Effect of Pouring Temperature and Melt Treatment on Microstructure of Lost Foam Casting of AL-Si LM6 Alloy

2011 ◽  
Vol 264-265 ◽  
pp. 295-300 ◽  
Author(s):  
Majid Karimian ◽  
Ali Ourdjini ◽  
Mohd Hasbullah Idris ◽  
M. Bsher ◽  
A. Asmael
Keyword(s):  
Cast Alloy ◽  
Eutectic Silicon ◽  
Lost Foam Casting ◽  
Grain Refiner ◽  
Pouring Temperature ◽  
Casting Quality ◽  
Melt Treatment ◽  
Different Temperatures ◽  
Lost Foam ◽  
Porosity Percentage

This paper presents the experimental investigation conducted on Al-Si cast alloy (LM6) cast using lost foam process. The main objective of the research is to investigate the effect of pouring temperature, section thickness and melt treatment on the microstructure of the lost foam casting of Al-Si alloy. Step pattern with five different sections was prepared from 20 kg/m³ density foam and poured at five different temperatures; 700, 720, 740, 760, and 780 with and without the addition of AlTiB as grain refiner. Analysis on microstructure, eutectic silicon spacing and porosity percentage were conducted to determine the effect of both parameters. The results show that pouring temperature has significant influence on the quality as well as microstructure of the lost foam casting of LM6 Al-Si alloy. Lower pouring temperature was found to produce finer microstructure casting. However, the addition of AlTiB as grain refiner did not affect the produced castings significantly whether in terms casting quality or microstructure.

DOE Analysis of the Influence of Sand Size and Pouring Temperature on Porosity in LFC

2011 ◽  
Vol 121-126 ◽  
pp. 2661-2665
Author(s):  
S. Izman ◽  
Amirreza Shayganpour ◽  
M.H. Idris ◽  
Hassan Jafari
Keyword(s):  
Cast Alloy ◽  
Experimental Investigations ◽  
Lost Foam Casting ◽  
Thin Wall ◽  
Pouring Temperature ◽  
New Process ◽  
Casting Porosity ◽  
Lost Foam ◽  
Significant Factors ◽  
Sand Size

Lost foam casting is a relatively new process in commercial terms and is widely used to produce defect free castings owing to its advantages like producing complex shape and acceptable surface finish. In the present research, experimental investigations in lost foam casting of aluminium-silicon cast alloy, LM6, were conducted. The main objective of the study was to evaluate the effect of different sand sizes and pouring temperatures on the porosity of thin-wall castings. A stepped pattern was used in the study and the focus of the investigations was at the thinnest 3 mm section. A full 2-level factorial design experimental technique was employed to plan the experiment and subsequently identify the significant factors which affect the casting porosity. The result shows that increasing in the pouring temperature decreases the porosity in the thin-wall section of casting. Finer sand size is more favourable than coarse size for LFC mould making process.

Effect of Pressure on Structure and Properties of Lost Foam Casting of Al-11Si Cast Alloy

2011 ◽  
Vol 110-116 ◽  
pp. 639-643 ◽  
Author(s):  
Ali Asghar Niakan ◽  
M.H. Idris ◽  
Majid Karimian ◽  
A. Ourdjini
Keyword(s):  
Cast Alloy ◽  
Eutectic Silicon ◽  
Testing Machine ◽  
Applied Pressure ◽  
Casting Process ◽  
Optical Microscope ◽  
Lost Foam Casting ◽  
Image Analyzer ◽  
Effect Of Pressure ◽  
Lost Foam

The paper presents the results of an investigation on aluminum-silicon (LM6) alloy using pressurized lost foam casting process. The study investigated the effect of pressure on casting integrity-geometry, eutectic silicon spacing, particle roundness and hardness. Following air pressures: 1bar, 2bar, 3bar and 4bar were applied on the solidifying alloy. The eutectic silicon spacing and particle roundness were measured using optical microscope which was equipped with image analyzer by averaging of at least ten results as well as Vickers hardness testing machine. For casting integrity-geometry all surfaces of solidified castings were captured by digital camera for better observation. The results show that applying pressure during solidification of the LM6 alloy has significant influence on casting integrity-geometry, eutectic silicon spacing, particle roundness and hardness of the alloy. By increasing the applied pressure, solidification time decline. Consequently, silicon spacing reduces as well as increasing of hardness. Besides, rising air pressure lead to fulfilling of molten which improves the casting integrity and particle roundness.

Determination of Optimal Temperature for Defect-Free Casting of Aluminium in the LP-LFC Process

2011 ◽  
Vol 101-102 ◽  
pp. 934-937
Author(s):  
Ji Qiang Li ◽  
Zhong Zhao ◽  
Zi Tian Fan ◽  
Zhi Xin Jia ◽  
Wen Liu ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Aluminium Alloys ◽  
Low Pressure ◽  
Experimental Results ◽  
Metal Temperature ◽  
Lost Foam Casting ◽  
Optimal Temperature ◽  
Pouring Temperature ◽  
Lost Foam

Fluidity of ZL101 aluminium alloys in the low-pressure lost foam casting (LP-LFC) process has been investigated by altering various temperature variables. The experimental results indicate that the LP-LFC process had fine fluidity, and the pouring temperature was lower than conventional lost foam casting. The effect of the metal temperature on the fluidity is marginal in the LP-LFC process. Excessive pouring temperature not only aggrandizes energy consumption but also deteriorates porosity defect. The success of casting cooling fin demonstrates the advantages of LP-EPC process in producing high-complicated castings.

Effect of Ultrasonic Melt Treatment on Solidification Structure of Fe-36Ni Invar Alloy

2013 ◽  
Vol 32 (5) ◽  
pp. 459-465 ◽  
Author(s):  
Hong-bing Peng ◽  
Wei-qing Chen ◽  
Yan-chong Yu ◽  
Hong-guang Zheng
Keyword(s):  
Ultrasonic Treatment ◽  
Solidification Process ◽  
Ultrasonic Cavitation ◽  
Solidification Structure ◽  
Invar Alloy ◽  
Pouring Temperature ◽  
Melt Treatment ◽  
Different Temperatures ◽  
Ultrasonic Melt Treatment ◽  
Average Size

AbstractThe effect of ultrasonic treatment on the solidification structure of Fe-36Ni invar alloy was investigated. The experiment results showed that the ultrasonic treatment before its solidification had no significant effect on the solidification structure. However, when ultrasonic was inputted into the molten alloy during its solidification process, the primary dendrites were broken up into lots of fragments and solidification structure was refined significantly. When ultrasonic treatment was applied in the melt doped with yttrium before its solidification, ultrasonic cavitation could break up precipitates into many small ones, which could refine its solidification structure as nucleation cores. In samples containing yttrium treated by ultrasonic at 1753 K, the number of the precipitates was 623/mm2 and its average size was 2.18 µm; while at 1803 K, they were 604/mm2 and 2.34 µm respectively. The ultrasonic cavitation had a similar effect at two different temperatures. The solidification structure refined greatly at 1753 K was due to its low pouring temperature.

Study of Artificial Aging Temperature Effect on Morphology of Structural Parameters in Aluminium Cast Alloy

2017 ◽  
Vol 891 ◽  
pp. 354-359
Author(s):  
Lenka Kuchariková ◽  
Eva Tillová ◽  
Mária Chalupová ◽  
Juraj Belan ◽  
Ivana Švecová ◽  
...  
Keyword(s):  
Artificial Aging ◽  
Cast Alloy ◽  
Structural Parameters ◽  
Eutectic Silicon ◽  
Solution Treatment ◽  
Analytical Techniques ◽  
Intermetallic Phases ◽  
Holding Time ◽  
Different Temperatures ◽  
Alloy Microstructure

The contribution describes changes in morphology of structural parameters in recycled (secondary) AlSi9Cu3 cast alloy microstructure. These changes depended on different temperatures of artificial aging. The T6 heat treatment, which was used for affecting the structural parameters morphology, consisted of solution treatment at temperature 515 °C with holding time 4 hours, water quenching at 40°C and artificial aging at different temperatures 130 °C, 150 °C, 170 °C, 190 °C and 210 °C with different holding time 2, 4, 8, 16 and 32 hours. The morphology of structural parameters was observed using combination of different analytical techniques (light microscopy upon black-white and colour etching, scanning electron microscopy - SEM upon deep etching). The different temperatures of artificial aging led to changes in microstructure include the spheroidization and coarsening of eutectic silicon, gradual disintegration, shortening and thinning of Fe-rich intermetallic phases, the dissolution of precipitates and the precipitation of finer hardening phase (Al2Cu).

Lost Foam Casting of Hydroturbine Blades Based on CAE

2011 ◽  
Vol 71-78 ◽  
pp. 694-697
Author(s):  
Jian Zhou ◽  
Li Jun Li ◽  
Jian Wen Yi ◽  
Ming Yang
Keyword(s):  
Model Material ◽  
Raw Material ◽  
Lost Foam Casting ◽  
Polystyrene Foam ◽  
Pouring Temperature ◽  
Fireproof Coating ◽  
Lost Foam ◽  
Foam Plastics ◽  
Lower Carbon ◽  
Carbon Martensite

The article studies the method which hydroturbine part is manufactured by lost foam casting for obtaining higher quality product.The lost model material is polystyrene foam plastics,the EPS diameters are selected in 0.5-0.76mm,the casting raw material is lower carbon martensite stainless steel(ZG06Cr13Ni4Mo).The style of open pouring system is adopted, ∑Fin-gate：∑Fcross-gate：∑Fdown-sprue=1：1.1：1.2, fireproof coating is mixed and coated,square sand box is used. The pouring temperature of liquid is 1600-1650°C.If the technology is strictly according to the design,good quality casting can be gotten.

Effect of Casting Parameters on Porosity in LFC

2011 ◽  
Vol 148-149 ◽  
pp. 1198-1201
Author(s):  
S. Izman ◽  
Amirreza Shayganpour ◽  
M.H. Idris
Keyword(s):  
Energy Savings ◽  
Cast Alloy ◽  
Casting Process ◽  
Experimental Investigations ◽  
Lost Foam Casting ◽  
Thin Wall ◽  
Thin Sections ◽  
Casting Porosity ◽  
Lost Foam ◽  
Significant Factors

Cast aluminium alloys often contain microstructural defects resulting from the casting process such as porosity. Developments of Lost foam casting (LFC) process is considered as one of the most rapid in casting technology owing to its unique advantages on energy savings and capabilities to produce castings with thin sections. In the present research, experimental investigations in lost foam casting of aluminium-silicon cast alloy, LM6, were conducted. The main objective of the study was to evaluate the effect of different pouring temperatures, slurry viscosities, vibration times and sand sizes on the porosity of castings. A stepped pattern was used in the study and the focus of the investigations was at the thinnest 3 mm section. A full 2-level factorial design experimental technique was employed to plan the experiment and subsequently identify the significant factors which affect the casting porosity. The result shows that increasing in the pouring temperature decreases the porosity in the thin-wall section and finer sand size is more favourable than coarse size for LFC mould making process.

scholarly journals Investigation of temperature, degree of vacuum, pattern coating thickness effects on mold filling in lost foam casting (LFC) process of A356 alloy

2015 ◽  
Vol 18 (2) ◽  
pp. 94-103
Author(s):  
Ha Ngoc Nguyen ◽  
Phong Quoc Le ◽  
Tri Nhat Nguyen ◽  
Hoai Dinh Lai
Keyword(s):  
Coating Thickness ◽  
A356 Alloy ◽  
Mold Filling ◽  
Complex Model ◽  
Production Costs ◽  
Lost Foam Casting ◽  
Pouring Temperature ◽  
Casting Technique ◽  
Lost Foam ◽  
Dipping Time

Lost foam casting (LFC) process with outstanding advantages has been known as a new casting technique in foundry engineering. Especially, the operation restricts errors of a mould because of using expanded patterns without parting line being appropriate for the complex model. Great interest in this technology of the casting manufacturers is mainly lower, compared with the traditional process, investment outlays and production costs. The use of unbounded sand also reduces its treatment cost, more friendly and simple with the environment. The study examines the simultaneous effects of pouring temperature, degree of vacuum, coating thickness (through dipping time) on mold filling in LFC. A356 aluminum alloy is used in this study. By using a full two-level factorial design of experimental technique to identify the significant manufacturing factors affecting the mold filling. Results of this investigation indicated that increasing pouring temperature, degree of vacuum and decreasing dipping time obtain casting with higher filling rate.

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