. The fatigue characteristics of automotive lower suspension arm made of semi-solid A357 aluminum castings have been investigated using metallurgical and analytical approaches. The critical stress areas capable of initiating cracks during fatigue tests are detected by using fatigue experimental design for real part materials by the installation of strain gages on the suspension arm to calculate maximum stress; further more, analytical approach is applied using modelling software. Microstructure characteristics of the semisolid A357 under T6 heat treatment conditions are examined using scanning electron microscope. The results show that using the SEED casting technology (Swirled Enthalpy Equilibration Device) has an efficient effect on the mechanical and metallurgical characteristics of real part materials that are also affected by castings design.

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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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Vanko, Branislav, Ladislav Stanček, and Roman Moravčík. "EN AW-2024 Wrought Aluminum Alloy Processed by Casting with Crystallization under Pressure." Strojnícky casopis – Journal of Mechanical Engineering 67, no. 2 (November 1, 2017): 109–16. http://dx.doi.org/10.1515/scjme-2017-0024.

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AbstractBy using the wrought aluminum alloys can be created castings with higher mechanical properties than the castings made of standard foundry aluminum alloys, but it is necessary to handle the process of making sound castings without any defects such as hot tears and shrinkage porosity. In experiments, we have been studied of wrought aluminum alloy EN AW-2024 which has been processed by the casting with crystallization under pressure with forced flow. Castings were heat treated by standard T6 heat treatment.

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Ichikawa, Junichi, Tatsuro Hayashida, and Shinsuke Suzuki. "Compressive Properties of Porous Aluminum Alloy Fabricated by Joining Pipes and Melt through Continuous Casting." Materials Science Forum 761 (July 2013): 151–55. http://dx.doi.org/10.4028/www.scientific.net/msf.761.151.

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A porous aluminum alloy was fabricated by joining pure aluminum pipes and Al-13mass% Si melt through continuous casting. Compressive tests were carried out with test specimens of the porous aluminum alloy fabricated by this method, non-porous aluminum alloy fabricated by continuous casting using Al-Si melt, and porous aluminum alloy consisting of only Al-Si fabricated by drilling non-porous Al-Si bar. From the compressive tests, it was confirmed that specific proof strength of the porous aluminum alloy fabricated by joining pipes and melt can be described by rule of mixture of Al-Si base metal, pure aluminium pipes and pores.

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Choudhari, C. M., K. J. Padalkar, K. K. Dhumal, B. E. Narkhede, and S. K. Mahajan. "Defect Free Casting by Using Simulation Software." Applied Mechanics and Materials 313-314 (March 2013): 1130–34. http://dx.doi.org/10.4028/www.scientific.net/amm.313-314.1130.

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The use of Aluminum castings parts in the automotive industry has increased dramatically over the past few decades. The driving force for this increased use is vehicle weight reduction for improved performance. In many cases the mechanical properties of the cast aluminum parts are superior to those of the cast iron or wrought steel parts being used.This paper proposes the computer simulation of the sand casting of Aluminum Plate. It aims to study the behavior of fluid flow during mould filling and solidification and to optimize the process parameters, which help to predict and control casting defects such as gas porosity and shrinkage porosity. Here an attempt is being made to model and simulate the casting process using the AutoCAST software. The technological as well as practical aspects of using casting software are illustrated with an industrial case study.

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Kuo, Yeong Sant. "Effects of Casting Geometry on the Mechanical Properties of A201 Aluminum Alloy Castings in Chromite Sand Molds." Advanced Materials Research 1104 (May 2015): 149–53. http://dx.doi.org/10.4028/www.scientific.net/amr.1104.149.

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Systematic change of riser size together with variation of thickness and length of A201 aluminum alloy plate castings were studied to investigate the correlation between mechanical properties and porosity content. The molds with end chill for plate castings were made of 100% chromite sand by CO2 process. If soundness throughout the whole plate casting has to be guaranteed, the riser diameter should be proper design to the dimension of the plate. The tensile strength and elongation of A201 aluminum alloy plate casting is governed by riser diameter, thickness, and length of the plate.

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Chang, Qing Ming, Yin Kai Yang, Jing Yuan, and Xia Chen. "Numerical Simulation of Mold Filling and Solidification Behavior in Permanente Casting Process." Applied Mechanics and Materials 313-314 (March 2013): 179–83. http://dx.doi.org/10.4028/www.scientific.net/amm.313-314.179.

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Melt flow and casting solidification are essential parts of the permanent mold casting process and affect significantly the quality of castings．For this reason, accurate prediction of mold filling pattern and temperature field in permanent mold castings plays on an important role in producing sound castings. In this paper, the model filling and solidification of a box casting produced from an aluminum alloy is studied. Different casting processes are employed, simulated and optimized to obtain sound castings. Simulation results reveal that with appropriate gating system, pouring rate, cooling line, a smooth mold filling, reduced shrinkages and other defects are available and desired sound castings can be produced.

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MATSUO, Mamoru. "Continuous casting of aluminum." Journal of Japan Institute of Light Metals 39, no. 7 (1989): 524–38. http://dx.doi.org/10.2464/jilm.39.524.

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MATSUO, Mamoru. "Continuous casting of aluminum." Journal of Japan Institute of Light Metals 44, no. 9 (1994): 510–25. http://dx.doi.org/10.2464/jilm.44.510.

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Mollard, Francois R., Merton C. Flemings, and Eisuke F. Niyama. "Aluminum Fluidity in Casting." JOM 39, no. 11 (November 1987): 34. http://dx.doi.org/10.1007/bf03257537.

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Bui, R. T. "Aluminum casting furnace modeling." JOM 41, no. 2 (February 1989): 43–47. http://dx.doi.org/10.1007/bf03220826.

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Zeng, Yi Dan, Li Tong He, and Jin Zhang. "Numerical Simulation of Casting Deformation and Stress of A356 Aluminum Alloy Thin-Walled Frame Casting." Materials Science Forum 1033 (June 2021): 24–30. http://dx.doi.org/10.4028/www.scientific.net/msf.1033.24.

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One of the main reasons for the scrap of cast thin-wall frame aluminum alloy castings is deformation and cracking. It is an effective method for solving the problem by predicting the distribution of casting stress, clarifying the size of the deformation and the location of the crack, and taking necessary measures in the process. This paper uses the ProCAST software to simulate the thermal stress coupling of A356 thin-walled frame castings, analyzes the influence of pouring temperature, pouring speed and mold temperature on the stress field distribution of castings, predicts the hot cracking trend and deformation, and optimizes Casting process..

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Mäsiar, H., L. Repka, P. Lipták, and O. Híreš. "Investigate the Possibility of Tekcast Methods Used for Casting Polymeric Resin Materials." Archives of Foundry Engineering 14, no. 2 (June 1, 2014): 119–22. http://dx.doi.org/10.2478/afe-2014-0049.

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Abstract Contribution gives an overview of knowledge about the method of centrifugal casting with orientate on Tekcast system. Company Tekcast Industries has developed a device for centrifugal casting, extending the area of production of castings or prototyping of metal or plastic. Materials suitable for the centrifugal casting with flexible operating parameters may include non-ferrous metal alloy based on zinc or aluminum or non-metallic materials such as polyester resins, polyurethane resins, epoxy resins, waxes and the like. The casting process is particularly suitable for a wide range of commercial castings and decorative objects.

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KITAOKA, Sanji. "Melting and casting technology of recent aluminum alloy castings." Journal of Japan Institute of Light Metals 43, no. 11 (1993): 567–73. http://dx.doi.org/10.2464/jilm.43.567.

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Marukovich, E. I., A. M. Branovitskiy, A. A. Kruglov, V. A. Dement’ev, and N. P. Sadovskiy. "PRODUCTION OF ROTARY ENGINES’ PARTS FROM ALUMINUM ALLOYS USING LOST FOAM CASTING PROCESS." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 1 (April 6, 2018): 16–21. http://dx.doi.org/10.21122/1683-6065-2018-1-16-21.

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The production technology of casting details for rotary engine from the aluminum alloy АК12М2 is developed. The bulk density of expanded polystyrene to ensure the best quality of the surface of castings has been experimentally established. The lost foam casting shop was organized in the experimental department of the Institute.

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Curle, U. A., J. D. Wilkins, and G. Govender. "Industrial Semi-Solid Rheocasting of Aluminum A356 Brake Calipers." Advances in Materials Science and Engineering 2011 (2011): 1–5. http://dx.doi.org/10.1155/2011/195406.

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Industrial semi-solid casting trials of aluminum A356 brake calipers were performed over five days with the CSIR-RCS and high-pressure die casting process cell. Consecutive visual passed castings were used as the measure of process stability, and common defects between trials were categorized. Short fill results are erratic and caused by unintended underdosing by the furnace or incomplete billet discharge at the delivery point in the shot sleeve. Cold shuts can be significantly reduced by adjusting the shot control profile. Surface finish defects include surface roughness and staining caused by lubricant burn off. Visual passed castings display none of the above-mentioned external defects. X-ray examination and pressure testing of heat-treated castings from the consecutive visual passed castings show improvement over the five days. These initial-stage industrialization efforts pave the way for process commercialization.

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Tsuji, Makoto. "Automation of Die Casting." International Journal of Automation Technology 2, no. 4 (July 5, 2008): 285–88. http://dx.doi.org/10.20965/ijat.2008.p0285.

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Die-casting is a process to manufacture high-accuracy castings at high productivity using nonferrous metals such as zinc, copper, aluminum and magnesium. Die-casting includes many processes such as lubricant spray to the die, injection of molten metal, taking off the casting from the die, and trimming of unnecessary parts. Nowadays all these processes of die casing can be conducted by fully automated die-casting machines. TOSHIBA MACHINE CO., LTD has taken the lead in development of die-casting machines. Here we will be introducing the common process flow and details of some of major components of the die-casting equipment.

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Kuo, Yeong Sant. "Study of Solidification Time and Solidus Velocity on Porosity Formation in High Strength Aluminum Alloy Castings." Applied Mechanics and Materials 575 (June 2014): 442–45. http://dx.doi.org/10.4028/www.scientific.net/amm.575.442.

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The purpose of the present study was to discuss the effects of local solidification time and solidus velocity on porosity formation in high strength aluminum alloy casting. With systematic change in the riser size, together with variation of thickness and length, A201 aluminum alloys were cast in 100% silica sand molds. The porosity content of A201 aluminum alloy was affected by the local solidification time and solidus velocity in this study. The correlation between porosity content and solidification time is found to be split into 2 bands, each being associated with one of the two thicknesses of plate castings. The longer the solidification time, the more the porosity content was measured in the A201 aluminum alloy plate casting. And the faster the solidus velocity, the more the porosity content in this study. The porosity content of A201 aluminum alloy was influenced by both of solidification time and solidus velocity at same time in this study. Basically, shorter local solidification time with slow solidus velocity seems get lower porosity content in A201 aluminum alloy castings.

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Baraz, Vladislav R., S. S. Gerasimov, and I. A. Gruzdeva. "Cu-Ni-Zn 15-20 Alloy - Particular Qualities of Alloying and Crystallization Parameters." Solid State Phenomena 265 (September 2017): 767–71. http://dx.doi.org/10.4028/www.scientific.net/ssp.265.767.

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The article is devoted to the study of Cu-Ni-Zn ternary alloy properties. German silver is applied in the instrument making industry, shipbuilding industry, and medical tool production. Furthermore, German silver is extensively used for domestic goods and costume jewelry. It is known that the aluminum and tin additions improve the Cu-Ni-Zn alloy flowing and casting mold fillability. It is a matter for the figurine and thin section casting production. That is why, using the experiment planning method we have studied the effect of Al and Sn alloyage and crystallization temperature on structure, casting characteristics and the casting characteristics of German silver. The study was realized by casting samples which were produced with lost wax method. Aluminum microadditives (0.4 %) have a positive impact on the casting mold fillability and improve markedly surface quality of casting samples. Tin leading into melt (about 4 %) ensure the marked growth of yield strength (by 65...70 %), while the elongation is maintained. The role of the mold temperature has a lesser impact on the yield strength. The mold temperature reduction from 550 °C to 450 °C leads to the grain size decrease and the little yield strength increase. Moreover, the surface condition measurement shows that aluminum and tin additions greatly reduce the castings surface roughness.

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Santoso, Eko Budi, and Eva Hertnacahyani Herraprastanti. "Pelatihan Pengecoran Limbah Aluminium Rumah Tangga untuk Meningkatkan Nilai Jual bagi Masyarakat di Kabupaten Madiun." J-ABDIPAMAS (Jurnal Pengabdian Kepada Masyarakat) 3, no. 2 (October 20, 2019): 81. http://dx.doi.org/10.30734/j-abdipamas.v3i2.538.

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ABSTRACTÂ The purpose of this activity is to conduct training for the community, especially from around Madiun, to be able to do aluminum waste treatment by doing re-casting to be printed into a craft that is worth selling. Re-casting in this activity uses the simplest tool in the hope that it can be reached by the target community. This casting can be done by using a simple kitchen by using a fire furnace with combustion using LPG. The training activity was held for 2 (two) days, with the details of the first day in the form of material about metals and casting while the second day was carried out by the practice. The results of this activity are in creasing knowledge about metals, especially aluminum and knowledge of simple casting practices.Keywords: Waste, aluminum, casting, sand moldABSTRAKÂ Tujuan dari kegiatan ini adalah melakukan pelatihan kepada masyarakat khususnya dari sekitar Madiun agar dapat melakukan pengolahan limbah aluminium dengan melakukan pengecoran ulang untuk di cetak menjadi kerajinan yang layak jual. Pengecoran ulang dalam kegiatan ini menggunakan alat yang paling sederhana dengan harapan bisa dijangkau oleh masyarakat kalayak sasaran. Pengecoran ini dengan menggunakan dapur sederhana dengan menggunakan tungku api dengan pembakaran menggunakan LPG. Kegiatan pelatihan ini dilaksanakan selama 2 (dua) hari, dengan rincian hari pertama berupa materi tentang logam dan pengecoran sedang hari kedua adalah dengan pelaksanaan praktek. Hasil dari kegiatan ini adalah bertambahnya pengetahuan mengenai logam khususnya aluminium dan pengetahuan praktek pengecoran sederhana.Â Kata Kunci: Limbah, aluminium, pengecoran, cetakan pasir

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Georgiev, Georgi Evt, Sasho Popov, Valentin Manolov, Rositsa Dimitrova, and Pavel Kuzmanov. "Heat Transfer Process Computer Simulation and Microstructure Prediction During Crystallization of Metal Alloys." Journal of Theoretical and Applied Mechanics 43, no. 1 (March 1, 2013): 71–78. http://dx.doi.org/10.2478/jtam-2013-0007.

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Abstract Processes of crystallization during casting formation from aluminum alloys, steel and cast iron have been studied using 3-D com- puter simulation. Temperature fields of castings have been obtained and the microstructure distribution of these castings has been predicted. A comparison between numerical results and experimental measurement has been performed. It is proved, that the proposed approach is suitable for investigation and analysis of casting technologies.

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Cheng, Le, Hong Xing Lu, Qiang Zhu, Xiang Kai Zhang, Ai Di Shen, and Peng Yang. "Evolution of Microstructure and Mechanical Properties of Semi-Solid Squeeze Cast A356.2 Aluminum Alloy during Heat Treatment." Solid State Phenomena 285 (January 2019): 139–45. http://dx.doi.org/10.4028/www.scientific.net/ssp.285.139.

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Semi-solid squeeze casting (SS-SC) is a new processing technology which combines semi-solid processing (SSP) and squeeze casting (SC). In this process, semi-solid slurry fills mold by using its rheological property and solidifies under high pressure. It has several advantages, such as stable filling, small heat impact to the mold, low cost, high density and excellent mechanical properties of castings, which receives more and more attention. The microstructure of castings provided by SS-SC is quite different from that of casting provided by conventional SC in as-cast condition, which leads to differences in the evolution of microstructure and mechanical properties in heat treatment process. In this study, A356.2 aluminum alloys castings were provided by both SS-SC and conventional SC respectively. The evolution of microstructure and mechanical properties of castings during heat treatment was investigated to obtain the best mechanical properties of semi-solid squeeze castings. Keywords:Microstructure, Mechanical properties, Heat treatment, A356 alloy, Semi-Solid Squeeze Casting

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Jie, Wan Qi, Xin Lei Li, and Qi Tang Hao. "Counter-Gravity Casting Equipment and Technologies for Thin-Walled Al-Alloy Parts in Resin Sand Molds." Materials Science Forum 618-619 (April 2009): 585–89. http://dx.doi.org/10.4028/www.scientific.net/msf.618-619.585.

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A counter-gravity casting equipment (CGCE) has been developed, which is specially designed for the production of large-size thin-walled high-quality aluminum alloy parts with resin sand molds. In this equipment, molten metal will be pushed upward counter-gravity into the mold at predetermined rate by compressed air, and solidified at an increased pressure. The equipment uses assembled valve system developed ourselves, and has sensitive pressure-adjusting property. All of the casting parameters, including filling rate, pressure-exerting sequence, pressure hold time etc., can be closely controlled by a self-designed computer program. Up to 2 ton casting can be produced with the equipment. Compared to the castings produced under conventional gravity conditions, the castings under counter-gravity condition have generally high soundness, higher tensile strengths and ductility. The pinhole defects are also degraded obviously. The equipment and the technology have been widely adopted by several users in China for the production of large-size thin-walled aluminum alloy castings with high property requirements.

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Ni, Li Yong, and Peng Liu. "Numerical Simulation and Production Trial of Aluminum Alloy Gear Box Housing." Applied Mechanics and Materials 703 (December 2014): 232–36. http://dx.doi.org/10.4028/www.scientific.net/amm.703.232.

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Die casting processing analysis was conducted and the gating system and the cooling system were designed for aluminum alloy gearbox housings. Numerical simulation software PROCAST was used to calculate the filling and solidification sequence and the temperature field of die castings. The reasonable designs of the gating system and the cooling system were obtained. The feasible die casting mould was designed and manufactured. Production trial showed that, casting molding effect is good, and there were not defects such as misrun, cold lap. After machining, there were not defects exceeding the allowed limited values including porosity, shrinkage, and slag inclusion in the products. The trial showed that the product mold design and die casting technology achieved the desired effect, which can realize batch production.

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Huang, Pei Hsing, Wei Jen Wu, and Chung Han Shieh. "Compute-Aided Design of Low Pressure Die-Casting Process of A356 Aluminum Wheels." Applied Mechanics and Materials 864 (April 2017): 173–78. http://dx.doi.org/10.4028/www.scientific.net/amm.864.173.

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The lightweight design of aluminum automobile wheel can easily bring about all kinds of defects during die-casting, which often causes wheel frame deformation and creep damages in the future use and in turn affects traffic safety. To understand the evolution of mold flow, temperature field, and solidification, the low pressure die-casting processes of A356 aluminum wheel were simulated by Anycasting software package. Various casting parameters combined with the designs of flow channel and overflows were adopted to reduce the defects occurred in wheel products. In addition, we adopted the retained melt modulus (RMM) to predict the position of defects to be formed as well as their distribution so as to eliminate the shrinkage voids and porosity defects during die-casting. The research findings showed that the setting up of overflow tank could effectively prevent the formation of shrinkage void and porosity of die-castings and significantly promote the quality and productivity of die-casting wheel products.

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Liu, Xiao Bo, and Wen Kang Yan. "Influence of Different Roll Casting Conditions on Casting Microstructure." Advanced Materials Research 652-654 (January 2013): 2432–36. http://dx.doi.org/10.4028/www.scientific.net/amr.652-654.2432.

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The changes of roll casting microstructure under different casting conditions on experimental casting machine was studied, which showed that solidification microstructure is different with different casting speed and thickness. When the casting speed is 1.3m/min,the thickness of strip is 6mm, coarse columnar grain dominates the solidification structure; when it continuously increases to 4m/min, the thickness of strip is 3mm, aluminum strip shows as hybrid organization with columnar grains in two sides and small equiaxed grains in the center; when the casting speed is over 12m/min,the thickness of strip is 1.75mm, columnar grains all convert into equiaxed grains in solidification structure. The deformation microstructures are different with the different casting speed and thickness of strip. When the casting speed is 0.9m/min, the thickness of strip is 6mm, typical processing flow lines come into being along longitudinal direction and transverse direction shows as squashed grains without re-crystallization. When the casting speed is 5.4m/min, the thickness of strip is 2.5mm, microstructure of aluminum strip becomes chevron organization from columnar crystal, there is a condensate in the center of aluminum strip, and the deformation of outer metal is more serious than inner, incomplete dynamic recrystallized grains come into being in the outer metal of the aluminum strip.

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Szalva, Péter, and Imre Norbert Orbulov. "Influence of Vacuum Support on the Fatigue Life of AlSi9Cu3(Fe) Aluminum Alloy Die Castings." Journal of Materials Engineering and Performance 29, no. 9 (August 27, 2020): 5685–95. http://dx.doi.org/10.1007/s11665-020-05050-y.

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Abstract High-pressure die casting (HPDC) is a near-net-shape process that produces high quality castings with narrow dimensional tolerances. The HPDC castings are being increasingly used due to good flexibility and high productivity, especially for the automotive industry. Depending on the location of the cast components, there are ever more complex geometries and increasing strength requirements that can be achieved by the application of vacuum-assisted die casting (VPDC). The most specific features of the HPDC process are the rapid mold filling, high cooling rate and intensification pressure. As a consequence of these highlighted features, the process generally leads to the formation of casting defects, such as gas porosity, shrinkage, and entrapped oxide films. However, the VPDC casting process is capable to significantly reduce the amount of these casting defects. The aim of this work is to compare the HPDC and VPDC castings’ high-cycle fatigue behavior and to describe how the casting defects affect the fatigue failure. Before the fatigue tests, the samples were investigated with non-destructive (NDT) materials testing methods such as hydrostatic weighing, x-ray, and computer tomography (CT) to characterize the gas pore and shrinkage pore populations of the material. The AlSi9Cu3(Fe) aluminum alloy castings have been subjected to constant amplitude load by uniaxial fatigue tests in the high-cycle fatigue region with a stress asymmetry ratios of R = −1 and R = 0.1. The resulting fracture surfaces are analyzed through light optical microscopy (LOM) and scanning electron microscopy (SEM). VPDC increased the number of cycles to fracture and decreased the scatter at the given load levels compared to conventional HPDC casting. Moreover, VPDC significantly decreased the porosity size and volume, and the occurrence of oxide flakes is also decreased, resulting in the improvement in the number of cycle to failure.

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Sadokha, M. A. "Technological features of piston casting." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 4 (December 16, 2020): 64–67. http://dx.doi.org/10.21122/1683-6065-2020-4-64-67.

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The results of studies of obtaining complex castings from aluminum alloys using the self-filling method are presented. The influence of a number of technological parameters (pouring time, chill cooling mode, the use of self-filling, etc.) on the quality of the resulting piston castings has been studied. The optimal time for filling the chill mold was determined when casting pistons. It is shown that the chill mold cooling mode has a significant impact on the quality of castings.

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Journal articles on the topic 'Aluminum casting'

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