Query: effect sand casting

title: Effect of cooling rate on microstructures and mechanical property of Al 1230 alloy in a sand casting process
abstract: Sand casting is a widely used process for making various products used in numerous industries such as medical, electrical, automotive etc. However, the poor mechanical properties and microstructural defects are the challenging concern to the foundry engineers for a last decade. In the present work, the microstructural and mechanical assets of Al 1230 alloy are investigated by slow and rapid cooling in a sand casting process. The effect of cooling strategy is analyzed using a scanning electron microscope (SEM) and ultimate tensile strength. Eventually, it is observed that the rapid cooling is a more suitable technique, which enhances the microstructural and mechanical properties of the cast component by inducing of silicon particles during the process. Hence, the proposed work is very useful to smart industries for achieving desired mechanical property while fabricating sand cast components.

title: Effect of Different Gating Systems and Sand Mold Binder on the Cast Quality of Bicycle Frame Produced through Sand Casting Method
abstract: The bicycle frame produced through the metal casting process by recycling aluminum alloys can be an environmentally friendly alternative solution. Mold types and gating systems used generally affects the quality of the casting product. In this experiment, the effect of gating number and riser type variations (for sand binder) observed on casting defects, hardness, and impact value. Subsequently, chemical composition and microstructure of recycled aluminum metal from bicycle frames produced through sand mold casting are also evaluated. Three types of risers are bentonite, water glass, and furan resin. The results indicate that mold with two gating system has a low porosity as casting defects. The cast bike frame produced using furan resin reaches the highest hardness value of 46 HRB compared to water glass and bentonite as the binder of sand molds. The impact test observes 3.9 J carried out by the ASTM E23 sample at room temperature.

title: Effect of Degassing Time and Cooling Rate on Microstructure and Porosity of Aluminum 6061 Alloy Using Sand Casting Method
abstract: This research is aimed to get a better understanding on the effort of reducing the porosity level in aluminum alloys. The degassing process (2, 5 and 8 minutes) is done to reduce the hydrogen content in liquid aluminum and cooling rate modifications (13 degC min, 20 degC min and 26 degC min) was performed to reduce the porosity by reducing the size of Dendrite Arm Spacing (DAS) The casting method used in this research is sand casting and raw materials were melted using an electric furnace at 720 degC. The microstructural images showed the DAS size are decreased by size from 137.3 mm to 87.58 mm obtained from cooling rates of 13 degC min and 26 degC min respectively. In the other hand, the level of porosity is also decreased from 3.58% at 2 min degassing and the cooling rate of 13 degC min to 1.8% at 5 min degassing and 26 degC min cooling rate. Furthermore, the tensile test results show that the value of tensile strength increases when the DAS size and porosity level are smaller. The highest ultimate tensile strength value is 105.9 and the lowest is 70,53 MPa.

title: Effect of composition and pouring temperature of Cu(20 24)wt.%Sn by sand casting on fluidity and mechanical properties
abstract: The effect of tin composition and pouring temperature on the length of fluidity, microstructure, density, hardness, tensile strength and bending of Cu Sn alloy with sand casting method has been investigated. Cu(20 24)wt.%Sn were casted in two different pouring temperatures (1000 oC and 1100 oC) in strip plate pattern sand mold. The sand mold has a length of 400 mm, width of 10 mm with a thickness of the mold cavity varied from 1.5 to 5 mm. The results show that the increase in composition (20 22) wt. Sn decreases the length of fluidity while the composition (22 24) wt. Sn length fluidity increase again. Increase of the pouring temperature and mold cavity thickness can increase the length of fluidity. Increasing tin composition and pouring temperature can increase the phase of a structure, porosity, hardness of the alloy and trigger the growth of dendrite columnar and secondary dendrite (DAS) microstructure.While the density, tensile strength and bending strength of the alloy tend to decrease. Increasing tin composition and pouring temperature in Cu(20 24) wt. Sn caused the alloy to be more brittle.

title: Effect of Mechanical Mould Vibration on the Properties of Sand Casting Aluminium (A 1100) Alloy
abstract: In the present research, the effect of mechanical mould vibrations on properties of sand casting alloys is studied. In A1100 alloy casting, it is an important and readily observable feature which determine the trouble of porosity. This process increases the quality and decreases the porosity and inner defect of moulding alloy or metal. Aluminium alloy A1100 is used for sand casting under the effect of mechanical vibration. The effect of mechanical mould vibration on hot tearing, grain size of cast and on the morphology of eutectic silicon of alloy A1100 are studied. A1100 alloy is tested on UTM machine to check its mechanical and metallurgical properties and note down any increase and improvement in these properties by comparing A1100 sand casted alloy the under effect of mechanical vibration with the A1100 sand casted alloy without mechanical vibration. The results showed improvement in characteristics and properties of alloy A1100 when mechanical vibration is applied during sand casting of the alloy. With this enhancement in quality and properties of A1100 alloy, it can be used more extensively in machinery and automobiles that can also improve cost/benefit ratio of A1100 alloy.  Mechanical mould vibrations, Sand casting, Alloy, Lathe Machine, UTM, Hot tearing, Porosity, and Grain Refining.

title: Effect of Top and Bottom Gating System in Sand Casting of Aluminum Alloy Al 6063 T5
abstract: During casting process of light metals mold filling significantly affect the casted part. Top and bottom gating system is the most significant design consideration in sand casting. It directly effects the mold filling pattern and solidification time. In this research work, the effect of varying gate sizes with top and bottom configuration on the ultimate tensile strength, solidification time and mold filling time was analyzed. For this purpose, eight experiments were performed by varying top and bottom gating sizes while keeping all other parameters constant. ASTM standard samples were prepared and MTS machine was used to observe the UTS of samples. The Matlab software was used to draw the graphs to analyze the effect of top and bottom gating system on UTS. Bottom gating system exhibits better UTS contrary to top gating system.

title: Effect of Mould Coatings and Pouring Temperature on the Fluidity of Different Thin Cross Sections of A206 Alloy by Sand Casting
abstract: Thin wall castings of the A206 alloy can pose a manufacturing problem associated with mould filling which results in fluidity defect. The mould coating generates a smooth surface, and reduces the friction between the melt and mould contact, thus reducing the heat transfer coefficient, which in turn leads to enhancement of fluidity and mechanical properties. The fluidity of A206 alloy was observed in various cross sections of the thin channels at three altered pouring temperatures i.e. 700, 750 and 780 degC for uncoated and coated green sand moulds. The Graphite and Soapstone powder coatings were used as sand mould coatings in the present investigation. It was found that the fluidity of aforesaid alloy was significantly increased with the Soapstone powder mould coating at pouring temperature of 750 degC. The characterization of the coating materials was performed by the X ray diffraction analysis and scanning electron microscope test with EDAX.

title: Modelling the Mechanical Attributes (Roughness, Strength, and Hardness) of Al alloy A356 during Sand Casting
abstract: Sand casting is a well established primary process for manufacturing various parts of A356 alloy. However, the quality of the casting is adversely affected by the change in the magnitude of the control variables. For instance, a larger magnitude of pouring velocity induces a drop effect and a lower velocity increases the likelihood of cold shut and mis run types of defects. Similarly, a high pouring temperature causes the formation of hot tears, whereas a low temperature is a source of premature solidification. Likewise, a higher moisture content yields microcracks (due to gas shrinkages) in the casting and a lower moisture content results in the poor strength of the mold. Therefore, the appropriate selection of control variables is essential to ensure quality manufactured products. The empirical relations could provide valuable guidance in this regard. Additionally, although the casting process was optimized for A356 alloy, it was mostly done for a single response. Therefore, this paper aimed to formulate empirical relations for the contradictory responses, i.e. hardness, ultimate tensile strength and surface roughness, using the response surface methodology. The experimental results were comprehensively analyzed using statistical and scanning electron microscopic analyses. Optimized parameters were proposed and validated to achieve castings with high hardness (84.5 HB) and strength (153.5 MPa) with minimum roughness (5.8 um)

title: SAND CASTING MANUFACTURER WITH MATERIAL ADDITIVE TO PERMEABILITY AND GREEN COMPRESSIVE STRENGTH CHARACTERISTIC
abstract: Sand casting as a main material in the casting process. To result from the product in good quality sand casting must be standardized such as high temperature resistance, good permeability to gas flow, high strength to enough to hold the loading press, and high shear strength to accept shear force. This study to aims effect of material added on green sand as sand casting to find the best composition on permeability, green compressive strength, and green shear strength. Glass powder in sample A and feldspar in sample B used to material binder selected an alternative beside bentonite because have high Silica (SiO) and Alumina (Al 2 O 3 to optimizing the sand casting characteristic. The binder material meshing in 80 Mesh with 10% 20% 30% 40% and 50% composition respectively with 10% constant addition of water. Every sample three times testing included clay content, Grain Fine Number based on SNI 19 0312 1989 while permeability, green compressive strength, and green shear strength. The result shows the permeability directly proportional with glass powder addition has a maximum of 63.67, while the addition of feldspar affected decrease the permeability value with a minimum of 51.67. The higher green compressive strength obtained from 10% w/t glass powder with value 96.87 kN/m 2 inversely proportional with green shear strength with value 76.27 kN/m 2 in 10% w/t addition.

title: Effect of sand dilation on distortions and pattern allowances during steel sand casting
abstract: Mechanical interactions between the sand mold and casting have a great impact on pattern allowances. In this study, the effect of core expansion on distortions during steel casting is investigated. A hollow steel cylinder is cast using silica and zircon sand cores. The evolution of the cylinder's inner diameter is measured in situ using LVDTs. During solidification, core expansion is found to distort the inner diameter into a barrel shaped profile, generating the largest expansion at the mid height. The experiments are simulated using a sequential thermo mechanical coupling. In the stress analysis, the steel and sand are modeled using an elasto visco plastic constitutive law and the Drucker Prager Cap model, respectively. The simulations reveal that sand dilation due to shear stresses, as opposed to thermal expansion, accounts for the majority of the increase in the inner diameter. The measured and predicted pattern allowances are found to be in excellent agreement.