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Low-Pressure Casting of Aluminium Alsi7mg03 (A356) in Sand and Permanent Molds
MATEC Web of Conferences 326, 06001 (2020) https://doi.org/10.1051/matecconf/202032606001 ICAA17 Low-Pressure Casting of Aluminium AlSi7Mg03 (A356) in Sand and Permanent Molds Franco Chiesa1*, Bernard Duchesne2, and Gheorghe Marin1 1Centre de Métallurgie du Québec, 3095 Westinghouse, Trois-Rivières, Qc, Canada G9A 5E1 2Collège de Trois-Rivières, 3500 de Courval, Trois-Rivières, Qc, Canada, G9A 5E6 Abstract. Aluminium A356 (AlSi7Mg03) is the most common foundry alloy poured in sand and permanent molds or lost-wax shells. Because of its magnesium content, this alloy responds to a precipitation hardening treatment. The strength and ductility combination of the alloy can be varied at will by changing the temper treatment that follows the solutionizing and quenching of the part. By feeding the mold from the bottom, the low-pressure process provides a tranquil filling of the cavity. A perfect control of the liquid metal stream is provided by programming the pressure rise applied on the melt surface. It compares favorably to the more common gravity casting where a turbulent filling is governed by the geometry of the gating system. 1 The low-pressure permanent 2) The very efficient feeding achieved via the mold process bottom feeder tube by applying a pressure of up to one atmosphere to the melt; the resulting yield is very high, typically 80-90% versus 50-60% for The low-pressure permanent mold casting gravity casting. However, the low-pressure (LPPM) [1], schematized in Figure 1a and shown process cannot pour any casting geometries. in Figure 1b and 1c, is a common process Low-pressure sand casting (LPS) is much less producing high quality castings resulting from common than LPPM; the sand mold rests on top two main characteristics: of the pressurized enclosure as shown in Figure 1) The perfectly controlled quiescent filling 1d. -
Implementation of Metal Casting Best Practices
Implementation of Metal Casting Best Practices January 2007 Prepared for ITP Metal Casting Authors: Robert Eppich, Eppich Technologies Robert D. Naranjo, BCS, Incorporated Acknowledgement This project was a collaborative effort by Robert Eppich (Eppich Technologies) and Robert Naranjo (BCS, Incorporated). Mr. Eppich coordinated this project and was the technical lead for this effort. He guided the data collection and analysis. Mr. Naranjo assisted in the data collection and analysis of the results and led the development of the final report. The final report was prepared by Robert Naranjo, Lee Schultz, Rajita Majumdar, Bill Choate, Ellen Glover, and Krista Jones of BCS, Incorporated. The cover was designed by Borys Mararytsya of BCS, Incorporated. We also gratefully acknowledge the support of the U.S. Department of Energy, the Advanced Technology Institute, and the Cast Metals Coalition in conducting this project. Disclaimer This report was prepared as an account of work sponsored by an Agency of the United States Government. Neither the United States Government nor any Agency thereof, nor any of their employees, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any Agency thereof. The views and opinions expressed by the authors herein do not necessarily state or reflect those of the United States Government or any Agency thereof. -
Manufacturing Technology I Unit I Metal Casting
MANUFACTURING TECHNOLOGY I UNIT I METAL CASTING PROCESSES Sand casting – Sand moulds - Type of patterns – Pattern materials – Pattern allowances – Types of Moulding sand – Properties – Core making – Methods of Sand testing – Moulding machines – Types of moulding machines - Melting furnaces – Working principle of Special casting processes – Shell – investment casting – Ceramic mould – Lost Wax process – Pressure die casting – Centrifugal casting – CO2 process – Sand Casting defects. UNIT II JOINING PROCESSES Fusion welding processes – Types of Gas welding – Equipments used – Flame characteristics – Filler and Flux materials - Arc welding equipments - Electrodes – Coating and specifications – Principles of Resistance welding – Spot/butt – Seam – Projection welding – Percusion welding – GS metal arc welding – Flux cored – Submerged arc welding – Electro slag welding – TIG welding – Principle and application of special welding processes – Plasma arc welding – Thermit welding – Electron beam welding – Friction welding – Diffusion welding – Weld defects – Brazing – Soldering process – Methods and process capabilities – Filler materials and fluxes – Types of Adhesive bonding. UNIT III BULK DEFORMATION PROCESSES Hot working and cold working of metals – Forging processes – Open impression and closed die forging – Characteristics of the process – Types of Forging Machines – Typical forging operations – Rolling of metals – Types of Rolling mills – Flat strip rolling – Shape rolling operations – Defects in rolled parts – Principle of rod and wire drawing – Tube drawing – Principles of Extrusion – Types of Extrusion – Hot and Cold extrusion – Equipments used. UNIT IV SHEET METAL PROCESSES Sheet metal characteristics – Typical shearing operations – Bending – Drawing operations – Stretch forming operations –– Formability of sheet metal – Test methods – Working principle and application of special forming processes – Hydro forming – Rubber pad forming – Metal spinning – Introduction to Explosive forming – Magnetic pulse forming – Peen forming – Super plastic forming. -
Casting Processes
2.4_3 Casting Processes • pouring a liquid material (molten metal) into a prepared mold • materials: iron steel aluminum brass bronze magnesium certain zinc alloys • iron is used most often - fluidity, low shrinkage, strength, rigidity, and ease of control Chap 2, Casting – p. 1 • Six factors of the casting process: 1) A mold cavity must be produced. - must have desired shape - must allow for shrinkage of the solidifying metal - a new mold must be made for each casting, or a permanent mold must be made 2) A suitable means must exist to melt the metal. - high temperatures - quality mix - low cost 3) The molten metal must be introduced into the mold so that all air or gases in the mold will escape. The mold must be completely filled so that there are no air holes. 4) The mold must be designed so that it does not impede the shrinkage of the metal upon cooling. 5) It must be possible to remove the casting from the mold. 6) Finishing operations must usually be performed on the part after it is removed from the mold. Chap 2, Casting – p. 2 Seven major casting processes: 1) Sand casting 5) Centrifugal casting 2) Shell-mold casting 6) Plaster-mold casting 3) Permanent-mold casting 7) Investment casting 4) Die casting Sand Casting • sand is used as the mold material • the sand (mixed with other materials) is packed around a pattern that has the shape of the desired part • the mold is made of two parts (drag (bottom) & cope (top)) • a new mold must be made for every part • liquid metal is poured into the mold through a sprue hole • the sprue hole is connected to the cavity by runners • a gate connects the runner with the mold cavity • risers are used to provide "overfill" Chap 2, Casting – p. -
Aluminum Foundry Products
ASM Handbook, Volume 2: Properties and Selection: Nonferrous Alloys and Special-Purpose Materials Copyright © 1990 ASM International® ASM Handbook Committee, p 123-151 All rights reserved. DOI: 10.1361/asmhba0001061 www.asminternational.org Aluminum Foundry Products Revised by A. Kearney, Avery Kearney & Company Elwin L. Rooy, Aluminum Company of America ALUMINUM CASTING ALLOYS are wrought alloys. Aluminum casting alloys cast aluminum alloys are grouped according the most versatile of all common foundry must contain, in addition to strengthening to composition limits registered with the alloys and generally have the highest cast- elements, sufficient amounts of eutectic- Aluminum Association (see Table 3 in the ability ratings. As casting materials, alumi- forming elements (usually silicon) in order article "Alloy and Temper Designation Sys- num alloys have the following favorable to have adequate fluidity to feed the shrink- tems for Aluminum and Aluminum Al- characteristics: age that occurs in all but the simplest cast- loys"). Comprehensive listings are also • Good fluidity for filling thin sections ings. maintained by general procurement specifi- The phase behavior of aluminum-silicon • Low melting point relative to those re- cations issued through government agencies compositions (Fig. 1) provides a simple quired for many other metals (federal, military, and so on) and by techni- • Rapid heat transfer from the molten alu- eutectic-forming system, which makes pos- cal societies such as the American Society sible the commercial viability of most high- minum to the mold, providing shorter for Testing and Materials and the Society of casting cycles volume aluminum casting. Silicon contents, Automotive Engineers (see Table 1 for ex- • Hydrogen is the only gas with apprecia- ranging from about 4% to the eutectic level amples). -
Shell Mold Casting
Shell Mold Casting Shell mold casting or shell molding is a metal casting process in manufacturing industry in which the mold is a thin hardened shell of sand and thermosetting resin binder backed up by some other material. Shell mold casting is particularly suitable for steel castings under 10 kg; however almost any metal that can be cast in sand can be cast with shell molding process. Also much larger parts have been manufactured with shell molding. Typical parts manufactured in industry using the shell mold casting process include cylinder heads, gears, bushings, connecting rods, camshafts and valve bodies. The Process The first step in the shell mold casting process is to manufacture the shell mold. The sand we use for the shell molding process is of a much smaller grain size than the typical greensand mold. This fine grained sand is mixed with a thermosetting resin binder. A special metal pattern is coated with a parting agent; (typically silicone), which will latter facilitate in the removal of the shell. The metal pattern is then heated to a temperature of (175 °C-370 °C) . The sand mixture is then poured or blown over the hot casting pattern. Due to the reaction of the thermosetting resin with the hot metal pattern a thin shell forms on the surface of the pattern. The desired thickness of the shell is dependent upon the strength requirements of the mold for the particular metal casting application. A typical industrial manufacturing mold for a shell molding casting process could be 7.5mm thick. The thickness of the mold can be controlled by the length of time the sand mixture is in contact with the metal casting pattern. -
Optimization of Mixed Casting Processes Considering Discrete
Journal of Mechanical Science and Technology Journal of Mechanical Science and Technology 23 (2009) 1899~1910 www.springerlink.com/content/1738-494x DOI 10.1007/s12206-009-0428-y Optimization of mixed casting processes considering discrete ingot sizes† Yong Kuk Park1,* and Jung-Min Yang2 1School of Mechanical and Automotive Engineering, Catholic University of Daegu, Hayang-Eup, Gyeongsan-si, Gyeongbuk, 712-702, Korea 2Department of Electrical Engineering, Catholic University of Daegu, Hayang-Eup, Gyeongsan-si, Gyeongbuk, 712-702, Korea (Manuscript Received September 18, 2008; Revised March 23, 2009; Accepted March 26, 2009) -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- Abstract Using linear programming (LP), this research devises a simple and comprehensive scheduling methodology for a complicated, yet typical, production situation in real foundries: a combination of expendable-mold casting, permanent- mold casting and automated casting for large-quantity castings. This scheduling technique to determine an optimal casting sequence is successfully applied to the most general case, in which various types of castings with different al- loys and masses are simultaneously produced by dissimilar casting processes within a predetermined period. The methodology proves to generate accurate scheduling results that maximize furnace or ingot efficiency. -
Metal Casting - 1
Metal Casting - 1 ME 206: Manufacturing Processes & Engineering Instructor: Ramesh Singh; Notes by: Prof. S.N. Melkote / Dr. Colton 1 Outline • Casting basics • Patterns and molds • Melting and pouring analysis • Solidification analysis • Casting defects and remedies ME 206: Manufacturing Processes & Engineering Instructor: Ramesh Singh; Notes by: Prof. S.N. Melkote / Dr. Colton 2 Casting Basics • A casting is a metal object obtained by pouring molten metal into a mold and allowing it to solidify. Aluminum manifold Gearbox casting Magnesium casting Cast wheel ME 206: Manufacturing Processes & Engineering 3 Instructor: Ramesh Singh; Notes by: Prof. S.N. Melkote / Dr. Colton Casting: Brief History • 3200 B.C. – Copper part (a frog!) cast in Mesopotamia. Oldest known casting in existence • 233 B.C. – Cast iron plowshares (in China) • 500 A.D. – Cast crucible steel (in India) • 1642 A.D. – First American iron casting at Saugus Iron Works, Lynn, MA • 1818 A.D. – First cast steel made in U.S. using crucible process • 1919 A.D. – First electric arc furnace used in the U.S. • Early 1970’s – Semi-solid metalworking process developed at MIT • 1996 – Cast metal matrix composites first used in brake rotors of production automobile ME 206: Manufacturing Processes & Engineering Instructor: Ramesh Singh; Notes by: Prof. S.N. Melkote / Dr. Colton 4 Complex, 3-D shapes • Near net shape • Low scrap • Relatively quick process • Intricate shapes • Large hollow shapes • No limit to size • Reasonable to gooD surface finish ME 206: Manufacturing Processes & Engineering Instructor: Ramesh Singh; Notes by: Prof. S.N. Melkote / Dr. Colton 5 Capabilities • Dimensions – sand casting - as large as you like – small - 1 mm or so • Tolerances – 0.005 in to 0.1 in • Surface finish – die casting 8-16 micro-inches (1-3 µm) – sand casting - 500 micro-inches (2.5-25 µm) ME 206: Manufacturing Processes & Engineering Instructor: Ramesh Singh; Notes by: Prof. -
Multiple-Use-Mold Casting Processes
Multiple-Use-Mold Casting Processes Chapter 13 ME-215 Engineering Materials and Processes Veljko Samardzic 13.1 Introduction • In expendable mold casting, a separate mold is produced for each casting – Low production rate for expendable mold casting • If multiple-use molds are used, productivity can increase • Most multiple-use molds are made from metal, so most molds are limited to low melting temperature metals and alloys ME-215 Engineering Materials and Processes Veljko Samardzic 13.2 Permanent-Mold Casting • Also known as gravity die casting • Mold can be made from a variety of different materials – Gray cast iron, alloy cast iron, steel, bronze, or graphite • Most molds are made in segments with hinges to allow rapid and accurate closing – Molds are preheated to improve properties • Liquid metal flows through the mold cavity by gravity flow ME-215 Engineering Materials and Processes Veljko Samardzic Permanent Mold Casting • Process can be repeated immediately because the mold is still warm from the previous casting • Most frequently cast metals – Aluminum, magnesium, zinc, lead, copper, and their alloys – If steel or iron is to be used, a graphite mold must be used ME-215 Engineering Materials and Processes Veljko Samardzic Advantages of Permanent-Mold Casting • Near- net shapes • Little finish machining • Reusable molds • Good surface finish • Consistent dimensions • Directional solidification ME-215 Engineering Materials and Processes Veljko Samardzic Disadvantages of Permanent Mold Casting • Limited to lower melting temperature -
Metal Casting Processes
ME 222 Manufacturing Technology - I (3-0-0-6) Introduction to manufacturing processes Casting processes: Moulding materials and their requirements; Patterns: Types and various pattern materials. Various casting methods, viz., sand casting investment casting, pressure die casting, centrifugal casting, continuous casting, thin roll casting; Mould design; Casting defects and their remedies. (14 classes) Metal forming processes: Various metal forming techniques and their analysis, viz., forging, rolling, extrusion, wire drawing, sheet metal working, spinning, swaging, thread rolling; Super plastic deformation; Metal forming defects. (14 classes) Metal joining processes: brazing, soldering, welding; Solid state welding methods; resistance welding; arc welding; submerged arc welding; inert gas welding; Welding defects, inspection. (9 classes) Powder metallurgy & its applications (3 classes) R.Ganesh Narayanan, IITG Texts: 1. A Ghosh and A K Mallik, Manufacturing Science, Wiley Eastern, 1986. 2. P Rao, Manufacturing Technology: Foundry, Forming And Welding, Tata McGraw Hill, 2008. 3. M.P. Groover, Introduction to manufacturing processes, John Wiley & Sons, 2012 4. Prashant P Date, Introduction to manufacturing technologies Principles and technologies, Jaico publications, 2010 (new book) References: 1. J S Campbell, Principles Of Manufacturing Materials And Processes, Tata McGraw Hill, 1995. 2. P C Pandey and C K Singh, Production Engineering Sciences, Standard Publishers Ltd., 2003. 3. S Kalpakjian and S R Schmid, Manufacturing Processes for Engineering Materials, Pearson education, 2009. 4. E. Paul Degarmo, J T Black, Ronald A Kohser, Materials and processes in manufacturing, John wiley and sons, 8th edition, 1999 Tentative grading pattern: QUIZ 1: 10; QUIZ 2: 15; MID SEM:R.Ganesh 30; Narayanan, END IITG SEM: 45; ASSIGNMENT: 10 Metal casting processes • Casting is one of the oldest manufacturing process. -
Permanent Mold Casting at Eagle Aluminum Tolerances, Capabilities and Design Recommendations
Permanent Mold Casting at Eagle Aluminum Tolerances, Capabilities and Design Recommendations Contents • Casting Characteristics • Mold & Pouring Capabilities • Design Recommendations • Inspection Services at EACP Eagle Aluminum Cast Products, Inc. 2134 Northwoods Drive Muskegon, MI 49442 231-788-4884 www.eaglealuminumcastproducts.com PERMANENT MOLD CASTING AT EAGLE ALUMINUM Tolerances, Capabilities and Design Recommendations Permanent mold casting is a metal casting process involving reusable molds. Compared to casting methods that use disposable molds, permanent mold casting can dramatically reduce per-part costs for high-volume runs, while also improving a variety of casting parameters. Molds for permanent mold casting cost considerably less than for die casting, yet they are capable of producing larger volumes. Characteristics of permanent mold castings at Eagle Aluminum:* Typical tolerance held +/- .015 for first inch; add .02” for every additional inch Wall thickness As low as .125” Typical weight range <1 lb to 50 lbs Largest pattern dimensions Up to 55” in diameter and a 6H Hall Tilt Press Surface finish MIN 300 RMS Typical production quantity 100-5,000 per run Mold and pouring capabilities: Mold material Steel (4140 or H13) or cast iron Mold temperature 600 to 800 degrees F Aluminum Alloys poured 319 and A356 Pouring temperature Between 1350 and 1450 degrees F Design recommendations: • Minimum radius: 1/32” • We recommend designing parts with rounded corners Inspection & quality control services offered by Eagle Aluminum Cast Products, Inc.: • Visual inspections • Gaging • EAGLE ALUMINUM CAST PRODUCTS, INC. IS ISO 9001:2015 CERTIFIED *Tolerances and characteristics based on experience and on the Aluminum Association’s Standards for Aluminum Sand Castings Eagle Aluminum Cast Products, Inc. -
Casting Expendable Mold Casting Waste Molding of Plaster Sand
Casting Casting is a manufacturing process by which a liquid material such as a suspension of minerals as used in ceramics or molten metal or plastic is introduced into a mould, allowed to solidify within the mould, and then ejected or broken out to make a fabricated part. Casting is used for making parts of complex shape that would be difficult or uneconomical to make by other methods, such as cutting from solid material. Casting may be used to form hot, liquid metals or meltable plastics (called thermoplastic), or various materials that cold set after mixing of components such as certain plastic resins such as epoxy, water setting materials such as concrete or plaster, and materials that become liquid or paste when moist such as clay, which when dry enough to be rigid is removed from the mold, further dried, and fired in a kiln or furnace. Substitution is always a factor in deciding whether other techniques should be used instead of casting. Alternatives include parts that can be stamped out on a punch press or deep-drawn, forged, items that can be manufactured by extrusion or by cold-bending, and parts that can be made from highly active metals. The casting process is subdivided into two distinct subgroups: expendable and nonexpendable mold casting. Expendable mold casting Expendable mold casting is a generic classification that includes sand, plastic, shell, plaster, and investment (lost-wax technique) moldings. This method of mold casting involves the use of temporary, nonreusable molds. Waste molding of plaster A durable plaster intermediate is often used as a stage toward the production of a bronze sculpture or as a pointing guide for the creation of a carved stone.