Transactions of Nonferrous Metals Society of China The Chinese Journal of Nonferrous Metals

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中国有色金属学报(英文版)

Transactions of Nonferrous Metals Society of China

Vol. 23    No. 10    October 2013

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Evaluation of significant manufacturing parameters in lost foam casting of thin-wall Al-Si-Cu alloy using full factorial design of experiment
Hassan JAFARI1,2, Mohd Hsbullah IDRIS1, Amirreza SHAYGANPOUR1

1. Department of Materials, Manufacturing and Industrial Engineering, Faculty of Mechanical Engineering,
Universiti Teknologi Malaysia, 81310, Skudai, Johor, Malaysia;
2. Department of Materials Engineering, Faculty of Mechanical Engineering,
Shahid Rajaee Teacher Training University, Tehran, 16785-136, Iran

Abstract:Controlling process parameters of lost foam casting (LFC) enables this process to produce defect-free complex shape castings. An experimental investigation on lost foam casting of an Al-Si-Cu cast alloy was carried out. The effects of pouring temperature, slurry viscosity, vibration time and sand size on surface finish, shrinkage porosity and eutectic silicon spacing of thin-wall casting were investigated. A full two-level factorial design of experimental technique was used to identify the significant manufacturing factors affecting the properties of casting. Pouring temperature was found as the most significant factor affecting Al-Si-Cu lost foam casting quality. It was shown that flask vibration time interacted with pouring temperature influenced eutectic silicon spacing and porosity percentage significantly. The results also revealed that the surface quality of the samples cast in fine sand moulds at higher pouring temperatures was almost unchanged, while those cast in coarse sand moulds possessed lower surface qualities. Furthermore, variation in slurry viscosity showed no significant effect on the evaluated properties compared to other parameters.

 

Key words: Al-Si-Cu alloy; lost foam casting; full factorial design; surface finish; porosity; silicon spacing

ISSN 1004-0609
CN 43-1238/TG
CODEN: ZYJXFK

ISSN 1003-6326
CN 43-1239/TG
CODEN: TNMCEW

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