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Influence of silicon content on the volume deficit characteristic of cast Al–Si alloys

Published online by Cambridge University Press:  16 December 2013

Samavedam Santhi*
Affiliation:
Department of Metallurgical and Materials Engineering, Mahatma Gandhi Institute of Technology, Hyderabad 500075, India
S.B. Sakri
Affiliation:
Special Fabrication Division, Defence Research and Development Laboratory, Hyderabad 500058, India
Dharwada Hanumantha Rao
Affiliation:
Mechanical Engineering Department, M.V.S.R. Engineering College, Hyderabad 501510, India
Srinivasan Sundarrajan
Affiliation:
National Institute of Technology, Trichy 620015, India
*
a)Address all correspondence to this author. e-mail: santhi_samave@yahoo.com

Abstract

Aluminum alloy castings find extensive applications in automobile and other engineering industries. Production of defect-free castings requires a good understanding of the volume deficit characteristic. The volume deficit of a casting depends on the casting material and casting conditions. Patterson and Engler have classified the volume deficit into four types namely, macrocavities, internal porosity, surface sinking, and volumetric contraction. The influence of process parameters on the characteristics determines the casting quality. The process parameters considered in this study are bottom chill, casting shape, and pouring temperature. Two basic shapes rectangle and cylinder are considered. The volume deficit decreases with an increase in the silicon content. The AA 356.0 alloy shows more amount of volume deficit than AA 413.0 alloy. X-ray computer tomography (XCT) helps to reveal the size, shape, and location of defects in castings. Quantification of internal closed porosity of AA 413.0 casting is done using XCT and successfully validated through destructive testing of castings.

Information

Type
Articles
Copyright
Copyright © Materials Research Society 2013 
Figure 0

TABLE I. Details of volume deficit.

Figure 1

FIG. 1. Classification of volume deficit. (a) classification of volume deficit; (b) description of volume deficit.

Figure 2

TABLE II. Chemical composition (wt%).

Figure 3

TABLE III. Dimensional details of castings considered.

Figure 4

TABLE IV. Experimental plan.

Figure 5

FIG. 2. Details of the pouring basin.

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FIG. 3. Details of the overflow core.

Figure 7

FIG. 4. Schematic diagram for the volume deficit experiment.

Figure 8

FIG. 5. (a, b) Prepared molds and the assembled mold for volume deficit.

Figure 9

FIG. 6. (a, b) Solidified castings of volume deficit experiment.

Figure 10

TABLE V. Details of the castings considered for XCT.

Figure 11

TABLE VII. Volume deficit values.

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TABLE VI. Volume deficit calculation for experimental run order 2.

Figure 13

FIG. 7. (a, b) XCT images of experimental run order 12.

Figure 14

FIG. 8. (a, b) Constructed porosity of experimental run order 12.

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TABLE VIII. Volume of internal closed porosity for experimental run order 8.

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TABLE IX. Volume deficit for experimental run order 8.

Figure 17

FIG. 9. (a, b) Sectioned castings of experimental run order 8.

Figure 18

TABLE X. Volume of internal closed porosity—a comparison.

Figure 19

FIG. 10. Influence of process parameters on volume deficit.

Figure 20

FIG. 12. (a, b) Internal porosity for rectangular shape castings.

Figure 21

FIG. 11. Macroshrinkage of cylindrical-shaped casting AA 356.0.

Figure 22

FIG. 13. (a, b) Scattered porosity and bouquet or cluster of shrinkage observed near the edge or at the macrocavities region at 50x magnification—AA 413.0.

Figure 23

FIG. 14. (a, b) Cluster of shrinkage observed near the edge at 50x magnification—AA 356.0.

Figure 24

FIG. 15. Interdendritic feeding—AA 356.0.

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FIG. 16. (a, b) Dispersed shrinkage and gaseous porosity observed near the edge or at the macrocavities region at 50x magnification—AA 356.0.

Figure 26

FIG. 17. Interdendritic feeding—AA 413.0.

Figure 27

FIG. 18. Scattered porosity at 50X magnification - AA 413.0.

Figure 28

TABLE XI. Volume deficit distribution for cylindrical-shaped castings.