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UNDER CONSIDERATION
• Hardness
• Tensile strength
• Ductility
COMPOSITION OF ALUMINUM
ALLOY LM 25:
Copper
Magnesium
Silicon
Iron
Manganese
Nickel
Zinc
Lead
Tin 0.15-0.2
0.20-0.65
6.5-7.5
0.45-0.55
0.35
0.15
0.05
Titanium 0.05-0.25
Aluminum Remainder
Chemical composition
Aluminium casting alloys
• Alloy designations:
• (i) Aluminium Association (AA)
system.
• (ii) Aluminium Association
casting Tamper Designation
system.
• (iii) American National Standards
Institute (ANSI ):
• (iv) The UNS Alloy Designation
System
Contd………..
Aluminum-Copper
Aluminum-Copper have been used
extensively in wrought and cast
form where strength and toughness
are required. These alloy exhibit
strength and hardness at room and
elevated temperatures
Alloy of this types are susceptible to
solidification cracking and to
interdendritic shrinkage.
Copper-containing aluminum alloys
are less resistance to corrosion and
Aluminum-Silicon-Copper
• Copper contributes to strengthening
and machinability and silicon
improves castability and reduces
hot shortness
• Al-Si-Cu alloys with less than 5-6%
Cu are heat-treatable, if Mg is
added then heat-treatment
response is enhanced
Aluminum-Silicon-
Magnesium
• Excellent properties after heat
treatment, high Corrosion
resistance, and a low level of
thermal expansion
• While not as strong as high-strength
Al-Cu and Al-Si-Cu alloys.
Aluminium-Silicon
• Binary aluminium-silicon alloys
exhibit excellent fluidity, castability,
and corrosion resistance. These
alloys display low strength and poor
machinability
• The strength, ductility, and
castabilityof hypoeutectic Al-Si
alloys can be further improved by
modification of Al-Si eutectic
through the controlled addition of
sodium and/ or strontium
Aluminium-Magnesium
• Single phase binary alloys with
moderate to high strength and
toughness
• Most important characteristics is the
corrosion resistance including
exposed to sea-water and marine
application
• Excellent weldability , machinability and
attractive appearance
• But they require greater control of
temperature gradient
• Mg in Al-alloys increases the oxidation
rates
Aluminium-Zinc-Magnesium
• Rapid solidification in these alloys
can result in microsegretion of
magnesium-zinc phases that
reduces hardening potential.
• The cost of heat-treatment, high
residual stress levels and distortion
are avoided
• The castability of Al-Zn-Mg alloys is
poor, and good foundry practices
are required to minimize hot
tearing and shrinkage defects
Aluminium-Tin
• Tin is the major alloying element in
compositions developed for bearing
application.
• Alloys containing 5.0 to 7.0% Sn are broadly
used in bearings and bushing in which low
friction, compressive strength, fatigue
strength, and resistance to corrosion are
important criteria
• Their light weight minimize loads in
reciprocating and heat dissipation
improves bearing life
• Al and tin are essentially immiscible before
and after solidification, tin is present in
dispersed form
• Parts may be plastically cold worked to
Effects of Alloying Elements
(i) Antimony
(iv) Boron
(vii) Phosphorus
As AlP , phosphorus nucleates and
3
refines primary silicon-phase
formation in hypereutectic Al-Si alloys
it coarsens the eutectic structure in
(viii) Tin
grain structure
TiB is necessary grain refinement
2
(x) Chromium
Chromium typically forms the
increases stress-corrosion
It reduces hot tear resistance and
ductility
The intermateilic phases FeAl ,
3
FeMnAl6, and α-AlFeSi. These
insoluble phases are responsible for
strength, especially at elevated
temperature, but also embrittlement
of the microstructure
Effect of Iron plus Silicon
impurities on Tensile
properties of Al
(v) Manganese
aluminium casting
Addition of Cu and/ or Mg, however,
• Sand Casting
• Sand casting is the simplest method
of casting aluminium. Sand is made
into a mould by forming around a
wooden "pattern". The pattern is
removed, the sand mould
assembled and molten metal
poured in. The process is chosen for
small production runs, for complex
shape castings requiring intricate
cores or for very large castings
Sand Casting
Gravity Die-Casting
• Castings are produced by pouring
molten metal into permanent metal
moulds. It is generally made from
cast iron. This process produces ‘
Chill Castings’
Gravity Die-Casting
Low Pressure Die-
Casting
• This is a repetitive process where
identical parts are cast by injecting
molten metal under low pressure
into metal dies. This process
requires complex machinery and is
similar to high pressure die-casting
Low Pressure Die-
Casting
High Pressure Die-
casting
• High pressure die- casting is a
repetitive process for casting
identical parts by injecting
Aluminium into metal moulds at
pressures in the order of 1000psi.
Complex machinery and expensive
tooling is required for this process.
It is characterized by very good
surface finish and dimensional
consistency. The advantage of this
system includes fast cycle times
and the convenience of melting the
High Pressure Die-
casting
Diesel Furnace
• A diesel furnace is a piece of equipment that
produces heat by burning diesel. The diesel
used to power the furnace can be of
petroleum origin. It is used to make casting
specimens. We used a K- type thermocouple
to measure the temperature. Temperature
Range – 0 to 1100 ºC. We also used a multi
channel temperature indicator for mesuring
casting temperature.
• The highest temperature that can be obtained
in a diesel furnace (in workshop) is 950ºC.
The temperature required to melt LM 25 alloy
was around 700ºC to 750ºC. It took around
20- 25 minutes to melt the material. After
that we took it to a crusible(refractory
container) and with the help of laddle we
poured the molten metal into the mould. It
took 2-3 days to solidify the molten metal and
the specimen was obtained. The specimen
BHN values comparision- graphite˂
metal˂ sand
Prepared Specimen
CASTING SIMULATION
USING PROCAST
FIRST ITERATION
Ø CAST SPECIMEN SPECIFICATION.
Ø One test bars with dimensions of 12mm diameter, 52mm gage
length.
Ø Cast material is LM25.
Ø Two circular section of 20 mm diameter and length 20 mm,
test section diameter 12 mm and 52 mm gauge length.
Ø Top gate is designed for this iteration.
CASTING DESIGN.
PROCESS PARAMTER SPECIFICATION
Parameter ’ s Magnitude
Parameter ’ s Magnitude
CASTING DESIGN.
PROCESS PARAMTER SPECIFICATION
Parameter’s Magnitude
Ø AT TIME 30.8 SEC.
Ø AT TIME 160 SEC.
Ø AT TIME 160 SEC.
TEMPATURE Vs TIME
AIR ENTRAPMENT.
FRACTION SOLID AT T= 40 SEC
FRACTION SOLID Vs TIME.
PROSOITY.
SOLIDIFICATION TIME.
FILL TIME.
CONCLUSION.
Ø THIS DESIGN IS BETTER THAN OTHER
AS THERE IS UNIFORM
SOLIDIFICATION TIME FOR
CASTING.
STANDARDIZATION
• We need to standardize the data of LM25 using
the instruments available in the campus so
that we can compare this data with the
enhanced alloy to be produced.
Standardization or standardization is the
process of developing and agreeing upon
technical standards. A standard is a
document that establishes uniform
engineering or technical specifications,
criteria, methods, processes, or practices.
Some standards are mandatory while others
are voluntary. Voluntary standards are
available if one chooses to use them. Some
are de facto standards, meaning a norm or
requirement which has an informal but
dominant status. Some standards are de jure,
meaning formal legal requirements. Formal
standards organizations, such as the
International Organization for Standardization
Metallographic Specimen
Preparation
Specimen Preparation
TYPES OF MOULD
SAND
METAL
GRAPHITE BHN
60
58
56 3.323
DIAMETER
3.213
3.267 OF
INDENTATION (d in mm)
Hardness Test Using Brinell
Hardness Testing Machine
Universal Measuring
Microscope
SURFACE ROUGHNESS
• Surface roughness is measure of the
finer surface irregularities in the
surface texture. These are results of
the manufacturing process employed
to create the surface. Surface
roughness Ra is rated as the
arithmetic average deviation are
large, the surface is rough; if they are
small the surface is smooth.
Roughness is typically considered t be
the frequency, short wavelength
component of a measured surface.
• The surface roughness of the machined
composites is measured by using
Measurement of surface
roughness using surface
profilometer.
OBTAINED DATA
Ra is the arithmetic average of the absolute values and Ry is
the range of the collected roughness data points
SAND MOULD GRAVITY METAL MOULD
MOULD
Ra Ry Ra Ry Ra Ry