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Title: Comparison of Lost Foam Casting of AM60B Alloy and A356 Alloy

Abstract

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.

Authors:
 [1];  [1];  [1];  [2];  [2];  [2];  [3];  [4];  [5]
  1. ORNL
  2. Tennessee Technological University
  3. Walford Technologies
  4. Foseco-Morval
  5. Kaiser Aluminum
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:
1041062
DOE Contract Number:
DE-AC05-00OR22725
Resource Type:
Conference
Resource Relation:
Conference: AFS 2007 metal casting congress, Houston, TX, USA, 20070515, 20070518
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; ALLOYS; ALUMINIUM; CASTING; CASTINGS; MAGNESIUM; MAGNESIUM ALLOYS; ORNL; PLATES; WINDOWS; Lost foam casting; aluminum alloy; magnesium alloy; solidification; porosity; castability

Citation Formats

Han, Qingyou, Dinwiddie, Ralph Barton, Sklad, Philip S, Currie, Kenneth, Vondra, Fred, Abdelrahman, Mohamed, Walford, Graham, Nolan, Dennis J, and Nedkova, Teodora. Comparison of Lost Foam Casting of AM60B Alloy and A356 Alloy. United States: N. p., 2007. Web.
Han, Qingyou, Dinwiddie, Ralph Barton, Sklad, Philip S, Currie, Kenneth, Vondra, Fred, Abdelrahman, Mohamed, Walford, Graham, Nolan, Dennis J, & Nedkova, Teodora. Comparison of Lost Foam Casting of AM60B Alloy and A356 Alloy. United States.
Han, Qingyou, Dinwiddie, Ralph Barton, Sklad, Philip S, Currie, Kenneth, Vondra, Fred, Abdelrahman, Mohamed, Walford, Graham, Nolan, Dennis J, and Nedkova, Teodora. Mon . "Comparison of Lost Foam Casting of AM60B Alloy and A356 Alloy". United States. doi:.
@article{osti_1041062,
title = {Comparison of Lost Foam Casting of AM60B Alloy and A356 Alloy},
author = {Han, Qingyou and Dinwiddie, Ralph Barton and Sklad, Philip S and Currie, Kenneth and Vondra, Fred and Abdelrahman, Mohamed and Walford, Graham and Nolan, Dennis J and Nedkova, Teodora},
abstractNote = {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.},
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:
Other availability
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  • 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
  • No abstract prepared.
  • 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 characterizedmore » 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.« less
  • Melting and casting characteristics of A356 (Al 7% Si) alloy reinforced with 10, 15, and 20 vol. % SiC particles were studied. Remelting followed by holding and solidification of these composites leads to settling of the SiC particles to the bottom of the mold. The height of the SiC particle-free zone formed at the top of the mold, as a result of settling, is referred to as the denuded zone. A356 with 20 vol. % SiC ({approximately}14-{mu} particle size) showed larger denuded zones for a given settling time compared to the system with 10 or 15 vol. % SiC. Themore » permanent mold and sand mold spiral fluidities, and permanent mold casting fluidity of Al A356-SiC particle melt slurry generally decrease with increasing vol. % of a given size SiC. The fluidity values increase with temperature until a temperature range of 740-760C. Solidification microstructures formed during static settling and during flow along the length of the casting fluidity for SiC particle composites were analyzed. Influences of cooling rate, settling time, and oxide films on solidification microstructures were investigated.« less
  • These experiments were done to evaluate the feasibility of locally modifying the surface properties of magnesium alloys with friction-stir processing. The magnesium alloy used for the study was high-pressure die-cast AM60B, nominally Mg-6Al-0.13 Mn (wt. %). Friction-stir passes were made with a translation speed of 1.7 mm/s using tool-rotation speeds of 1,250 rpm or 2,500 rpm. Stir passes with good appearance were obtained under both conditions. In some cases up to five passes were overlapped on a single bar to produce stir zones with cross-sectional dimensions of about 1.5 mm x 10 mm. Metallographic examinations indicated that the stir zonesmore » were largely comprised of a magnesium solid solution with equiaxed grains on the order of 5-10 {micro}m in size. Hardness mapping showed that the stir zones experienced increases of 16-25% compared to the as-cast metal. Room-temperature testing showed that, compared to the cast metal, the stir zones had flow stresses nearly 20% higher with about twice the tensile elongation.« less