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Title: LOST FOAM CASTING OF MAGNESIUM ALLOYS

Abstract

The lost foam casting process has been successfully used for making aluminum and cast iron thin walled castings of complex geometries. Little work has been carried out on cast magnesium alloys using the lost foam process. The article describes the research activities at Oak Ridge National Laboratory and Tennessee Technological University on lost foam casting of magnesium alloys. The work was focused on castings of simple geometries such as plate castings and window castings. The plate castings were designed to investigate the mold filling characteristics of magnesium and aluminum alloys using an infrared camera. The pate castings were then characterized for porosity distribution. The window castings were made to test the castability of the alloys under lost foam conditions. Significant differences between lost foam aluminum casting and lost foam magnesium casting have been observed.

Authors:
 [1];  [1];  [1];  [2];  [2];  [2];  [3];  [4]
  1. ORNL
  2. Tennessee Technological University
  3. Walford Technologies
  4. Foseco-Morval
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
1041060
DOE Contract Number:
DE-AC05-00OR22725
Resource Type:
Conference
Resource Relation:
Conference: TMS 2007 Annual Meeting, Orlando, FL, USA, 20070225, 20070301
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; ALLOYS; ALUMINIUM; CAST IRON; CASTING; CASTINGS; DISTRIBUTION; MAGNESIUM; MAGNESIUM ALLOYS; ORNL; PLATES; POROSITY; WINDOWS; Lost Foam Casting; Magnesium Alloy; Aluminum Alloy; Castability; and Porosity

Citation Formats

Han, Qingyou, Dinwiddie, Ralph Barton, Sklad, Philip S, Currie, Kenneth, Abdelrahman, Mohamed, Vondra, Fred, Walford, Graham, and Nolan, Dennis J. LOST FOAM CASTING OF MAGNESIUM ALLOYS. United States: N. p., 2007. Web.
Han, Qingyou, Dinwiddie, Ralph Barton, Sklad, Philip S, Currie, Kenneth, Abdelrahman, Mohamed, Vondra, Fred, Walford, Graham, & Nolan, Dennis J. LOST FOAM CASTING OF MAGNESIUM ALLOYS. United States.
Han, Qingyou, Dinwiddie, Ralph Barton, Sklad, Philip S, Currie, Kenneth, Abdelrahman, Mohamed, Vondra, Fred, Walford, Graham, and Nolan, Dennis J. Mon . "LOST FOAM CASTING OF MAGNESIUM ALLOYS". United States. doi:.
@article{osti_1041060,
title = {LOST FOAM CASTING OF MAGNESIUM ALLOYS},
author = {Han, Qingyou and Dinwiddie, Ralph Barton and Sklad, Philip S and Currie, Kenneth and Abdelrahman, Mohamed and Vondra, Fred and Walford, Graham and Nolan, Dennis J},
abstractNote = {The lost foam casting process has been successfully used for making aluminum and cast iron thin walled castings of complex geometries. Little work has been carried out on cast magnesium alloys using the lost foam process. The article describes the research activities at Oak Ridge National Laboratory and Tennessee Technological University on lost foam casting of magnesium alloys. The work was focused on castings of simple geometries such as plate castings and window castings. The plate castings were designed to investigate the mold filling characteristics of magnesium and aluminum alloys using an infrared camera. The pate castings were then characterized for porosity distribution. The window castings were made to test the castability of the alloys under lost foam conditions. Significant differences between lost foam aluminum casting and lost foam magnesium casting have been observed.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Mon Jan 01 00:00:00 EST 2007},
month = {Mon Jan 01 00:00:00 EST 2007}
}

Conference:
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  • No abstract prepared.
  • With the increased emphasis on vehicle weight reduction, production of near-net shape components by lost foam casting will make significant inroad into the next-generation of engineering component designs. The lost foam casting process is a cost effective method for producing complex castings using an expandable polystyrene pattern and un-bonded sand. The use of un-bonded molding media in the lost foam process will impose less constraint on the solidifying casting, making hot tearing less prevalent. This is especially true in Al-Mg and Al-Cu alloy systems that are prone to hot tearing when poured in rigid molds partially due to their longmore » freezing range. Some of the unique advantages of using the lost foam casting process are closer dimensional tolerance, higher casting yield, and the elimination of sand cores and binders. Most of the aluminum alloys poured using the lost foam process are based on the Al-Si system. Very limited research work has been performed with Al-Mg and Al-Cu type alloys. With the increased emphasis on vehicle weight reduction, and given the high-strength-to-weight-ratio of magnesium, significant weight savings can be achieved by casting thin-wall (≤ 3 mm) engineering components from both aluminum- and magnesium-base alloys.« less
  • The article describes the research activities at Oak Ridge National Laboratory and Tennessee Technological University on lost foam casting of magnesium alloys. The work was focused on castings of simple geometries such as plate castings and window castings in order to compare the difference in castability between magnesium alloys and aluminum alloy using the lost foam casting process. Significant differences between lost foam aluminum casting and lost foam magnesium casting have been observed.
  • A feasibility study on the ability to produce a lost foam casting using magnesium based alloys.
  • The paper presents the result of an experimental investigation conducted on medium aluminum silicon alloy casting- LM6, using no-vacuum assisted lost foam casting process. The study is directed for establishing the relationship between the flask vibrations times developed for molded sample on the casting integrity, surface penetration and coating inclusion defects of the casting. Four different flask vibration times namely 180, 120, 90 and 60 sec. were investigated. The casting integrity was investigated in terms of fulfilling in all portions and edges. The surface penetration was measured using optical microscope whilst image analyzer was used to quantify the percentage ofmore » coating inclusion in the casting. The results show that vibration time has significant influence on the fulfilling as well as the internal integrity of the lost foam casting. It was found that the lower vibration time produced comparatively sound casing.« less