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Journal articles on the topic 'Aluminum castings. Metals'

Author: Grafiati

Published: 4 June 2021

Last updated: 1 February 2022

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1

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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2

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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3

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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4

Opsal Bakke, Aina, Arne Nordmark, Lars Arnberg, and Yanjun Li. "Interfacial microstructure formation in A356/steel compound castings using metal coating." MATEC Web of Conferences 326 (2020): 06005. http://dx.doi.org/10.1051/matecconf/202032606005.

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Compound castings between aluminum and steel have great potential for applications in the automotive industry. However, due to large differences in thermal and mechanical properties between steel and aluminum, and the formation of stable aluminum oxides at the interface, it is difficult to form high strength metallic bonding between the two metals. In this work, A356/steel compound castings were produced through a gravity casting process. Various metal coatings, including galvanizing, aluminizing and brass-coating, were applied on the steel inserts to ensure that the A356 aluminum melt could react sufficiently with an oxide-free steel surface, resulting in a high-quality metallurgical bond. The reaction layer formed between the alloys was investigated using Optical Microscopy (OM), Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS). In addition, Vickers Micro-hardness was measured across the aluminum-steel interface. Results showed that metallurgical bonding could be achieved with all three coatings. However, for the brass-coated components only local bonding areas were found. In the aluminized and galvanized components, thick reaction layers consisting of binary Al-Fe and ternary Al-Fe-Si phases formed in the aluminum-steel interface. Between the A356 aluminum and aluminized layer, nearly no reaction layer formed. The mechanism for the formation of the various intermetallic phases at the reaction layers are discussed.

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5

Nikitin, K. V., A. V. Sokolov, V. I. Nikitin, and N. V. D’yachkov. "THE USE OF ALUMINUM SLAG RECYCLING PRODUCTS IN INVESTMENT CASTING TECHNOLOGIES." Izvestiya Vuzov Tsvetnaya Metallurgiya (Proceedings of Higher Schools Nonferrous Metallurgy, no. 6 (December 14, 2018): 58–71. http://dx.doi.org/10.17073/0021-3438-2018-6-58-71.

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The studies of fractional, chemical and phase compositions of aluminum-containing slags of different origin found that slags are multi-component systems consisting of metal and non-metal parts. The non-metal part contains water-soluble and water-insoluble components. A practical scheme for recycling aluminum-containing slags was proposed in order to isolate the water-insoluble component to be further used a secondary refractory dusting material. It was found that the secondary refractory dusting material has a positive effect on the quality of refractory ceramic molds in investment casting and the surface finish of experimental aluminum castings. This material improves the strength of refractory ceramic molds by 9 times in comparison with silica sand molds and increases gas permeability by 15 % to 33 % in comparison with fused alumina and silica sand molds, respectively. The study covers the processes used to produce refractory ceramic molds based on the secondary refractory dusting material. The mechanism of interaction between dusting material particles and suspension is theoretically justified in terms of colloid chemistry. Negatively charged aluminum hydroxide micelles appear when ceramic mold layers are formed using the secondary refractory dusting material. Interaction between differently charged Al(OH)3 and SiO2 micelles makes secondary refractory dusting material particles come in close contact with each other. The theoretically justified processes of ceramic mold layer formation with the secondary refractory dusting material make it possible to explain the reduction in the surface roughness of castings made of AK9ch aluminum casting alloy using investment casting by 3.7 times compared with standard production processes.

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6

Górny, M., and M. Kawalec. "Role of Titanium in Thin Wall Vermicular Graphite Iron Castings Production." Archives of Foundry Engineering 13, no. 2 (June 1, 2013): 25–28. http://dx.doi.org/10.2478/afe-2013-0030.

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Abstract In this paper the effects of titanium addition in an amount up to 0.13 wt.% have been investigated to determine their effect on the microstructure and mechanical properties of Thin Wall Vermicular Graphite Iron Castings (TWVGI). The study was performed for thinwalled iron castings with 3-5 mm wall thickness and for the reference casting with 13 mm. Microstructural changes were evaluated by analyzing quantitative data sets obtained by image analyzer and also using scanning electron microscope (SEM). Metallographic examinations show that in thin-walled castings there is a significant impact of titanium addition to vermicular graphite formation. Thinwalled castings with vermicular graphite have a homogeneous structure, free of chills, and good mechanical properties. It may predispose them as a potential use as substitutes for aluminum alloy castings in diverse applications.

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7

Dolata, A. J. "Centrifugal Castings Locally Reinforced with Porous AL2O3 Preform." Archives of Metallurgy and Materials 59, no. 1 (March 1, 2014): 345–48. http://dx.doi.org/10.2478/amm-2014-0057.

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Abstract The main objective of presented researches were tests of infiltration of the porous ceramic preforms at the pressure in centrifugal casting process. Make an assumption that the porous preform will be create the local reinforcement layer in specific area of the casting. For investigations the alumina porous ceramic preforms were applied (Al2O3). The pressure to infiltrate molten aluminum alloy into ceramic preforms was generated by centrifugal force. The structure of composites was examined by light and electron microscope. The investigations of composites microstructure exhibited high degree of infiltration of spherical macropores in Al2O3 ceramic preforms by the molten aluminium alloy. On the basis of structural studies has been shown that centrifugal force is effective as a driving force for the infiltration of porous preforms.

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8

Wyatt, J. E., J. T. Berry, and A. R. Williams. "Residual stresses in aluminum castings." Journal of Materials Processing Technology 191, no. 1-3 (August 2007): 170–73. http://dx.doi.org/10.1016/j.jmatprotec.2007.03.018.

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9

Žbontar, Matic, Mitja Petrič, and Primož Mrvar. "The Influence of Cooling Rate on Microstructure and Mechanical Properties of AlSi9Cu3." Metals 11, no. 2 (January 21, 2021): 186. http://dx.doi.org/10.3390/met11020186.

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The aim of this study was to determine the correlation between the size and the distribution of microstructural constituents and their cooling rate, as well as the correlation between the mechanical properties and the cooling rate of AlSi9Cu3 aluminum alloy when cast in high-pressure die casting (HPDC) conditions. In other words, the ultimate goal of the research was to determine the mechanical properties for a casting at different cooling rates. Castings with different wall thicknesses were chosen, and different cooling rates were assumed for each one. Castings from industrial technological practice were systematically chosen, and probes were extracted from those castings for the characterization of their mechanical properties. Special non-standard cylinders were created on which compressive tests were carried out. The uniqueness of this research lies in the fact that the diameters of the designed cylinders were in direct correlation to the actual wall thickness of the castings. This is important because the solidification of metal in the die cavity is complex, in that the cooling rates are higher on the surface of the casting than in the center. Local in-casting cooling rates were determined using numerical simulations. It was discovered that with increasing cooling rates from 60 K/s to 125 K/s the values for strength at 5% deformation increased on average from 261 MPa to 335 MPa.

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10

Fraś, E., M. Górny, and W. Kapturkiewicz. "Thin Wall Ductile Iron Castings: Technological Aspects." Archives of Foundry Engineering 13, no. 1 (March 1, 2013): 23–28. http://dx.doi.org/10.2478/afe-2013-0005.

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Abstract The paper discusses the reasons for the current trend of substituting ductile iron castings by aluminum alloys castings. However, it has been shown that ductile iron is superior to aluminum alloys in many applications. In particular it has been demonstrated that is possible to produce thin wall wheel rim made of ductile iron without the development of chills, cold laps or misruns. In addition it has been shown that thin wall wheel rim made of ductile iron can have the same weight, and better mechanical properties, than their substitutes made of aluminum alloys.

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11

Władysiak, R. "Effect of Multipoint Sequential Water Mist Cooling of Casting Die on Microstructure and Mechanical Properties of AlSi11 Alloy." Archives of Foundry Engineering 12, no. 4 (December 1, 2012): 145–50. http://dx.doi.org/10.2478/v10266-012-0123-9.

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Abstract The work is a continuation of research on the use of water mist cooling in order to increase efficiency of the die-casting process for aluminum alloys. The paper describes the multipoint sequential cooling system of the casting die and its computer control and monitoring. It also includes results of the tests and analysis of cooling methods during making of the casting. These methods differ from each other in the sequence of casting die cooling and cause effective changes in microstructure and mechanical properties of castings made of AlSi11 alloy. The study demonstrated that the use of multipoint sequential cooling with water mist affects the microstructure refinement and reduces the segregation in the cast as well as more than by 20% increases the mechanical properties of castings in the rough state. The study also demonstrates that the sequential cooling of casting die accelerates the cooling of the casting and shortens die-casting cycle.

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12

Merta, Václav, Jaroslav Beňo, Tomáš Obzina, Filip Radkovský, Ivana Kroupová, Petr Lichý, Martin Folta, Kamila Janovská, Isabel Nguyenová, and Miroslav Dostál. "Innovative Inorganic Binder Systems for the Production of Cores for Non-Ferrous Metal Alloys Reflecting the Product Quality Requirements." Metals 11, no. 5 (April 29, 2021): 733. http://dx.doi.org/10.3390/met11050733.

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The aim of this study is the evaluation of the parameters of core mixtures using different binder systems with regard to the collapsibility of cores after casting and the resulting product quality of castings reflecting surface requirements based on non-ferrous alloys. The research compares organically bonded core mixtures based on phenol-formaldehyde resins for the production of cores with the shell molding (resin coated sand), currently used in the production of aluminum alloy castings in the Brembo Czech s.r.o., and mixtures using innovative inorganic binder systems based on geopolymers; GEOPOL® W. The aim of the research is to compare the advantages and disadvantages of these binder systems in order to evaluate the potential of inorganically bonded mixtures to replace organically bonded mixtures, which would lead to a significant reduction in the environmental impacts of industrial production of castings.

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13

Cao, Hanxue, Chengcheng Wang, Junqi Che, Ziwei Luo, Luhan Wang, Lang Xiao, Jing Wang, and Tao Hu. "Effect of Flow State of Pure Aluminum and A380 Alloy on Porosity of High Pressure Die Castings." Materials 12, no. 24 (December 16, 2019): 4219. http://dx.doi.org/10.3390/ma12244219.

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Air entrapment defects prevent the heat treatment from improving the mechanical properties of die castings, which limits the die casting of high-performance components. The flow pattern of the filling process is complicated and experimental analysis is difficult in thin-walled complex die castings. In this study, we constructed a shock absorption tower to observe in real-time the filling process of pure aluminum and A380 aluminum alloy at different fast injection speeds. The degree of breakup of pure aluminum was larger than that of A380 during the filling process, which caused the porosity of pure aluminum to be greater than that of the A380 at each observation position. Re-Oh diagrams explained the difference in porosity between the two metals. The porosity in different regions was closely related to the flow state of aluminum liquid. In addition to porosity measurements, we specifically analyzed the relationship between the porosity of the flowback zone, the final filling zone, and the near-tail zone of cylinder. At the same injection velocity, the porosity at flowback zone was greater than that at the final filling position, the porosity at final filling position was larger than that at the near-tail zone of cylinder, and the final filling position changed as the injection velocity changed.

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14

YANAGIMOTO, Shigeru. "New technologies of aluminum castings. Continuous casting of narrow billet for forging." Journal of Japan Institute of Light Metals 47, no. 11 (1997): 605–12. http://dx.doi.org/10.2464/jilm.47.605.

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15

OKANO, Shinobu. "New technologies of aluminum castings. Processing of semi-solid aluminum alloys." Journal of Japan Institute of Light Metals 47, no. 11 (1997): 598–604. http://dx.doi.org/10.2464/jilm.47.598.

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16

YAO, Qiang, Toshiro KOBAYASHI, Hiroyuki TODA, and Hisashi HORI. "New technologies of aluminum castings. Effect of microstructure on fracture toughness of cast and forged aluminum casting alloys." Journal of Japan Institute of Light Metals 47, no. 11 (1997): 613–19. http://dx.doi.org/10.2464/jilm.47.613.

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17

SATOH, Takashi. "New technologies of aluminum castings. The latest technology of die casting and low pressure casting process." Journal of Japan Institute of Light Metals 47, no. 11 (1997): 591–97. http://dx.doi.org/10.2464/jilm.47.591.

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18

Hangai, Yoshihiko, and Takao Utsunomiya. "Manufacture of Porous Aluminum Using Containing Gases Inside Aluminum Alloy Die Castings." Journal of the Japan Institute of Metals 73, no. 6 (2009): 484–86. http://dx.doi.org/10.2320/jinstmet.73.484.

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19

A. Hussein, Hussein, Mohammed J. Kahdim, and Alaa Abdulhasan Atiyah. "Corrosion Behaviour of Passive Layer Growth by Controlling Additives of Nano-Metals-Phosphate to Pure Aluminum." Diyala Journal of Engineering Sciences 13, no. 4 (December 9, 2020): 1–9. http://dx.doi.org/10.24237/djes.2020.13401.

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This study investigates how microstructure and chemistry effects by Nano-Metal-Phosphate and the kinetics of growth passive layer and passivity breakdown. Additionally, the passive layer germination behavior on aluminum alloy 1050 with anticorrosive properties. The passive layer is an alloying method which allows an aluminum oxide to germinate. Morphologically and structurally, the aluminum oxide films were characterized using microscopy analyzes and XRD analysis. Results indicated that the reinforcements are well distributed and the grin size is downy. Corrosion behavior tested by Cyclic polarization exam and done at room temperature in (3.5 per cent NaCl) solution. The reinforcement increased the hardness for processed aluminum from Hv81.1 to HV=120.492 as castings. The parameter Nano-Metal-Phosphate has attenuated the current density of corrosion (7.15μA / cm2) compared to the as-cast sample results.

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20

Hangai, Yoshihiko, and Takao Utsunomiya. "Fabrication of Porous Aluminum Using Gases Intrinsically Contained in Aluminum Alloy Die Castings." Metallurgical and Materials Transactions A 40, no. 6 (April 18, 2009): 1284–87. http://dx.doi.org/10.1007/s11661-009-9835-z.

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21

Tiryakioğlu, Murat, Pedram Yousefian, and Paul D. Eason. "Quantification of Entrainment Damage in A356 Aluminum Alloy Castings." Metallurgical and Materials Transactions A 49, no. 11 (August 9, 2018): 5815–22. http://dx.doi.org/10.1007/s11661-018-4865-z.

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22

NISHIMURA, Tetsuzo. "New technologies of aluminum castings. Cast and forge process." Journal of Japan Institute of Light Metals 47, no. 11 (1997): 587–90. http://dx.doi.org/10.2464/jilm.47.587.

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23

Moizumi, Ken. "Strength of aluminum alloy castings on automotive engine parts." Journal of Japan Institute of Light Metals 63, no. 3 (March 30, 2013): 125–31. http://dx.doi.org/10.2464/jilm.63.125.

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24

Chen, Shuying, Shengnan Ma, Zhilin Chen, Xudong Yue, and Guowei Chang. "Casting Defects in Transition Layer of Cu/Al Composite Castings Prepared Using Pouring Aluminum Method and Their Formation Mechanism." High Temperature Materials and Processes 38, no. 2019 (February 25, 2019): 199–206. http://dx.doi.org/10.1515/htmp-2017-0124.

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AbstractIn this study, Cu/Al composite castings were prepared using the pouring aluminum method, and the casting defects in the transition layer and their formation mechanism were investigated. Shrinkage cavities, shrinkage porosities, and cracks were easily formed in the transition layer, and the thickness of the transition layer was uneven after recombination of the solid Cu and liquid Al. Shrinkage cavities easily formed within the α + eutectic (α + CuAl2) phase, and cracks mainly appeared within the Cu9Al4 and CuAl2 phases. The transition layer with uneven thickness and irregular shape readily formed where the metals solidified last during the solidification; the difference in density between solid Cu and liquid Al, as well as the natural convection in the melt, were responsible for these irregular shapes. As the metals shrunk, shrinkage cavities and porosities formed without external melt feeding. Cracks formed in the Cu9Al4 and CuAl2 phases and at the Cu9Al4/CuAl2 and CuAl2/eutectic (α(Al + CuAl2) interfaces during the solid shrinkage process after the solidification was complete.

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25

Dybalska, Agnieszka, Adrian J. Caden, David J. Parker, John Wedderburn, and William D. Griffiths. "Liquid Metal Flow Studied by Positron Emission Tracking." Metallurgical and Materials Transactions B 51, no. 5 (July 6, 2020): 1912–17. http://dx.doi.org/10.1007/s11663-020-01897-7.

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Abstract To improve the properties of castings, a new technique to observe the fluid flow and study the motion of oxygen-bearing inclusions has been developed. This new technique, Positron Emission Particle Tracking (PEPT), enabled a single radioactive tracer particle, moving inside a liquid metal casting, to be tracked with an accuracy of some millimeters, depending on the properties of the liquid metal and the mold. These novel experiments give promising results to observe the liquid metal flow and locate the tracked particle in a casting. Experiments have shown that various particle sizes (200 to 600 μm presented here) can be used to observe the liquid metal flow, if the particle has sufficiently initial radioactivity. Different sizes of particles are considered and their radioactivity compared in terms of their usefulness for tracking in flowing liquid aluminum according to the specific surface area.

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26

Han, Qingyou. "A Modified Cast-on Method for the Reinforcement of Aluminum Castings with Dissimilar Metals." Metallurgical and Materials Transactions B 47, no. 6 (February 29, 2016): 3266–73. http://dx.doi.org/10.1007/s11663-016-0612-2.

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27

MURASHIMA, Izumi, Akira ISHIKAWA, Hideto SASAKI, and Naomi NISHI. "Formation mechanism of surface segregation in aluminum alloy die castings." Journal of Japan Institute of Light Metals 49, no. 10 (1999): 487–92. http://dx.doi.org/10.2464/jilm.49.487.

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28

SHINODA, Takeshi, and Mika KAWAI. "Surface modification of aluminum alloy castings using plastic flow phenomenon." Journal of Japan Institute of Light Metals 53, no. 1 (2003): 15–19. http://dx.doi.org/10.2464/jilm.53.15.

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29

Shangguan, Haolong, Jinwu Kang, Chengyang Deng, Yongyi Hu, and Tao Huang. "3D-printed shell-truss sand mold for aluminum castings." Journal of Materials Processing Technology 250 (December 2017): 247–53. http://dx.doi.org/10.1016/j.jmatprotec.2017.05.010.

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30

Verran, G. O., R. P. K. Mendes, and L. V. O. Dalla Valentina. "DOE applied to optimization of aluminum alloy die castings." Journal of Materials Processing Technology 200, no. 1-3 (May 2008): 120–25. http://dx.doi.org/10.1016/j.jmatprotec.2007.08.084.

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31

YOKOTA, Shigeaki, Kaneo MIZUNO, and Tatsuichi FUKUSAKO. "Effect of casting modulus on structure and mechanical strength of AC4B aluminum alloy square column castings." Journal of Japan Institute of Light Metals 50, no. 5 (2000): 198–202. http://dx.doi.org/10.2464/jilm.50.198.

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32

Wang, Q. G., and P. E. Jones. "Prediction of Fatigue Performance in Aluminum Shape Castings Containing Defects." Metallurgical and Materials Transactions B 38, no. 4 (September 18, 2007): 615–21. http://dx.doi.org/10.1007/s11663-007-9051-4.

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Popov, A. V., I. A. Zamorkina, and A. F. Smirnov. "Structure of aluminum castings produced by directed crystallization in ultrasonic fields." Metal Science and Heat Treatment 31, no. 9 (September 1989): 705–7. http://dx.doi.org/10.1007/bf00717494.

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MIZUNO, Kaneo, Shigeo FURUTANI, Shigeaki YOKOTA, and Tatsuichi FUKUSAKO. "Effect of casting modulus on mechanical strength and dendrite arm spacing of AC4B flat aluminum alloy castings." Journal of Japan Institute of Light Metals 46, no. 2 (1996): 55–60. http://dx.doi.org/10.2464/jilm.46.55.

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SHINODA, Takeshi, Jinqi LI, and Akira YOSHIZAWA. "Surface modification of AC2B aluminum alloy castings using friction thermomechanical process." Journal of Japan Institute of Light Metals 49, no. 12 (1999): 607–12. http://dx.doi.org/10.2464/jilm.49.607.

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HANGAI, Yoshihiko, Soichiro KITAHARA, and Shigeyasu AMADA. "Reduction of porosity in aluminum alloy die castings by compression load." Journal of Japan Institute of Light Metals 56, no. 2 (2006): 112–16. http://dx.doi.org/10.2464/jilm.56.112.

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37

Ridgeway, Colin D., Keith Ripplinger, Duane Detwiler, and A. A. Luo. "A New Model for Predicting Oxide-Related Defects in Aluminum Castings." Metallurgical and Materials Transactions B 51, no. 5 (August 14, 2020): 1989–2002. http://dx.doi.org/10.1007/s11663-020-01918-5.

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38

Te, Alino, Bryer C. Sousa, Brajendra Mishra, and Danielle L. Cote. "Subsurface Microstructural Evolution of High-Pressure Diecast A365: From Cast to Cold-Sprayed and Heat-Treated Conditions." Metals 11, no. 3 (March 5, 2021): 432. http://dx.doi.org/10.3390/met11030432.

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The use of cold spray deposition, coupled with diffusion-driven thermal postprocessing, is considered herein as a surface modification process such that near-surface microstructural, micromechanical, and microchemical property improvements can be procured for cost-effective and common aluminum alloy castings. Since the present work was an exploratory investigation into the realm of cold spray induced, high-pressure diecast aluminum subsurface property development and evolution, as well as surface modification, one significant aim was to formalize a set of fundamental observations for continued consideration of such an approach to achieving premium aluminum alloy properties from cost-effective alternatives. Nickel, copper, and titanium cold spray modified near-surface regions of the cost-effective high-pressure diecast A365 system was considered. Near-surface, subsurface, and surface evolution was documented across each of the three pure metal coatings. The analysis was continued across two postprocessing coating-substrate atomic diffusion inspired heat-treated conditions as well. Using energy-dispersive X-ray spectroscopy, field-emission scanning electron microscopy, optical microscopy, and various insights gleaned from an original contextualization of the relevant cold spray literature, noteworthy results were recorded and discussed herein. When copper feedstock was employed alongside thermal postprocessing, diverse surface-based intermetallic compounds formed alongside exotic diffusion zones and severely oxidized regions, thus eliminating thermally activated copper cold-sprayed consolidations from future work too. However, both nickel and titanium cold spray surface modification processing demonstrated potential and promise if correct processing stages were performed directly and chronologically. Consequently, a platform is presented for further research on cold sprayed surface microstructural and property modification of cost-effective alloyed aluminum castings.

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39

Ramrattan, S. "Evaluating a Ceramic Resin-Coated Sand for Aluminum and Iron Castings." International Journal of Metalcasting 13, no. 3 (October 11, 2018): 519–27. http://dx.doi.org/10.1007/s40962-018-0269-5.

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40

Lumley, Roger N., Maya Gershenzon, and Dayalan R. Gunasegaram. "Alloy Design for Enhancing the Fracture Resistance of Heat Treated High Pressure Die-Castings." Materials Science Forum 654-656 (June 2010): 954–57. http://dx.doi.org/10.4028/www.scientific.net/msf.654-656.954.

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Recently, heat treatment technologies have been developed by the CSIRO Light Metals Flagship in Australia that allow the 0.2% proof stress of conventional aluminum alloy high pressure diecastings (HPDC’s) to be more than doubled without encountering problems with blistering or dimensional instability [1,2]. A range of other properties may also be improved such as fatigue resistance, thermal conductivity and fracture resistance. However, the current commercial HPDC Al-Si-Cu alloys have not been developed to exploit heat treatment or to optimize these specific mechanical properties, and one potential limitation of heat treating HPDC’s is that fracture resistance may be reduced as strength is increased. The current paper presents the outcomes of a program aimed at developing highly castable, secondary Al-Si-Cu HPDC alloys which display significantly enhanced ductility and fracture resistance in both the as-cast and heat treated conditions. Kahn-type tear tests were conducted to compare the fracture resistance of the conventional A380 alloy with a selection of the newly developed compositions. A comparison has also been made with the current permanent mold cast aluminium alloys and it is shown that the new HPDC compositions typically display higher levels of both tensile properties and fracture resistance.

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YAE, Hitoshi, Ryosuke KIMURA, Makoto YOSIDA, Gen SASAKI, Jin PAN, Koichi YOKOYAMA, and Hideharu FUKUNAGA. "Effect of powder lubricants on surface quality of aluminum alloy die-castings." Journal of Japan Institute of Light Metals 52, no. 7 (2002): 303–7. http://dx.doi.org/10.2464/jilm.52.303.

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Lumley, Roger N. "A Preliminary Evaluation on the Fracture Toughness of Heat Treated Aluminium High Pressure Diecastings." Advanced Materials Research 41-42 (April 2008): 141–46. http://dx.doi.org/10.4028/www.scientific.net/amr.41-42.141.

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Until recently, the solution heat treatment of conventional aluminum high pressure die cast (HPDC) parts has been considered impractical because the high temperatures involved cause surface blistering and dimensional instability. Now, a new heat treatment procedure has been developed by the CSIRO Light Metals Flagship in Australia which avoids these problems and, in many cases, allows tensile properties such as 0.2% proof stress to be doubled with little change to ductility. This development has the potential to reduce costs by allowing existing HPDC parts to be re-designed to use less metal and still achieve performance requirements. One issue, however, is the possibility that heat treating die castings to increase tensile properties may have an adverse effect on fracture toughness. This paper reports preliminary results of Kahntype tear tests conducted to assess the fracture resistance of as-cast and heat treated HPDCs. Studies of the alloys A360, A380 and C380 have shown that T4 and underaged (UA) T6 tempers produce an optimal combination of fracture resistance and tear strength. Furthermore, the fracture properties compare well with permanent mold and sand cast aluminium alloys that have similar tensile properties.

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Wu, Shi-ping, Ru-jia Wang, Ye Wang, Wei Chen, and Ze-sheng Ji. "Reduction of shrinkage porosities in aluminum alloy castings by external pressure fluctuation under gravity field." China Foundry 15, no. 5 (September 2018): 372–77. http://dx.doi.org/10.1007/s41230-018-7247-7.

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De Cicco, Michael, Lih Sheng Turng, Xiao Chun Li, and John H. Perepezko. "Semi-Solid Casting of Metal Matrix Nanocomposites." Solid State Phenomena 116-117 (October 2006): 478–83. http://dx.doi.org/10.4028/www.scientific.net/ssp.116-117.478.

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Semi-solid casting (SSC) techniques have proven useful in the mass production of high integrity castings for the automotive and other industries. Recent research has shown metal matrix nanocomposite (MMNC) materials to have greatly improved properties in comparison to their base metals. However, current methods of MMNC production are costly and time consuming. Thus development of a process that combines the integrity and cost effectiveness of semi-solid casting with the property improvement of MMNCs would have the potential to greatly improve cast part quality available to engineers in a wide variety of industries. This paper presents a method of combining SSC with MMNC in a way that benefits from MMNCs’ tendency to naturally form the globular microstructure necessary for SSC. This method uses ultrasonically dispersed nanoparticles as nucleating agents to achieve globular primary grains such that fluidity is maintained even at high solid fractions. Once particle dispersion is achieved, the material needs no further processing to become a semi-solid slurry of globular primary grains as it cools. This quiescent method of slurry production, while still imposing some constraints on cooling rates, has a large process window making this process capable of industrial rates of throughput. It was found that the key factor to achieving globular microstructure is a sufficiently slow cooling rate at the onset of solidification such that particle-induced nucleation can occur. Once nucleation occurs, continued cooling is virtually unconstrained, with globular microstructure evident in quenched samples as well as samples cooled at rates as slow as 1 °C/min. This method was demonstrated in several material systems using zinc (Zn), aluminum (Al), and magnesium (Mg) alloys and nanoparticles of aluminum oxide (Al2O3), silicon carbide (SiC), and titanium oxide (TiO2). Additionally, several nucleation models are examined for applicability to nanoscale composites.

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Xiao, Bowang, Qigui Wang, Parag Jadhav, and Keyu Li. "An experimental study of heat transfer in aluminum castings during water quenching." Journal of Materials Processing Technology 210, no. 14 (November 2010): 2023–28. http://dx.doi.org/10.1016/j.jmatprotec.2010.07.026.

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Schwankl, Matthias, Matthias Rübner, Markus Flössel, Sylvia Gebhardt, Alexander Michaelis, Robert F. Singer, and Carolin Koerner. "Active functionality of piezoceramic modules integrated in aluminum high pressure die castings." Sensors and Actuators A: Physical 207 (March 2014): 84–90. http://dx.doi.org/10.1016/j.sna.2013.12.016.

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Haselhuhn, Amberlee S., Paul G. Sanders, and Joshua M. Pearce. "Hypoeutectic Aluminum–Silicon Alloy Development for GMAW-Based 3-D Printing Using Wedge Castings." International Journal of Metalcasting 11, no. 4 (January 25, 2017): 843–56. http://dx.doi.org/10.1007/s40962-017-0133-z.

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Battaglia, Eleonora, Franco Bonollo, and Paolo Ferro. "Experimental Damage Criterion for Static and Fatigue Life Assessment of Commercial Aluminum Alloy Die Castings." Metallurgical and Materials Transactions A 48, no. 5 (March 7, 2017): 2574–83. http://dx.doi.org/10.1007/s11661-017-4038-5.

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Hangai, Yoshihiko, Shota Maruhashi, Soichiro Kitahara, Osamu Kuwazuru, and Nobuhiro Yoshikawa. "Nondestructive Quantitative Evaluation of Porosity Volume Distribution in Aluminum Alloy Die Castings by Fractal Analysis." Metallurgical and Materials Transactions A 40, no. 12 (October 2, 2009): 2789–93. http://dx.doi.org/10.1007/s11661-009-0009-9.

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KAWAI, Mika, and Takeshi SHINODA. "Effect of tool shape on surface modification of AC4C aluminum alloy castings applied FSW phenomenon." Journal of Japan Institute of Light Metals 53, no. 10 (2003): 405–9. http://dx.doi.org/10.2464/jilm.53.405.

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