scholarly journals Modelling the Mechanical Attributes (Roughness, Strength, and Hardness) of Al-alloy A356 during Sand Casting

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 598 ◽  
Author(s):  
Kashif Ishfaq ◽  
Muhammad Asad Ali ◽  
Naveed Ahmad ◽  
Sadaf Zahoor ◽  
Abdulrahman M. Al-Ahmari ◽  
...  
Keyword(s):  
Moisture Content ◽  
A356 Alloy ◽  
High Hardness ◽  
Casting Process ◽  
Sand Casting ◽  
Al Alloy ◽  
Electron Microscopic ◽  
Control Variables ◽  
Lower Velocity ◽  
Empirical Relations

Sand-casting is a well established primary process for manufacturing various parts of A356 alloy. However, the quality of the casting is adversely affected by the change in the magnitude of the control variables. For instance, a larger magnitude of pouring velocity induces a drop effect and a lower velocity increases the likelihood of cold-shut and mis-run types of defects. Similarly, a high pouring temperature causes the formation of hot tears, whereas a low temperature is a source of premature solidification. Likewise, a higher moisture content yields microcracks (due to gas shrinkages) in the casting and a lower moisture content results in the poor strength of the mold. Therefore, the appropriate selection of control variables is essential to ensure quality manufactured products. The empirical relations could provide valuable guidance in this regard. Additionally, although the casting process was optimized for A356 alloy, it was mostly done for a single response. Therefore, this paper aimed to formulate empirical relations for the contradictory responses, i.e., hardness, ultimate tensile strength and surface roughness, using the response surface methodology. The experimental results were comprehensively analyzed using statistical and scanning electron microscopic analyses. Optimized parameters were proposed and validated to achieve castings with high hardness (84.5 HB) and strength (153.5 MPa) with minimum roughness (5.8 µm).

OPTIMISATION OF SAND CASTING PROCESS FOR IMPELLER USING TAGUCHI METHODOLOGY

2020 ◽  
Vol XVII (2) ◽  
pp. 23-33
Author(s):  
Faisal Hafeez ◽  
Salman Hussain ◽  
Wasim Ahmad ◽  
Mirza Jahanzaib
Keyword(s):  
Surface Roughness ◽  
Surface Defects ◽  
A356 Alloy ◽  
Casting Process ◽  
Sand Casting ◽  
Gate Length ◽  
Taguchi Methodology ◽  
Confirmatory Tests ◽  
Binder Ratio ◽  
Response Measures

This paper presents the study to investigate the effects of binder ratio, in-gate length and pouring height on hardness, surface roughness and casting defects of sand casting process. Taguchi methodology with L9 orthogonal array was employed to design the experimentation. Sand casting of six blade impeller using A356 alloy was performed and empirical models for all the above response measures were formulated. Confirmatory tests and analysis of variance results confirmed the accuracy of the model. Binder ratio was found to be the most significant parameter affecting casting surface defects and surface roughness. This was followed by pouring height and in-gate length.

scholarly journals Effect of Moisture Content on the Permeability of Tailing Sand Samples Gathered from Ex Tin Mines in Perak State Malaysia

2011 ◽  
Vol 66-68 ◽  
pp. 1384-1389
Author(s):  
A. Abdullah ◽  
Shamsuddin Sulaiman ◽  
B.T. Hang Tuah Baharudin ◽  
M.K.A.M. Arifin ◽  
T.R. Vijayaram
Keyword(s):  
Moisture Content ◽  
Research Work ◽  
Casting Process ◽  
Vital Role ◽  
Sand Casting ◽  
Sand Sample ◽  
Molding Sand ◽  
Sand Mixture ◽  
Testing Procedures ◽  
Work Samples

Tailing sand is one of the residue minerals obtained after tin extraction. It contains silica in between 94% and 99.5% and available in abundance at the Kinta Valley, Perak State, Malaysia. Permeability is one of the important molding sand properties and considered much in the sand casting mold preparation. This molding sand property plays a vital role in the sand casting process and helps to remove the gases during the casting processing. In this research work, samples of tailing sands were gathered from four identified ex tin mines located at the Perak State, Malaysia. They were investigated by the standard sand testing procedures prescribed by the American Foundrymen Society (AFS). Sand specimens of size Ø50 mm×50 mm in height from various sand–water ratios bonded with 4% and 8% clay were compacted on applying three ramming blows of 6666 g each by using a Ridsdale-Dietert metric standard rammer. The specimens were tested for permeability number with the aid of a Ridsdale-Dietert permeability meter. Before the tests were conducted, the moisture content was measured by using a moisture analyzer. The results were compared with the properties of the molding sand samples collected from RCS Manufacturing Sdn. Bhd., the company supplying sand to the Proton Casting unit car manufacturing company. The molding sand sample sample bonded with 8% clay was found to have maximum permeability with an optimum allowable moisture content range of 3.5-6.0% and for the sand mixture bonded with 4% clay at 3.0-3.5% moisture.

scholarly journals Geometrical Parametric Optimisation of A356 Alloy Composite in a Two-Stage Casting Process for Automobile Wheel Covers using Response Surface Methodology

2020 ◽  
Vol 7 (1) ◽  
pp. 457-478 ◽  
Author(s):  
Sunday Oke ◽  
Stephen Chidera Nwafor ◽  
Chris Abiodun Ayanladun
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Regression Models ◽  
Predictive Accuracy ◽  
A356 Alloy ◽  
Casting Process ◽  
Sand Casting ◽  
Phase Method ◽  
Technical Solution ◽  
Two Phase

In recent years, novel products from out–of–use A356 alloy engine components are increasingly produced for the automobile industries. Despite being a promising method the sand casting of these products reveals an inadequately understood cast geometry phenomenon for the process. At present, there is no technical solution to the optimisation of cast geometries for A356 alloy reconfigured into composites through organic matter reinforcements. This paper models and analyse sand casting process product geometries in a two–phase method. It utilises the response surface methodology with data on inputs and outputs to create the regression. Volume and density of the first casting process and the weight loss were evaluated for the various groupings of casting process variables, including length, weight, height, width of product for the first casting, weight, length, breadth of the product for the second casting, and the total weight of organic materials. The input and output associations were established in two models of regression analysis representing the central composite design, CCD. The influences of the cast geometrical variables on the evaluated responses were analysed. Furthermore, the predictive accuracy of the two regression models was evaluated. Results revealed that the applied CCD and the regression models reveals statistical adequacy and are competent to predict accurately.

Morphology of aluminium with nickel addition on sand casting process

2018 ◽  
Vol 1 (87) ◽  
pp. 13-17
Author(s):  
P. Puspitasari ◽  
R. Fauzan ◽  
T.L. Ginta ◽  
M. Mustapha ◽  
D. Puspitasari
Keyword(s):  
Mechanical Properties ◽  
Grain Boundary ◽  
Casting Process ◽  
Sand Casting ◽  
Silica Sand ◽  
Phase Identification ◽  
Al Alloy ◽  
Simple Route ◽  
Ni Alloy ◽  
Nickel Addition

Purpose: his research aimed to examine the morphology, elemental changes, and phase in the aluminium cast alloys with variations in nickel addition of 1%, 2% and 3%. Design/methodology/approach: Aluminium 98% was melted in sand casting process. The sand casting process was operated at 7000C and atmospheric pressure. The addition of nickel contain of 92.19% of its element. Specimens consist of 4 pieces Al-Ni with the size of 1 x 1 x 0.5 cm for morphological testing, while for phase identification testing consist of 4 pieces Al-Ni with the size of 1 x 1 x 2 cm. The morphological testing was performed using FEI Inspect S50 Scanning Electron Microscope (SEM) and the phase characterisation was conducted using Nikon ME5 Optical Microscope. Findings: The results showed that the addition of 1% nickel in the aluminium cast product could affect the morphology in granular shape with as similar size, at 2% nickel addition also has granular shape, while at 3% of nickel addition, the morphology of Al-Ni was in elongated shape. Phase identification of Al-Ni cast alloy shows that there were Al matrix with nickel that spread in grain boundary of Al. By increasing the percentage of nickel, it shows that the nickel dominated the grain boundary of Al. These results shows that Al-Ni alloy can be produced at simple route on sand casting process. Research limitations/implications: Sand casting process with 80% silica sand, 10% bentonite, 5% water. Raw material of aluminium contains of 92-99% of purity. Nickel as addition element contain of 90-92% purity. Practical implications: The addition of nickel should be prepared wisely in term of the calculation of alloying treatment because it will effect the mechanical properties of Al alloy itself. This research can be improved by varying the temperature of casting process, variation of nickel percentage, and observation of mechanical properties of Al-Ni alloy. Originality/value: Simple route of making Al-Ni alloy using sand casting method in laboratory and also the observation of nickel addition in aluminium matrix as the result of casting product.

A microscopic marker experiment study on high temperature oxidation of Ni-Al alloy

1986 ◽  
Vol 44 ◽  
pp. 514-515
Author(s):  
Shou-kong Fan
Keyword(s):  
Transport Mechanism ◽  
High Temperature Oxidation ◽  
Transverse Section ◽  
Al Alloy ◽  
Metal Interface ◽  
Electron Microscopic ◽  
Temperature Oxidation ◽  
Analytical Electron ◽  
Microscopic Studies ◽  
First Time

Transmission and analytical electron microscopic studies of scale microstructures and microscopic marker experiments have been carried out in order to determine the transport mechanism in the oxidation of Ni-Al alloy. According to the classical theory, the oxidation of nickel takes place by transport of Ni cations across the scale forming new oxide at the scale/gas interface. Any markers deposited on the Ni surface are expected to remain at the scale/metal interface after oxidation. This investigation using TEM transverse section techniques and deposited microscopic markers shows a different result,which indicates that a considerable amount of oxygen was transported inward. This is the first time that such fine-scale markers have been coupled with high resolution characterization instruments such as TEM/STEM to provide detailed information about evolution of oxide scale microstructure.

scholarly journals Experimental and simulation analysis on multi-gate variants in sand casting process

2021 ◽  
Vol 62 ◽  
pp. 119-131
Author(s):  
I. Rajkumar ◽  
N. Rajini ◽  
A. Alavudeen ◽  
T. Ram Prabhu ◽  
S.O. Ismail ◽  
...  
Keyword(s):  
Simulation Analysis ◽  
Casting Process ◽  
Sand Casting

scholarly journals Experimental and numerical investigations of oxide-related defects in Al alloy gravity die castings

2021 ◽  
Author(s):  
Giulia Scampone ◽  
Raul Pirovano ◽  
Stefano Mascetti ◽  
Giulio Timelli
Keyword(s):  
Fluid Dynamic ◽  
Casting Process ◽  
Numerical Code ◽  
Al Alloy ◽  
Numerical Investigations ◽  
Die Casting Process ◽  
Experimental Findings ◽  
Die Castings ◽  
Filling And Solidification ◽  
Image Analysis Techniques

AbstractThis research aimed to study the formation and distribution of oxide-related defects in the gravity die casting process of an AlSi7Cu0.5Mg alloy by using experimental and numerical investigations. Metallographic and image analysis techniques were conducted to map the distribution of oxide inclusions inside the casting at the microscopic level. Numerical simulations were used to analyse the filling and solidification stages, and to foresee the turbulence of the melt and the formation of the oxide defects. The results show that most of the defects were correlated with the oxide layers or bubbles entrained inside the liquid metal. The accuracy of the numerical code in simulating the metal fluid-dynamic behaviour and the heat transfer was verified, and the results were in agreement with the experimental findings. The numerical distribution of defects was consistent with the experimental results, proving that the model successfully predicted the formation of oxide-related defects.

scholarly journals Mechanical Properties of Al Matrix Composite Enhanced by In Situ Formed SiC, MgAl2O4, and MgO via Casting Process

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1767
Author(s):  
Yuhong Jiao ◽  
Jianfeng Zhu ◽  
Xuelin Li ◽  
Chunjie Shi ◽  
Bo Lu ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Matrix Composite ◽  
Compression Strength ◽  
Casting Process ◽  
Al Alloy ◽  
Pyrolysis Process ◽  
Alloy Matrix ◽  
Al Matrix Composite ◽  
Al Matrix

Al matrix composite, reinforced with the in situ synthesized 3C–SiC, MgAl2O4, and MgO grains, was produced via the casting process using phenolic resin pyrolysis products in flash mode. The contents and microstructure of the composites’ fracture characteristics were analyzed by X-ray diffraction (XRD) and scanning electron microscopy (SEM). Mechanical properties were tested by universal testing machine. Owing to the strong propulsion formed in turbulent flow in the pyrolysis process, nano-ceramic grains were formed in the resin pyrolysis process and simultaneously were homogeneously scattered in the alloy matrix. Thermodynamic calculation supported that the gas products, as carbon and oxygen sources, had a different chemical activity on in situ growth. In addition, ceramic (3C–SiC, MgAl2O4, and MgO) grains have discrepant contents. Resin pyrolysis in the molten alloy decreased oxide slag but increased pores in the alloy matrix. Tensile strength (142.6 ± 3.5 MPa) had no change due to the cooperative action of increased pores and fine grains; the bending and compression strength was increasing under increased contents of ceramic grains; the maximum bending strength was 378.2 MPa in 1.5% resin-added samples; and the maximum compression strength was 299.4 MPa. Lath-shaped Si was the primary effect factor of mechanical properties. The failure mechanism was controlled by transcrystalline rupture mechanism. We explain that the effects of the ceramic grains formed in the hot process at the condition of the resin exist in mold or other accessory materials. Meanwhile, a novel ceramic-reinforced Al matrix was provided. The organic gas was an excellent source of carbon, nitrogen, and oxygen to in situ ceramic grains in Al alloy.

Investigation of Functionally Graded Aluminium A356 Alloy and A356-10%SiCp Composite for Hydro Turbine Bucket Application

2016 ◽  
Vol 26 ◽  
pp. 30-46 ◽  
Author(s):  
Williams S. Ebhota ◽  
Akhil S. Karun ◽  
Freddie L. Inambao
Keyword(s):  
Heat Treatment ◽  
Tensile Stress ◽  
Centrifugal Casting ◽  
A356 Alloy ◽  
Casting Process ◽  
Ultimate Tensile Stress ◽  
Functionally Graded ◽  
Cnc Machining ◽  
Mould Material ◽  
Turbine Bucket

The study investigates the application of centrifugal casting process in the production of a complex shape component, Pelton turbine bucket. The bucket materials examined were functionally graded aluminium A356 alloy and A356-10%SiCp composite. A permanent mould for the casting of the bucket was designed with a Solidworks software and fabricated by the combination of CNC machining and welding. Oil hardening non-shrinking die steel (OHNS) was chosen for the mould material. The OHNS was heat treated and a hardness of 432 BHN was obtained. The mould was put into use, the buckets of A356 Alloy and A356-10%SiCp composite were cast, cut and machined into specimens. Some of the specimens were given T6 heat treatment and the specimens were prepared according to the designed investigations. The micrographs of A356-10%SiCp composite shows more concentration of SiCp particles at the inner periphery of the bucket. The maximum hardness of As-Cast A356 and A356-10%SiCp composite were 60 BRN and 95BRN respectively, recorded at the inner periphery of the bucket. And these values appreciated to 98BRN and 122BRN for A356 alloy and A356-10%SiCp composite respectively after heat treatment. The prediction curves of the ultimate tensile stress and yield tensile stress show the same trend as the hardness curves.

XD™ Titanium Aluminide Composites

1988 ◽  
Vol 120 ◽  
Author(s):  
L. Christodoulou ◽  
P. A. Parrish ◽  
C. R. Crowe
Keyword(s):  
Titanium Aluminide ◽  
Elevated Temperatures ◽  
Coefficient Of Thermal Expansion ◽  
Measurement Techniques ◽  
Physical Property ◽  
Casting Process ◽  
Matrix Composition ◽  
Al Alloy ◽  
Matrix Composites ◽  
New Generation

AbstractThe advantages of reinforcing metals with ceramic particles to produce metal matrix composites are well known. The behavior of discontinuously reinforced intermetallic compounds, however, has not been extensively studied. Martin Marietta Laboratories has produced a new generation of discontinuously reinforced titanium aluminide composites using a proprietary casting process known as XD™ technology. These new materials possess enhanced properties at room and elevated temperatures and may be cast, extruded, or forged. The effects of matrix composition, reinforcing phase, and thermal mechanical processing on properties have been studied using optical and various electron microscopy and mechanical and physical property measurement techniques to characterize the alloys. To date, most work has been done on a two-phased lamellar Ti-45 a/o Al alloy reinforced with TiB2 ceramic having an equiaxed morphology. Data on temperature dependence of the dynamic Young's modulus, coefficient of thermal expansion, deformation and fracture behavior, and microstructure are presented.

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