Details

Title

Assessment of Mechanical Behaviors of Sand Cast Al-Mg7-Cu2 Aluminum Alloy in Tilt and Vertical Gravity Casting Conditions

Journal title

Archives of Foundry Engineering

Yearbook

2025

Volume

vol. 25

Issue

No 1

Authors

Affiliation

Gül, K.A. : Istanbul Technical University, Turkey ; Gül, K.A. : Groupe Renault, Turkey ; Sahin, H. : VESUVIUS Foundry R&D Center, Netherlands ; Dispinar, D. : VESUVIUS Foundry R&D Center, Netherlands

Keywords

Vertical top pouring ; Tilt pouring ; Hydraulic jump ; Defect formation on aluminum alloys ; Melt treatments

Divisions of PAS

Nauki Techniczne

Coverage

169-179

Publisher

The Katowice Branch of the Polish Academy of Sciences

Bibliography

  1. Campbell, J. (2006). Entrainment defects. Materials Science And Technology. 22(2), 127-145. http://dx.doi.org/10.1179/174328406X74248.
  2. Campbell, J. (2012). Stop pouring, start casting. International Journal of Metal Casting. 6(3), 7-18. https://doi.org/10.1007/BF03355529.
  3. Mohamed, A. M. A., Samuel, E., Samuel, A. M., Doty, H. W., Songmene, V. & Samuel, F. H. (2023). Effect of intermetallics and tramp elements on porosity formation and hardness of Al–Si–Mg and Al–Si–Cu–Mg alloys. International Journal of Metalcasting. 17(2), 664-681. https://doi.org/10.1007/s40962-022-00813-w.
  4. Costa, T.A., Dias, M., Gomes, L.G. Rocha, O.L. & Garcia, A. (2016). Effect of solution time in T6 heat treatment on microstructure and hardness of a directionally solidified Al–Si–Cu alloy. Journal of Alloys and Compounds. 683, 485-494. https://doi.org/10.1016/j.jallcom.2016.05.099.
  5. Campbell, J. (2015). Complete casting handbook: Metal casting processes, metallurgy, techniques and design. UK: Butterworth-Heinemann.
  6. Ibrahim, A., Elgallad, E., Samuel, A., Doty, H. & Samuel, F. (2018). Effects of heat treatment and testing temperature on the tensile properties of Al–Cu and Al–Cu–Si based alloys. International Journal of Materials Research. 109(4), 314-331. https://doi.org/10.3139/146.111605.
  7. Salihu, S., Isa, and A. & Polycarp, E. (2012). Influence of magnesium addition on mechanical properties and microstructure of Al-Cu-Mg alloy. IOSR Journal of Pharmacy and Biological Sciences. 4(5), 15-20. https://doi.org/10.9790/3008-0451520.
  8. Rana, R. S., Purohit, R., & Das, S. (2012). Reviews on the influences of alloying elements on the microstructure and mechanical properties of aluminum alloys and aluminum alloy composites. International Journal of Scientific and Research Publications, 2(6).
  9. Mansurov, Y., Letyagin, N., Finogeyev, A. & Rakhmonov, J.U. (2018). Influence of impurity elements on the casting properties of Al-Mg based alloys. Non-Ferrous Metals. 44(1), 24-29.
  10. Mikhaylovskaya, V., Mochugovskiy, A.G., Levchenko, V.S., Tabachkova, N.Y., Mufalo, W. & Portnoy, V.K. (2018). Precipitation behavior of L12 Al3Zr phase in Al-Mg-Zr alloy. Materials Characterization. 139, 30-37. https://doi.org/10.1016/j.matchar.2018.02.030.
  11. Mortensen, A., Grimes, R. & Suresh, S. (2000). Aluminum alloys for aerospace applications. Materials Science and Engineering: A. 280(1), 37-49.
  12. Scampone, G., Pirovano, R., Mascetti, S. et al.Experimental and numerical investigations of oxide-related defects in Al alloy gravity die castings. Int J Adv Manuf Technol 117, 1765–1780 (2021). https://doi.org/10.1007/s00170-021-07680-5
  13. Nadella, R., Eskin, D., Katgerman, L. (2016). Effect of Grain Refining on Defect Formation in DC Cast Al-Zn-Mg-Cu Alloy Billet. In: Grandfield, J.F., Eskin, D.G. (eds) Essential Readings in Light Metals. Springer, Cham. https://doi.org/10.1007/978-3-319-48228-6_105.
  14. Barnett, M.R. (2000). Review: The influence of copper additions on the age-hardening behaviour of aluminium alloys. Materials Science and Engineering: A. 280(1), 1-13.
  15. Lee, S.-L., Wu, C.-T. & Chen, Y.-D. (2015). Effects of minor Sc and Zr on the microstructure and mechanical properties of Al-4.6Cu-0.3Mg-0.6Ag alloys. Journal of Materials Engineering and Performance. 24, 10-20, https://doi.org/10.1007/s11665-014-1364-2.
  16. Bai, S., Huang, T., Xu, H., Liu, Z., Wang, J. & Yi, X. (2019). Effects of small Er addition on the microstructural evolution and strength properties of an Al–Cu–Mg–Ag alloy aged at 200°C. Materials Science and Engineering: A. 766, 138351. https://doi.org/10.1016/j.msea.2019.138351.
  17. Elgallad, E., Samuel, F., Samuel, A. & Doty, H. (2009). Development of new Al-Cu based alloys aimed at improving the machinability of automotive castings. International Journal of Metalcasting. 3, 29-41. https://doi.org/10.1007/BF03355446.
  18. Mahmoud, M. G., Samuel, A. M., Doty, H. W. & Samuel, F. H. (2020). Effect of the addition of La and Ce on the solidification behavior of Al–Cu and Al–Si–Cu cast alloys. International Journal of Metalcasting. 14, 191–206. https://doi.org/10.1007/s40962-019-00351-y.
  19. Yao, D., Qiu, F., Jiang, Q., Li, Y. & Arnberg, L. (2013). Effect of lanthanum on grain refinement of casting aluminum-copper alloy. International Journal of Metalcasting. 7, 49-54. https://doi.org/10.1007/BF03355544.
  20. Ibrahim, A. I., Samuel, A. M., Doty, H. W., & Samuel, F. H. (2018). Response of varying levels of silicon and transition elements on room- and elevated-temperature tensile properties in an Al–Cu alloy. International Journal of Metalcasting. 12, 396-414. https://doi.org/10.1007/s40962-017-0177-0.
  21. Ibrahim, A. I., Elgallad, E. M., Samuel, A. M., Doty, H. W., & Samuel, F. H. (2018). Effects of addition of transition metals on intermetallic precipitation in Al–2%Cu–1%Si-based alloys. International Journal of Metalcasting. 12, 574-588. https://doi.org/10.1007/s40962-017-0196-x.
  22. Gyarmati, G., Fegyverneki, G., Tokár, M. & Mende, T. (2020). The effects of rotary degassing treatments on the melt quality of an Al–Si casting alloy. International Journal of Metal Casting. 15(1), 141-151. https://doi.org/10.1007/s40962-020-00428-z.
  23. Uludağ, M., Çetin, R., Dispinar, D. & Tiryakioğlu, M. (2017). Characterization of the effect of melt treatments on melt quality in Al-7wt%Si-Mg alloys. Metals. 7(5), 157, 1-16. https://doi.org/10.3390/met7050157.
  24. Eskin, D., Alba-Baena, N., Pabel, T. & da Silva, M. (2015). Ultrasonic degassing of aluminium alloys: basic studies and practical implementation. Materials Science and Technology. 31(1), 79-84. https://doi.org/10.1179/1743284714Y. 0000000587.
  25. Fan, Z. Y., Zuo, Y. B., & Jiang, B. (2011). A new technology for treating liquid metals with intensive melt shearing. Materials Science Forum. 690, 141-144.
  26. Zuo, Y.B., Jiang, B., Zhang, Y.J. & Fan, Z. (2013). Degassing LM25 aluminium alloy by novel degassing technology with intensive melt shearing. International Journal of Cast Metals Research. 26(1), 16-21. https://doi.org/10.1179/1743133612Y.0000000019.
  27. Yamamoto, T., Kato, K., Komarov, S.V., Ueno, Y., Hayashi, M. & Ishiwata, Y. (2018). Investigation of melt stirring in aluminum melting furnace through water model. Journal of Materials Processing Technology. 259, 409-415. https://doi.org/10.1016/j.jmatprotec.2018.04.025.
  28. Puga, H., Barbosa, J., Azevedo, T., Ribeiro, S. & Alves, J.L. (2016). Low pressure sand casting of ultrasonically degassed AlSi7Mg0.3 alloy: Modelling and experimental validation of mould filling. Materials & Design. 94, 384-391. https://doi.org/10.1016/j.matdes.2016.01.059.
  29. Puga, H., Barbosa, J., Teixeira, J.C. & Prokic, M. (2014). A new approach to ultrasonic degassing to improve the mechanical properties of aluminum alloys. Journal of materials engineering and performance. 23(10), 3736-3744. https://doi.org/10.1007/s11665-014-1133-2.
  30. Puga, H., Barbosa, J., Seabra, E., Ribeiro, S. & Prokic, M. (2009). The influence of processing parameters on the ultrasonic degassing of molten AlSi9Cu3 aluminum alloy. Materials Letters. 63(9-10), 806-808. https://doi.org/10.1016/j.matlet.2009.01.009.
  31. Uludağ, M., Gemi, L., Çetin, R. & Dispinar, D. (2016). The effect of holding time and solidification rate on porosity of A356. American Journal of Engineering Research (AJER). 5(12), 271-275. e-ISSN: 2320-0847.
  32. Atakav, B., Gürsoy, Ö., Erzi, E., Tur, K. & Dispinar, D. (2020). Sr addition and its effect on the melt cleanliness of A356. Materials Research Express. 7(2), 026549. DOI: 10.1088/2053-1591/ab735b.
  33. Raiszadeh R. & Griffiths, W.D. (2011). The effect of holding liquid aluminum alloys on oxide film content. Metallurgical and Materials Transactions B. 42(1), 133-143. https://doi.org/10.1007/s11663-010-9439-4.
  34. Piccioli, M., Aanesen, S.V., Zhao, H., Dudek, M. & Øye, G. (2020). Gas flotation of petroleum produced water: A review on status, fundamental aspects, and perspectives. Energy & Fuels. 34(12), 15579-15592. https://doi.org/10.1021/ acs.energyfuels.0c03262.
  35. Shen, W., Mukherjee, D., Koirala, N., Hu, G., Lee, K., Zhao, M. & Li, J. (2022). Microbubble and nanobubble-based gas flotation for oily wastewater treatment: A review. Environmental Reviews. 30(3), 359-379. https://doi.org/10.1139/er-2021-0127.
  36. Hamzah, E., Prayitno, D. & Ghazali, M.Z.M. (2022). Effect of mold tilt angle on the mechanical properties of as-cast aluminum alloy. Materials & design. 23(2), 189-194. https://doi.org/10.1016/S0261-3069(01)00068-1.
  37. Birsan, G., Ashtari, P. & Shankar, S. (2011). Valid mold and process design to cast tensile and fatigue test bars in tilt pour casting process. International Journal of Cast Metals Research. 24(6), 378-384. https://doi.org/10.1179/1743133611Y.0000000005.
  38. Şahin, H. (2022). Effect of different addition ratio of rare earth elements erbium and europium on microstructure and mechanical properties of A356 (Al-7Si-0.3Mg) alloy. Master Thesis, Istanbul Technical University.
  39. Nabawy, A. M., Samuel, A. M., Doty, H. W., & Samuel, F. H. (2021). A review on the criteria of hot tearing susceptibility of aluminum cast alloys. International Journal of Metalcasting. 15, 1362-1374. https://doi.org/10.1007/s40962-020-00559-3.
  40. Tao, C., Huang, H., Yuan, X., Yue, C., Su, M., & Zuo, X. (2022). Effect of Y element on microstructure and hot tearing sensitivity of as-cast Al–4.4Cu–1.5Mg–0.15Zr alloy. International Journal of Metalcasting. 16(2), 1010-1019. https://doi.org/10.1007/s40962-021-00666-9.
  41. Patel, J. B., Yang, X., Mendis, C. L., & Fan, Z. (2017). Melt conditioning of light metals by application of high shear for improved microstructure and defect control. JOM, 69(6), 1071-1078. https://doi.org/10.1007/s11837-017-2335-5
  42. Şahin H. & Dispinar, D. (2024). Estimating toughness limit of cast aluminum alloys with reduced pressure test. International Journal of Metalcasting. 1-7. https://doi.org/10.1007/s40962-024-01453-y.
  43. Dispinar, D. & Campbell, J. (2004). Critical assessment of reduced pressure test. Part 1: Porosity phenomena. International Journal of Cast Metals Research. 17(5), 280-286. https://doi.org/10.1179/136404604225020696.
  44. Dispinar, D. & Campbell, J. (2004). Critical assessment of reduced pressure test. Part 2: Quantification. International Journal of Cast Metals Research. 17(5), 287-294. https://doi.org/10.1179/136404604225020704.
  45. Fuchs, P., Kröger, T. & Garbe, C.S. (2021). Defect detection in CT scans of cast aluminum parts: A machine vision perspective. Neurocomputing. 453, 85-96. https://doi.org/10.1016/j.neucom.2021.04.094.
  46. Gyarmati, G., Fegyverneki, G., Mende, T. & Tokár, M. (2019). Characterization of the double oxide film content of liquid aluminum alloys by computed tomography. Materials Characterization. 157, 109925, 1-10. https://doi.org/10.1016/j.matchar.2019.109925.
  47. Gul, K. A., Dispinar, D., Kayali, E. S. & Aslan, O. (2023). Assessment of tensile properties of cast high Mg-containing Al-Mg-Cu aluminum alloy with correlation of computed tomography scans and optical crack surface analysis. International Journal of Metalcasting. 17(4), 2622-2637. https://doi.org/10.1007/s40962-023-01038-1.
  48. Gul, A., Aslan, O., Kayali, E.S. & Bayraktar, E. (2023). Assessing cast aluminum alloys with computed tomography defect metrics: A Gurson porous plasticity approach. 13(4), 752, 1-20. https://doi.org/10.3390/met13040752.
  49. Zhang, H., Zhang, C., Zhou, P., Du, Y., Peng, Y., Liu, S., Wang, J. & Li, K. (2018). Experimental investigation of the Mo–Ti–Zr ternary phase diagrams. Journal of Phase Equilibria and Diffusion. 39, 789-799. https://doi.org/10.1007/s11669-018-0668-6.
  50. Majidi H. & Beckermann, C. (2019). Effect of pouring conditions and gating system design on air entrainment during casting. International Journal of Metalcasting. 13(2), 255-272. https://doi.org/10.1007/s40962-018-0272-x.

Date

28.03.2025

Type

Article

Identifier

DOI: 10.24425/afe.2025.153787
×