{"id":3055,"date":"2018-02-06T03:37:14","date_gmt":"2018-02-06T03:37:14","guid":{"rendered":"http:\/\/www.adtechamm.com\/?p=3055"},"modified":"2018-02-06T03:45:42","modified_gmt":"2018-02-06T03:45:42","slug":"study-casting-characteristics","status":"publish","type":"post","link":"https:\/\/www.adtechamm.com\/tr\/study-casting-characteristics\/","title":{"rendered":"D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA"},"content":{"rendered":"<p>A STUDY OF CASTING CHARACTERISTICS FOR \u201c DIE-CAST ALUMINUM ALLOY\u201d<\/p>\n<p>CASTING CHARACTERISTICS FOR \u201cDIE-CAST ALUMINUM ALLOYS<\/p>\n<p>CONTENTS:<br \/>\nINTRODUCTION<br \/>\nCAST ABILITY<br \/>\nTYPE OF STANDARD DIE CAST ALUMINUM ALLOYS<br \/>\nCHEMICAL COMPOSITION<br \/>\nPHYSICAL AND MECHANICAL PROPERTIES<br \/>\nCHARACTERISTICS OF DIE CAST ALUMINUM ALLOYS<br \/>\nCOMPARISON DIFFERENT DIE CAST MATERIAL WITH DIE CAST AL-ALLOY<br \/>\nDIE SOLDERING:<br \/>\n<a href=\"http:\/\/www.adtechamm.com\/tr\/2018\/01\/23\/flux-for-aluminum-melting\/\">SLUDGE FORMATION<\/a><br \/>\nEFFECT OF HOLDING TEMPERATURES FOR SLUDGE FORMATION<br \/>\nSLUDGE FORMATION FACTORS<br \/>\nFLUDITY<br \/>\nFACTORS WHICH EFFECT ON FLUDITY<br \/>\nPOROSITY<\/p>\n<p>INTRODUCTION<br \/>\nDie casting technology is one of the mainly applied manufacturing practice In the die casting process the molten metal is injected under pressure into the hardened steel dies.<\/p>\n<p>Different casting processes require the alloy to have different casting characteristics. We will define here the different casting characteristics of die cast AL- Alloy.<br \/>\n1) Cast ability<br \/>\n2) sludge Formation<br \/>\n3) Alloy fluidity<br \/>\n4) Machine ability<br \/>\n5) Die soldering<br \/>\n6) Porosity<br \/>\n7) Macro segregation<\/p>\n<p>D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA<\/p>\n<p>CASTABILITY:<br \/>\nCast ability is the property of an alloy to be cast without formation of defects such as cracks, segregations, pores or mis runs.<br \/>\nAlloy dependent the phenomena that determine castability, fluidity, macro segregation, hot tearing and porosity.<br \/>\nCast ability of aluminum alloys can also defined such as solidification path, dendrite coherency, solidification shrinkage and inter dendrite permeability.<br \/>\nThe influence of alloy composition on fluidity, macro segregation, hot tearing and porosity will be described. coherency, fluidity, permeability and shrinkage will be presented.<\/p>\n<p>TYPE OF ALUMINUM DIE CASTING ALLOYS<br \/>\nAluminum die casting alloys are lightweight, offer good corrosion resistance, ease of casting, good mechanical properties and dimensional stability. Although a variety of aluminum alloys can be die cast from primary or recycled metal, designers select a standard alloy listed below.<br \/>\nA360 &#8212; Selected for best corrosion resistance and pressure tightness.<br \/>\nA380 &#8212; The most common and cost effective of AL- die casting alloys. Provides the best combination of utility and cost.<br \/>\nA383 &amp; A384 &#8212; These alloys are a modification of 380. Both provide better die filling but with a moderate sacrifice in mechanical properties such as toughness.<br \/>\nA390 &#8212; Selected for special applications where high strength, fluidity and wearresistance and bearing properties are required.<br \/>\nA413 (A13) &#8212; Used for maximum pressure tightness and fluidity.<\/p>\n<p>CHEMICAL COMPOSITION OF DIE CAST ALUMINUM ALLOYS<br \/>\nThe following table will provide a general idea of the differences in different Aluminum Die Cast alloys. This table will help us technical comparison in Al. alloys.<\/p>\n<p>DIE SOLDERING:<br \/>\nThere are several classes of process parameters that influence die soldering. These are under :<br \/>\nTemperature of the metal and die.<br \/>\nNature and constituents of casting alloy and inter metallic layers.<br \/>\nDie Lubrication and coating.<br \/>\nNature of the die and operating parameters.<\/p>\n<p>D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA<\/p>\n<p>THE MECHANISM OF DIE SOLDERING OCCURS IN SIX STAGES:<br \/>\nSTAGE I ==&gt; Erosion of grain boundaries on the die surface<br \/>\nSTAGE II ==&gt; Pitting of the die surface<br \/>\nSTAGE III ==&gt; Formation of iron-aluminum compounds<br \/>\nSTAGE IV ==&gt; Formation of pyramid shaped inter metallic phases<br \/>\nSTAGE V ==&gt; Adherence of aluminum onto the pyramids of inter metallic phases<br \/>\nSTAGE VI ==&gt; Merging and straightening of erosion pits and inter metallic phases<\/p>\n<p>EFFECT OF VARIOUS ELEMENTS ON THE INTERMEDIATE LAYER THICKNESS.<br \/>\nThe effects of alloy composition on the die soldering for the A 380 type alloys and effects of some key elements on the growth of the intermediate layer between the tool steel surface and the soldered Aluminum.<\/p>\n<p><img class=\"alignnone wp-image-3056 size-full\" title=\"D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA\" src=\"http:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.1.jpg\" alt=\"D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA\" width=\"863\" height=\"543\" srcset=\"https:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.1.jpg 863w, https:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.1-300x189.jpg 300w, https:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.1-768x483.jpg 768w, https:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.1-700x440.jpg 700w\" sizes=\"(max-width: 863px) 100vw, 863px\" \/><\/p>\n<p>D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA<\/p>\n<p>SLUDGE<br \/>\nSludge is made up of primary crystals containing Al, Si, Fe, Mn, Cr, Mg,<br \/>\netc. and having high melting temperature and high specific gravity.<br \/>\nFactors that affect sludge formation:<br \/>\nAlloy composition .<br \/>\nMelting and holding temperatures<br \/>\nCooling rate<br \/>\nSludge factor (SF)<br \/>\n(SF) = (1 x wt % Fe) + (2 x wt% Mn) + (3 x wt % Cr<br \/>\nWith an increase in cooling rate, the size of the sludge particles and the volume fraction of sludge decrease,Sludge formed at the low cooling rate as large platelets, and polyhedral particles.<br \/>\nAt the high cooling rate, SLUDGE is in the form of platelets and star-like particles.<\/p>\n<p>EFFECT OF HOLDING TEMPERATURES<br \/>\nRelation of sludge forming temperature with Fe<br \/>\ncontent:<br \/>\nTemperature (\u00b0C) = 645.7 + 34.2 (%Fe)2<\/p>\n<p><img class=\"alignnone wp-image-3057 size-full\" title=\"D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA\" src=\"http:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.2.jpg\" alt=\"D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA\" width=\"538\" height=\"425\" srcset=\"https:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.2.jpg 538w, https:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.2-300x237.jpg 300w\" sizes=\"(max-width: 538px) 100vw, 538px\" \/><\/p>\n<p><img class=\"alignnone wp-image-3058 size-full\" title=\"D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA\" src=\"http:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.3.jpg\" alt=\"D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA\" width=\"617\" height=\"386\" srcset=\"https:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.3.jpg 617w, https:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.3-300x188.jpg 300w\" sizes=\"(max-width: 617px) 100vw, 617px\" \/><\/p>\n<p><img class=\"alignnone wp-image-3059 size-full\" title=\"D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA\" src=\"http:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.4.jpg\" alt=\"D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA\" width=\"271\" height=\"308\" srcset=\"https:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.4.jpg 271w, https:\/\/www.adtechamm.com\/wp-content\/uploads\/2018\/02\/1.4-264x300.jpg 264w\" sizes=\"(max-width: 271px) 100vw, 271px\" \/><\/p>\n<p>D\u00d6K\u00dcM \u00d6ZELL\u0130KLER\u0130 \u00dcZER\u0130NE B\u0130R \u00c7ALI\u015eMA<\/p>\n<p>When the alloys solidify at low cooling rate, holding at 670 \u00b0C and 720 \u00b0C does not affect sludge formation.<br \/>\nWhen the alloys solidify at high cooling rate,more sludge was found in A380 alloy afterholding at 670\u00b0C.<br \/>\nIn 380 type alloys, the sludge phases are mainly Fe-rich compounds consisting of Al, Fe, Mn, Cr, Ni.<br \/>\nAlloys with higher SF have a higher tendency to form sludge and form larger volume fraction of sludge.<br \/>\nThe morphology of sludge is influenced by the Fe:Mn: Cr ratio and by the cooling rate.Slow cooling favours formation of sludge.<br \/>\nHolding at 670\u00b0C (~1240\u00b0F) and 720\u00b0C (1328\u00b0F) does not affect sludge formation in all the alloys solidify slowly. When cooling fast, more sludge formed in A380 alloy after holding at 670\u00b0Cthan at 720\u00b0C.<\/p>\n<p>FLUIDITY:<br \/>\nFluidity is a material\u2019s ability to flow into and fill a given cavity, as measured by the dimensions of that cavity under specific conditions.<br \/>\nThe length of molten liquid metal that can flow through a given mould before freezing Fluidity is heavily dependent on heat flow during solidification.<br \/>\nFluidity of Al- Alloy depends on lubricant coatings, alloying additions, head pressure, and temperature of molten metal.<br \/>\nIncreasing the solidification range results in decreasing fluidity<\/p>\n<p>FACTORS WHICH EFFECT ON FLUDITY:<br \/>\nAlloy chemical composition play a important role in die filling that is the fluidity of molten metal.<br \/>\nAlloying Elements that lean to form high temperature compounds, e.g., Fe, Mn, Cr, and Mg, tend to decrease fluidity.<\/p>","protected":false},"excerpt":{"rendered":"<p>A STUDY OF CASTING CHARACTERISTICS FOR \u201c DIE-CAST ALUMINUM ALLOY\u201d CASTING CHARACTERISTICS FOR \u201cDIE-CAST ALUMINUM ALLOYS CONTENTS: INTRODUCTION CAST ABILITY TYPE OF STANDARD DIE CAST ALUMINUM ALLOYS CHEMICAL COMPOSITION PHYSICAL AND MECHANICAL PROPERTIES CHARACTERISTICS OF DIE CAST ALUMINUM ALLOYS COMPARISON DIFFERENT DIE CAST MATERIAL WITH&#8230;<\/p>","protected":false},"author":1,"featured_media":3058,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":[],"categories":[52,1],"tags":[794,797,796],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v19.6 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>A STUDY OF CASTING CHARACTERISTICS-AdTech<\/title>\n<meta name=\"description\" content=\"A STUDY OF CASTING CHARACTERISTICS Die casting technology is one of the mainly applied manufacturing practice In the die casting process the molten....\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, 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