A STUDY OF CASTING CHARACTERISTICS FOR “ DIE-CAST ALUMINUM ALLOY” ME8109: Casting And Solidification of Material Department of Mechanical & Industrial Engineering Graduate Program in Mechanical Engineering Ryerson University ME8109: Casting And Solidification of Material Submitted To: Dr. C.RAVINDRAN Prepared by: Anwar Hussain 1
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A STUDY OF CASTING CHARACTERISTICS
FOR “ DIE-CAST ALUMINUM ALLOY”
ME8109: Casting And Solidification of Material
Department of Mechanical & Industrial Engineering
Graduate Program in Mechanical Engineering
Ryerson University
ME8109: Casting And Solidification of MaterialSubmitted To: Dr. C.RAVINDRAN
Prepared by: Anwar Hussain
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• CONTENTS:
• INTRODUCTION
• CAST ABILITY
• TYPE OF STANDARD DIE CAST ALUMINUM ALLOYS
• CHEMICAL COMPOSITION
• PHYSICAL AND MECHANICAL PROPERTIES
• CHARACTERISTICS OF DIE CAST ALUMINUM ALLOYS
CASTING CHARACTERISTICS FOR “DIE-CAST ALUMINUM ALLOYS
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• CHARACTERISTICS OF DIE CAST ALUMINUM ALLOYS
• COMPARISON DIFFERENT DIE CAST MATERIAL WITH DIE CAST AL-ALLOY
• DIE SOLDERING:
• SLUDGE FORMATION
• EFFECT OF HOLDING TEMPERATURES FOR SLUDGE FORMATION
• SLUDGE FORMATION FACTORS
• FLUDITY
• FACTORS WHICH EFFECT ON FLUDITY
• POROSITY
CASTING CHARACTERISTICS FOR “DIE-CAST ALUMINUM ALLOYS
INTRODUCTION
Die 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 .
Different casting processes require the alloy to have different casting
characteristics. We will define here the different casting characteristics of die cast
AL- Alloy
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1) Cast ability
2) sludge Formation
3) Alloy fluidity
4) Machine ability
5) Die soldering
6) Porosity
7) Macro segregation
CASTING CHARACTERISTICS FOR “DIE-CAST ALUMINUM ALLOYS
�Cast ability is the property of an alloy to be cast without formation of defects such as
cracks, segregations, pores or mis runs.
�Alloy dependent the phenomena that determine castability, fluidity, macro segregation,
hot tearing and porosity.
�Cast ability of aluminum alloys can also defined such as solidification path, dendrite
CASTABILITY:
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�Cast ability of aluminum alloys can also defined such as solidification path, dendrite
coherency, solidification shrinkage and inter dendrite permeability.
�The influence of alloy composition on fluidity, macro segregation, hot tearing and
porosity will be described. coherency, fluidity, permeability and shrinkage will be
presented
CASTING CHARACTERISTICS FOR “DIE-CAST ALUMINUM ALLOYS
Aluminum 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.
A360 -- Selected for best corrosion resistance and pressure tightness.
TYPE OF ALUMINUM DIE CASTING ALLOYS
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A360 -- Selected for best corrosion resistance and pressure tightness.
A380 -- The most common and cost effective of AL- die casting alloys. Provides the best
combination of utility and cost.
A383 & A384 -- These alloys are a modification of 380. Both provide better die filling
but with a moderate sacrifice in mechanical properties such as toughness.
A390 -- Selected for special applications where high strength, fluidity and wear-
resistance and bearing properties are required.
A413 (A13) -- Used for maximum pressure tightness and fluidity.
CASTING CHARACTERISTICS FOR “DIE-CAST ALUMINUM ALLOYS
ALLOY
COMPOSITION (% max or range) A360 A380 A383 A384 A390 A413
(A13)
Silicon 9-10 7.5-9.5 9.5-11.5 10.5-12 16-18 11-13
( ALLOY – CHEMICAL COMPOSITION)
CHEMICAL COMPOSITION OF DIE CAST ALUMINUM ALLOYS
The 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
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Silicon
Iron 1.3 1.3 1.3 1.3 1.3 1.3
Copper 0.6 3.4 2.3 3-4.5 4-5 1.0
Manganese 0.35 0.50 0.50 0.50 0.50 0.35
Magnesium 0.4-0.6 0.10 0.10 0.10 0.45-0.65 0.10
Nickel 0.50 0.50 0.30 0.50 0.10 0.50
Zinc 0.50 3.0 3.0 3.0 1.5 0.50
Tin 0.15 0.35 0.35 0.35 0.20 0.15
Titanium - - - - 0.20 -
Total others 0.25 0.50 0.50 0.50 0.20 0.25
Aluminum BAL. BAL. BAL. BAL. BAL. BAL.
CASTING CHARACTERISTICS FOR “DIE-CAST ALUMINUM ALLOYS