Browse Topic: Casting

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Docking Methodology for Large-Sized Irregular Castings via Industrial Robot Manipulation2026-99-01707/31/2026
Large-sized irregular castings are critical components extensively employed in large-scale equipment manufacturing. Due to their substantial dimensions and complex geometries, the assembly and docking processes between different components present significant challenges. To address the docking problem between large-scale irregular castings, this study proposes a casting docking method based on relative pose, along with a modeling approach for irregular castings, and accomplishes the docking process through the control of an industrial robot. Firstly, the current poses of feature points on the docking surfaces are measured. Based on these measurements, the relative pose transformation relationship between the center point of the docking surface and the robot’s Tool Center Point (TCP) is established, thereby constructing the docking model. This model calculates the relative deviation between the current pose and the theoretical pose. Subsequently, the robot motion is controlled according to this deviation to achieve precise docking. Finally, a simulation environment was built using KUKA. Sim Pro with Office Lite to simulate the docking process of large-sized irregular castings. The results demonstrate that the relative pose-based docking method effectively accomplishes the docking task. This study provides an effective solution for the docking of large-sized irregular castings.
Liu, Haoran, Jia, Haili, Wang, Aimin, Xigang, Fan, Peidong, Su
A Data-Driven Model for Predicting Casting Solidification Time and Mold Thermal Stress2026-01-50557/31/2026
This study proposes a data-driven surrogate modeling framework for predicting solidification time and mold thermal stress during low-pressure die casting (LPDC) of aluminum alloy wheels. The methodology employed an optimal Latin hypercube design (OLHD) to sample key parameters including cooling channel geometry and process conditions. A sequential simulation methodology combining ProCAST and Abaqus was implemented to generate a comprehensive dataset of solidification times and thermal stress distributions. Based on this dataset, surrogate models were developed using Support Vector Regression, Kriging, and Polynomial Response Surface Methodology, with their hyperparameters automatically tuned through Bayesian Optimization (BO). The optimized models were rigorously evaluated using four statistical metrics: Coefficient of Determination (R2), Mean Squared Error (MSE), Mean Absolute Error (MAE), and Root Mean Squared Error (RMSE). The evaluation results show that the BO–SVR model demonstrated superior prediction accuracy for both output responses and exhibited exceptional nonlinear fitting capability. This work establishes an effective modeling approach for simultaneous quality and efficiency optimization in wheel manufacturing.
Fuhao, Fan, Zhan, Yunlang, Zhan, Zhenfei, Yang, Yutong, Xiao, Yong, Huang, Shiyao
Quantifying Life Cycle Environmental Impact of Emerging Aluminum High-Pressure Die Cast (HPDC) Mega-Castings Replacing Stamped Steel Solutions13-07-01-00046/4/2026
Over the last few years, there has been an uptick in the exploration and implementation of aluminum high-pressure die casting (HPDC) mega-castings as replacements for conventional stamped steel parts in vehicles. This trend is expected to increase with common justifications, including claims of reduced costs and lower environmental impacts associated with the replacement of dozens of individual parts with a single casted piece, along with reduced demands on associated tooling and machinery. However, the data and literature to support these claims are limited and at times contradictory, with some studies showing increased costs and energy demands for mega-casting technologies. This study presents the results of a literature review and a gate-to-gate life cycle inventory (LCI) adapted from conventional HPDC aluminum casting unit processes that may be used to quantify potential life cycle global warming potential (GWP), cumulative energy demand (CED), and other environmental impacts of aluminum mega-castings. A set of cradle-to-gate example calculations is also provided to demonstrate the application of the inventory and significance of the findings, which point to significantly higher GWP and CED for aluminum mega-castings versus stamped steel parts and warrant further study to inform vehicle design decision makers.
Sebastian, Brandie, Balzer, Russ
Wear Resilience Characteristics of Silicon Nitride Strengthened AZ31 Magnesium Composite2026-26-07406/1/2026
To develop magnesium matrix composites, ceramic silicon nitride (Si3N4) particles are added to the magnesium (AZ31) matrix at 2 wt.%. The composite is produced via disintegrated melt deposition vacuum-stir-casting procedure. Microstructural studies reveal the presence of Si3N4 particles and their uniform spreading. An L9 orthogonal array, planned using Taguchi’s experimental design, is selected for three wear parameters; axial load (AL), rotational speed (RS), and time duration (TD) with trials as per the G99 standard in the pin-on-disc apparatus to assess the wear resilient of the composite. Experimental results show an increase in axial stress, and wear loss (WL) increases dramatically. Because the area of contact shrinks as RS increases, WL diminishes dramatically. When the AL is low, the friction coefficient (CoF) increases, and when the AL is large, CoF drops. When the RS is increased, CoF decreases. To optimize multiple responses effectively, the TOPSIS (Technique for Order Preference by Similarity to Ideal Solution) approach was adopted. According to the analysis, the ideal combination turned out to be a 10 N A, an RS of 275 rpm, and a TD of 1000 seconds. ANOVA results show that AL (56.99%) and RS (27.2%) contribute more, with a regression coefficient of 92.99%. Abrasive and adhesive wear mechanisms are observed from the worn-out surface micrographs.
Senthilkumar, N., Dhinakar Raj, C K
Steel, Corrosion-Resistant, Investment Castings, 16Cr - 1.9Ni - 0.08N (431), As CastAMS5353G (Current)4/12/2026
This specification covers a corrosion-resistant steel in the form of investment castings.
AMS F Corrosion and Heat Resistant Alloys Committee
Tensile and Fatigue Behavior of High Pressure Die Cast AE44 Magnesium Alloy at Elevated Temperatures2026-01-02344/7/2026
Tensile and cyclic behavior of high pressure die cast AE44 magnesium alloy have been studied at room temperature and elevated temperatures up to 350°C. Anelastic behavior has been found in both tensile and cyclic loading at the temperature below 200°C. With increasing temperature, the anelasticity disappears, and tensile and cyclic behaviors become like other engineering materials, such as steels and aluminum alloys, i.e. the total strain contains only elastic strain and plastic strain. A method to determine the yield strength at 0.2% plastic strain (σ0.2) is proposed. By using the proposed method, the yield strength σ0.2 is found to be higher than that determined using the traditional method, which is more suitable to the materials that do not exhibit anelasticity. It is believed that the anelasticity is closely related to twinning in Mg alloy, which disappears at elevated temperatures.
Liu, Yi, Yang, Wenying, Coryell, Jason
Machine Learning-Based Prediction of Tensile Properties in Cast Stainless Steel Influenced by Chemical Composition Variation2026-01-02374/7/2026
In the category of cast stainless steels, there are several variants per different level of addition of chromium, vanadium along with some minor elements, such as molybdenum, niobium, tungsten to meet the requirement of corrosion and oxidation resistance. However, the influence of chemical composition variations on the mechanical properties of cast SS continues to lack a clear understanding. In the present study, via machine learning, the effects of each element on the tensile properties of the selected cast stainless steel are studied. The machine learning model is then used to predict how variations in elements affect tensile behavior, with the predictions validated through physical testing.
Mishra, Neelam, Biswas, Surjayan, V S, Rajamanickam, Aluru, Phani, Liu, Yi, Akbari, Meysam, Coryell, Jason
Multi-Material Front Structures: A Pathway to Safer and More Sustainable Vehicle Design2026-26-04561/16/2026
Frontal crash structures play a vital role in occupant safety, but traditional designs often involve a trade-off between structural strength and weight efficiency. In the pursuit of safer and more sustainable mobility, this study explores a physics-based methodology that leverages the principle of dynamic equilibrium to guide the integration of dissimilar materials in front-end vehicle structures. Specifically, examined a novel configuration wherein aluminum High-pressure die cast (single HPDC part) is introduced which covers swan neck region as well as the base of the front longitudinal member, while retaining steel in the frontal crush zone. This arrangement aims to redistribute crash loads and control deformation mechanisms, enabling improved energy absorption without compromising structural integrity. To evaluate the proposed strategy, a series of detailed finite element simulations were conducted using LS-DYNA, a widely adopted tool for vehicle crash analysis. The results reveal that the dynamic equilibrium approach offers a rational and most efficient framework for material allocation, allowing for the optimization of crash performance metrics while simultaneously achieving weight reduction. Compared to conventional all-steel or all-aluminum designs, the hybrid structure demonstrate efficient, improved crashworthiness, with measurable mass savings. By grounding material decisions in mechanical principles rather than empirical iteration, this research presents a scalable methodology applicable to a wide-range of vehicle platforms. The outcomes offer a compelling case for the adoption of multi-material architectures as a pathway toward enhanced crash safety and reduced environmental impact.
Revanth, Goshika, Bhagat, Milind, Joshi, Vikas, Mankhair, Abhijit, Sudarshan, B.Sudarshan, Kollipara, Jahanavi
Comparative Study of ADC12, A356, and AlSi10Mg Alloys in Sand Casting of EV Battery Housing2026-26-02961/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines. The objective was to evaluate the filling behavior, solidification characteristics, and final casting quality of ADC12 in sand molds, and to determine its potential for use in applications where die casting is not viable. A comprehensive evaluation was conducted covering key casting parameters: Fluidity and mold filling behavior (evaluated through flow pattern simulations and casting trials) Casting defects and internal integrity (analyzed using real-time X-ray radiography and defect quantification techniques). Density Index (DI) to assess gas entrapment and hydrogen porosity. Mechanical properties, including tensile strength, yield strength, elongation, and hardness (tested according to ASTM standards). Microstructural characterization via optical microscopy and SEM/EDS to examine grain structure, silicon morphology, and intermetallic phases. Fractography of failed tensile specimens to understand failure modes and defect influence. Preliminary results indicate that although ADC12 exhibits higher susceptibility to porosity and reduced ductility in sand cast form compared to A356 and AlSi10Mg, it is still capable of producing structurally acceptable components with optimized gating and venting designs. The study contributes new insights into the adaptability of ADC12 for sand casting, expands the material selection range for low-volume or prototype production scenarios, and provides a technical basis for further optimization of casting parameters to enhance the performance of ADC12 in sand mold applications.
Subramani, Rajesh, Singh, Gajendra, Doddamani, Mrityunjay
Effect of Flow Forming Process on the Mechanical Properties and Microstructure of GDC & LPDC Cast Aluminium Alloy Wheels2026-26-02981/16/2026
Aluminum alloy wheels have become the preferred choice over steel wheels due to their lightweight nature, enhanced aesthetics, and contribution to improved fuel efficiency. Traditionally, these wheels are manufactured using methods such as Gravity Die Casting (GDC) [1] or Low Pressure Die Casting (LPDC) [2]. As vehicle dynamics engineers continue to increase tire sizes to optimize handling performance, the corresponding increase in wheel rim size and weight poses a challenge for maintaining low unsprung mass, which is critical for ride quality. To address this, weight reduction has become a priority. Flow forming [3,4], an advanced wheel rim production technique, which offers a solution for reducing rim weight. This process employs high-pressure rollers to shape a metal disc into a wheel, specifically deforming the rim section while leaving the spoke and hub regions unaffected. By decreasing rim thickness, flow forming not only enhances strength and durability but also reduces overall wheel weight. This study investigates and compares the mechanical properties of conventional GDC and LPDC cast alloy wheels with flow-formed counterparts, focusing on the rim region. Results reveal that the flow-forming process facilitates a 30% thickness reduction in the rim section. Furthermore, it leads to a slight increase in yield and tensile strength while significantly improving elongation in parallel to the flow-forming direction. The study also examines microstructural changes, including the deformation behavior of silicon dendrites [5].
Singh, Ram Krishnan, Medaboyina, HarshaVardhan, G K, Balaji, Gopalan, Vijaysankar, Sundaram, Raghupathi, Paua, Ketan
Design and Application of Large-Segment Cable Hanging Baskets for Long-Span High-Speed Railway Cable-Stayed Bridges2025-99-021912/23/2025
With the advancement of cable-stayed bridge construction technology, the application of long-span concrete girder cable-stayed bridge is gradually extensive, making the study of construction technology and equipment for concrete main girders increasingly important. The cable hanging basket, a crucial piece of equipment for cable-stayed bridge construction, maximizes the cable’s bearing capacity, improves construction efficiency, and ensures safety and stability during construction. However, due to the varying structural designs and construction environments, the cable hanging basket must be specifically tailored for different cases. The Hanjiang Bridge on the Xi’an-Shijiazhuang High-speed Railway is China’s first steel-truss-reinforced PC box-girder cable-stayed bridge, with a main span of 420 meters. If conventional diamond-shaped hanging baskets are used for suspended casting of small sections, the construction period will not meet the construction requirements of this bridge. To save construction time, the concrete main beam is constructed using large-segment cable-stayed hanging basket suspended casting. This paper focuses on the Hanjiang Bridge of the West High-Speed Railway, studying the design of the cable hanging basket. The traveling method, thrust structure, tensioning anchor beam, and side formwork lateral movement method were optimized and innovated to improve construction efficiency. Structural design and safety are evaluated through numerical calculations, providing strong support for advancing suspension pouring technology for large sections of long-span concrete beams.
Li, Jian
Higher-Strength, Higher-Toughness Die Cast Wheel Material using Recycled Aluminum2025-32-000711/3/2025
In an attempt to reduce CO2 release from alloy wheel production, we have developed an aluminum alloy for casting that satisfies necessary property requirements using recycled aluminum, but without heat treatment. The wheel is a critical safety feature of any vehicle, and it should have toughness and strength .In many wheels, virgin aluminum containing small amounts of impurities is used to maintain toughness, and heat treatment (T6), which is post-casting quick heating and quenching, is applied to provide strength. At the start of this project, we focused on two wheel-manufacturing processes, production of virgin aluminum and heat treatment, from which a large amount of CO2 is released. By switching to recycled aluminum, CO2 was reduced to one-ninth the original amount. The issue with recycled material is that impurities grow in the metal structures as intermetallic compounds and this reduces toughness. To deal with this issue, we have chosen high-pressure die casting (HPDC), in which the hot material after the casting is quenched to allow dispersion of intermetallic compounds in the form of fine particles. As for the chemical composition, we determined the amounts of additives (Mn) that facilitated fine particles of Fe, which is a common impurity that lowers toughness. Combining with the quenching effect, the amounts of additives (Si and Mg) were determined to obtain the target strength without heat treatment. With this process, we achieved a wheel using recycled aluminum and ordinary casting equipment without heat treatment that is the same weight as one made of virgin aluminum. The elimination of heat treatment helps to enhance wheel production efficiency by 15% and reduce CO2 release by 80%.
Suzuki, Noritaka
Research on the Sinker Location of Light Buoy Based on Mean Shift Algorithm2025-99-003610/17/2025
In order to determine the actual position of the beacon buoy, improve the casting accuracy of the beacon buoy, and reduce the frequency of the beacon buoy being hit, the mean shift model of the sinker location was established according to the real-time position data of the beacon telemetry and remote control, and the probability density distribution of the beacon buoy position was obtained and the actual position of the beacon buoy was analyzed. In order to ensure the comprehensiveness and accuracy of the research results, real-time data of light buoy positions in different sea areas and at different times were selected, and MATLAB simulation experiments were conducted to compare the actual sinker location with the designed position. The experimental results show that the mean shift algorithm can accurately predict the actual position of the stone, which provides a useful reference for improving the casting accuracy of the Marine light buoy.
Liu, Huan, Song, Shaozhen, Ju, Xin, Lin, Xiaozhuo
Aluminum Alloy, Investment Castings, 7.0Si - 0.32Mg (356.0-T6), Solution and Precipitation Heat TreatedAMS4260H (Current)10/3/2025
This specification covers an aluminum alloy in the form of castings (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Die Castings 9.5Si - 0.50Mg (360.0-F) As CastAMS4290N (Current)9/17/2025
This specification covers an aluminum alloy in the form of die castings.
AMS D Nonferrous Alloys Committee
Effect of Casting Microstructure on the Mechanical Performance of Recycled EN AC-43200 Al-Si Alloy2025-01-03579/15/2025
This work investigates the influence of casting microstructure on the mechanical performance of ad hoc samples of recycled EN AC-43200 Al-Si alloy. Three batches are produced by modifying the casting process parameters (i.e., molten alloy temperature and in-mold cooling conditions) to obtain different casting microstructures. Room temperature tensile and high-cycle fatigue tests, coupled with metallography, X-ray tomography, and fatigue fracture surface analysis, are performed to elucidate the relationship between microstructural characteristics and mechanical properties of the investigated alloy. The findings indicate that casting pores and intermetallic precipitates play a pivotal role in influencing the mechanical behavior and performance of cast, recycled EN AC-43200 Al-Si alloy. Additionally, an inverse correlation between secondary dendrite arm spacing (SDAS) and both tensile properties and fatigue life is established.
Pavesi, Arianna, Barella, Silvia, D'Errico, Fabrizio, Bonfanti, Andrea, Bertasi, Federico
Aluminum Alloy Castings, Investment, 7.0Si - 0.32Mg (356.0-T51), Precipitation Heat TreatedAMS4261H (Current)8/22/2025
This specification covers an aluminum alloy in the form of investment castings (see 8.6).
AMS D Nonferrous Alloys Committee
Cobalt Alloy, Corrosion- and Heat-Resistant, Investment Castings 50.5Co - 26Cr - 15Ni - 6.0Mo (Stellite® 30) As-CastAMS5380H (Current)7/22/2025
This specification covers a corrosion- and heat-resistant cobalt alloy in the form of investment castings.
AMS F Corrosion and Heat Resistant Alloys Committee
Cobalt Alloy, Corrosion- and Heat-Resistant, Investment Castings 62Co - 27Cr - 2.8Ni - 5.5Mo (Stellite® 21) As-CastAMS5385J (Current)7/18/2025
This specification covers a corrosion- and heat-resistant cobalt alloy in the form of investment castings.
AMS F Corrosion and Heat Resistant Alloys Committee
Cobalt Alloy, Corrosion- and Heat-Resistant, Investment Castings 54Co - 25.5Cr - 10.5Ni - 7.5W (Stellite® 31) As-CastAMS5382L (Current)7/18/2025
This specification covers a corrosion- and heat-resistant cobalt alloy in the form of investment castings.
AMS F Corrosion and Heat Resistant Alloys Committee
Nickel Alloy, Corrosion- and Heat-Resistant, Investment Castings 73Ni - 12Cr - 4.5Mo - 2.0Cb (Nb) - 0.70Ti - 0.05C - 6.0Al - 0.010 - 0.10Zr (IN-713 - Low Carbon) Vacuum Cast, As-CastAMS5377H (Current)7/18/2025
This specification covers a corrosion- and heat-resistant nickel alloy in the form of investment castings.
AMS F Corrosion and Heat Resistant Alloys Committee
Nickel Alloy, Corrosion- and Heat-Resistant, Investment Castings 73Ni - 0.14C - 13Cr - 4.5Mo - 2.3Cb (Nb) - 0.75Ti - 6.0Al - 0.010B - 0.10Zr (IN-713) Vacuum Cast, As-CastAMS5391J (Current)7/16/2025
This specification covers a corrosion- and heat-resistant nickel alloy in the form of investment castings.
AMS F Corrosion and Heat Resistant Alloys Committee
Alloy, Corrosion- and Heat-Resistant, Investment Castings 30Fe - 21Cr - 20Ni - 20Co - 3.0Mo - 2.5W - 1.0Cb - 0.15N (N-155) As-CastAMS5376J (Current)7/16/2025
This specification covers a corrosion- and heat-resistant iron alloy in the form of investment castings.
AMS F Corrosion and Heat Resistant Alloys Committee
Castings, Leaded Bronze, Sand and Centrifugal, 80Cu - 10Sn - 9.5Pb, As CastAMS4842G (Historical)6/17/2025
This specification covers a leaded bronze in the form of sand and centrifugal castings (see 8.6).
AMS D Nonferrous Alloys Committee
Nickel-Aluminum-Bronze, Martensitic, Sand, Centrifugal and Continuous Castings, 78Cu - 11Al - 5.1Ni - 4.8Fe, Quench Hardened and Temper AnnealedAMS4881E (Current)6/17/2025
This specification covers a nickel-aluminum-bronze alloy in the form of sand, centrifugal, and continuous castings (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Bronze, Centrifugal and Chill Castings, 85Cu - 11Al - 3.6Fe, As CastAMS4870G (Current)6/17/2025
This specification covers an aluminum bronze alloy in the form of centrifugal and chill castings (see 8.5).
AMS D Nonferrous Alloys Committee
Film Cast PTFE Liner and Tubing: An Inside Look at Quality from a Manufacturing PerspectiveTBMG-532846/1/2025
Optimization of Stainless Steel Casting Process Based on Numerical Simulation05-19-01-00065/10/2025
Due to the increasing precision requirements for stainless steel castings in the current industrial field, we take stainless steel as the object, use numerical simulation to analyze the manufacturing process of castings, and explore the mechanism of related defects and preventive measures. The results indicate that in the process optimization of small castings, the maximum shrinkage and porosity of the conventional scheme, the optimization scheme with the addition of cold iron and insulation riser, and the optimization scheme with the improved pouring system combined with the optimal parameters are 1.83%, 1.64%, and 1.42%, respectively. The optimal pouring temperature, pouring speed, and shell preheating temperature of medium- and large-sized castings are: 1620°C, 1.5 kg/s, and 1100°C, respectively. According to the aforementioned findings, the study raises the standard of precision production for stainless steel, and fuel the growth of the precision casting sector.
Huang, Jie, Zhang, Hongshan
A Review of Warm Forming for Steels: History, Methodology and Emerging Trends2025-01-88144/1/2025
Many manufacturing techniques and processes have been implemented over the years to improve the formability of sheet metals. Warm forming of sheet metals is one such established method. However, it is more commonly and successfully applied to aluminum grades. The re-evaluation of less-used metal forming technologies, such as warm forming and sheet hydroforming for steel are responses to the challenges posed by competitive processes like large castings and the geometry requirements of new BEV parts. By understanding the effects of elevated temperatures (above or below recrystallization temperatures) on different steel grades and the impact of various heating methodologies, the industry can adapt and optimize these proven techniques for modern applications. This paper is a thorough summary of the effect of elevated temperatures on various grades of steel. Different heating techniques, their cycle times and effects on final forming feasibility are contrasted. The effect of chemistry variation on the mechanical behavior of the material for the same grade of steel is also compared. Furthermore, some emerging industrial trends are discussed.
Kella, Caroline, Wormald, Tom
Mitigating Paint Blistering Defects in Aluminum Casted Parts: A QC Story Approach Utilizing Computed Tomography2025-01-82294/1/2025
Blistering in aesthetic parts poses a significant challenge, affecting overall appearance and eroding brand image from the customer's perspective and blister defects disrupt painting line efficiency, resulting in increased rework and rejection rates. This paper investigates the causes and effects of blistering, particularly in the context of internal soundness of Aluminum castings, emphasizing the crucial role of Computed Tomography in defect analysis. Computed Tomography is an advanced Non-Destructive Testing technique used to examine the internal soundness of a material. This study follows a structured 7-step QC story approach, from problem identification to standardization, to accurately identify the root Cause and implement corrective actions to eliminate blister defect. The findings reveal a strong link between internal soundness and surface quality. Based on the root cause, changes in the casting process and die design were made to improve internal soundness, leading to reduced rework and rejection rates in the paint shop.
D, Balachandar, Nataraj, Naveenkumar
Self-Piercing Riveting (SPR) of Magnesium High Pressure Die Casting and Dissimilar Materials2025-01-82314/1/2025
Solid state joining processes are attractive for magnesium alloys as they can offer robust joints without the porosity issue typically associated with welding of magnesium and dissimilar materials. Among these techniques, Self-Piercing Riveting (SPR) is a clean, fast and cost-effective method widely employed in automotive industry for aluminum alloys. While SPR has been proven effective for joining aluminum and steel, it has yet to be successfully adapted for magnesium alloy castings. The primary challenge in developing magnesium SPR technology is the cracking of the magnesium button, which occurs due to magnesium's low formability at room temperature. Researchers and engineers approached this issue with several techniques, such as pre-heating, applying rotation to rivets, using a sacrificial layer and padded SPR. However, all these methods involve the employment of new equipment or introduction of extra processing steps. The aim of this work is to develop a SPR technique which adapts current SPR machines with minimal changes to existing processes to create crack-free joint between magnesium and dissimilar materials. In the current study, feasibility of joining coupons of typical structural materials including high strength steel, aluminum alloys and composite to magnesium high pressure die casting (HPDC) was investigated. It was demonstrated that a joint is achieved which is crack-free both internally and externally. Also, the lap shear strength of the joints was investigated. Given its flexibility in material selection and compatibility with existing SPR process lines, this method holds significant potential to facilitate more applications on materials with limited ductility.
Tabatabaei, Yousef, Wang, Gerry, Weiler, Jonathan
Advanced Characterization of Mechanical and Cyclic Fatigue Properties of Aluminum Cast Materials for Optimized Industrial Applications2025-01-82374/1/2025
Given the strategic importance of aluminum cast materials in producing lightweight, high-performance products across industries, it is fundamental to assess their mechanical and cyclic fatigue properties thoroughly. This investigation is primarily for optimizing material utilization and enhancing the efficiency and reliability of aluminum cast components, contributing to significant conservation of raw materials and energy throughout both the manufacturing process and the product's lifecycle. In this study, a systematic material investigation was conducted to establish a reliable estimation of the fatigue behavior of different aluminum cast materials under different loading ratios and elevated temperatures. This paper presents an analysis of the statistical and geometrical influences on various aluminum alloys, including AlSi10MnMg, AlSi7Mg0.3, and AlSi8Cu3Fe, produced via pressure die casting and gravity die casting (permanent mold casting), and subjected to different heat treatment techniques, namely T5, T6, and T7. Furthermore, to optimize component design, the effects of surface finish (machined versus unmachined with cast skin), temperature, and microstructural changes (e.g., secondary dendritic arm spacing) on fatigue strength were investigated and documented.
Qaralleh, Ahmad, Niewiadomski, Jan, Bleicher, Christoph
Microstructure, Tensile and Fracture Behaviors of Squeeze Cast Wrought Mg Alloy AZ802025-01-82304/1/2025
Wrought magnesium alloy AZ80 with a thick section of 20 mm was prepared by squeeze casting (SC) and permanent steel mold casting (PSMC). The porosity measurements of the SC and PSMC showed that the SC AZ80 had a porosity of 0.52%, which was the 77% lower than that (2.21%) of the PSMC counterpart. The microstructure analyses and phase identification indicated that the cast AZ80 alloy consisted of a primary α-Mg phase, eutectic Mg-Al-Zn phases and Al-Mn intermetallic. The fine primary α-Mg dendrites and a high amount of the intermetallic phase were present in the SC AZ80 alloy. The yield strength (YS), ultimate yield strength (UTS), elongation (ef), elastic modulus (E) and strain hardening rate of the cast AZ80 specimens were evaluated by tensile testing. The measured engineering stress versus strain curves showed that the SC AZ80 alloy exhibited 84.68 MPa in YS, 168.23 MPa in UTS, 5.07% in ef, and 25.1GPa in modulus while the YS, UTS and ef of the PSMC specimen were only 71.61 MPa, 109.04 MPa, 1.85% and 21.9GPa. The calculated resilience and tensile toughness indicated that the SC AZ80 was more capable of resisting energy loads in elastic deformation and had an ability to absorb energy during plastic deformation than that of the PSMC AZ80. Also, the analyses of the true stress versus strain curves revealed that, upon the onset of plastic deformation, the strain-hardening rate of the SC AZ80 sample was 10,341 MPa, which was 9% higher than that (9,489 MPa) of the PSMC AZ80 specimen. The obtained mechanical properties showcased the fit of the casting process to wrought magnesium AZ80 alloy, which was squeeze casting. The low porosity level, fine dendritic structure and a high content of intermetallic phase should be somewhat responsible for high mechanical properties of the SC AZ80 alloy.
Ying, Peilin, Hu, Henry, Hu, Anita, Shen, Wutian
Image-Based Machine Learning Methods in Materials Microstructure and Failure Analysis2025-01-83244/1/2025
Image-based machine learning (ML) methods are increasingly transforming the field of materials science, offering powerful tools for automatic analysis of microstructures and failure mechanisms. This paper provides an overview of the latest advancements in ML techniques applied to materials microstructure and failure analysis, with a particular focus on the automatic detection of porosity and oxide defects and microstructure features such as dendritic arms and eutectic phase in aluminum casting. By leveraging image-based data, such as metallographic and fractographic images, ML models can identify patterns that are difficult to detect through conventional methods. The integration of convolutional neural networks (CNNs) and advanced image processing algorithms not only accelerates the analysis process but also improves accuracy by reducing subjectivity in interpretation. Key studies and applications are further reviewed to highlight the benefits, challenges, and future directions of using ML in material failure analysis through image processing.
Akbari, Meysam, Wang, Andy, Wang, Qigui, Yan, Cuifen
NdFeB Magnets Manufactured by Hot Pressing Using Strip-Cast and Melt-Spun Powders2025-01-82174/1/2025
The initial powder used for the manufacturing of NdFeB permanent magnets is usually prepared through rapid cooling, either by melt spinning or strip casting. The powders produced by these two methods are suitable for different applications: while melt-spun powder is a good initial material for bonded and hot-deformed magnets, strip-cast powder is normally used for sintered magnets. To investigate the suitability of using strip-cast powder to manufacture hot-deformed magnets, NdFeB powder prepared by strip casting was hot pressed (without particle alignment) and compared with melt-spun powder prepared under the same conditions (700 °C, 45 MPa, 90 min). Although the processing parameters are the same (pressed in the same mold), the magnetic properties of the magnets made from the two powders are significantly different. Surprisingly, the magnet made from the strip-cast powder (after ball milling) shows comparable magnetic properties to those of isotropic magnets, with coercivity (HcJ) of 1270 kA/m and remanence (Br) of 0.7 T, while that made from the melt-spun powder exhibits much lower properties: HcJ = 480 kA/m, Br = 0.5 T, although the melt-spun powder initially shows much better magnetic properties than the strip-cast powder. Possible reasons for such a difference in magnetic properties are discussed. It was shown that the particle size of the initial powder plays an important role in determining the final magnetic properties of the hot-pressed magnets.
He, Youliang, Song, Shaochang, Walsh, Dan, Bernier, Fabrice, Mozharivskyj, Yurij, Peng, Philip
WITHDRAWAL NOTICE2025-01-8238.014/1/2025
Aspects for the Optimization of Car Production Regarding Efficiency, Availability and Sustainability2025-01-86094/1/2025
Nowadays, more than in the recent decades, the design process for the body in white for passenger cars is driven by efficiency. This results in the enhanced usage of large-scale cast components made of aluminum, for the battery compartment, the front or rear body and other components. While the automotive industry is striving towards even larger structures made with so-called “Giga-Casting”, challenges in the casting and supply chain processes, but also maintenance and repair processes of these large structures, arise. Other tasks to solve might follow from controlling local microstructures, and thus the strength of the parts, when the flow length of the molten metal increases with component size, especially in relation to an increased fraction of recycled aluminum. Within the Fraunhofer-internal project “FutureCarProduction”, focus is directed towards understanding what drives efficiency, availability and sustainability of modern processes for the production of a car body. Moreover, the project addresses questions along the complete product chain of a car body, in terms of optimization of casting and joining, and quality assurance processes and seeks to give solutions for the efficiency and quality of different manufacturing processes. In the present paper, an overview of the project scope itself and the recent findings of “FutureCarProduction” are presented with a focus on the influences of higher fractions of secondary/recycled aluminum on the casting process, the occurring microstructure and defect situation in body in white components. This forms the basis for further investigations on the performance of different manufacturing and design opportunities for automotive components.
Bleicher, Christoph, Qaralleh, Ahmad, Lehmhus, Dirk, Haesche, Marco, Fernandes Gomes, Leonardo, Pintore, Manuel, Kleinhans, Robert, Sommer, Silke, Tlatlik, Johannes
Rings, Sealing, Cast Tin Bronze, 80Cu - 19Sn, As CastAMS7322H (Current)3/5/2025
This specification covers a cast tin bronze in the form of sealing rings (see 8.5).
AMS D Nonferrous Alloys Committee
Performance Evaluation of Nano Silicon Carbide Configured Aluminium Alloy with Titanium Nanocomposite via Semisolid Stir Cast2024-01-523512/10/2024
High-strength, lightweight aluminium-based composites show great potential for future weight-reduction applications. The aluminium alloy (AA5052) is commonly used in various engineering applications and serves as the primary matrix material for this study. The objective of this research is to produce and improve the properties of the AA5052 alloy composite by integrating titanium (Ti) and nano silicon carbide (SiC) particles using an advanced vacuum stir casting process. Additionally, an inert atmosphere is used to minimize voids, porosity, and oxidation. The final developed composites include AA5052, AA5052/3wt% Ti, AA5052/5wt% SiC, and AA5052/3wt% Ti/5wt% SiC, which were subjected to metallographic, tensile, elongation, and hardness studies. The mechanical evaluation is carried out following ASTM E8 and E384 standards. Microstructural analysis revealed uniform dispersion of Ti &SiC particles with no significant casting defects. The composite with AA5052/3wt% Ti/5wt% SiC exhibited the highest tensile strength, elongation, and hardness, measuring 243MPa, 34%, and 93HV, respectively. The contribution of Ti and SiC with an effective interface with the AA5052 matrix is the reason for the enhancement of mechanical behaviour.
Venkatesh, R., Kaliyaperumal, Gopal, Manivannan, S., Karthikeyan, S., Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad, Karthikeyan, N.
Magnesium Alloy Hybrid Composite Properties are Featured with Boron Carbide Particle for Automotive Seat Frame Usage2024-01-520712/10/2024
With the advancement of lightweight magnesium-based hybrid composites, are potential for weight management applications. The liquid state stir cast process is the best way to produce complex shapes and most industries are preferred. However, the melting of magnesium alloy and achieving homogenous particle distribution are the major challenges for the conventional stir-casting process, and hot crack formation is spotted due to thermal variations. The main objectives of the present research are to enhance the microstructural and mechanical behaviour of magnesium alloy hybrid nanocomposite (AZ91E) adopted with boron carbide (B4C) and alumina (Al2O3) nanoparticles through a semisolid stir cast technique associated with inert atmosphere helps to limits the oxide formation and reduce risk of magnesium fire. The effect of composite processing and multiple reinforcements on surface morphology, tensile strength, impact strength, and hardness were thoroughly evaluated and compared. The results of surface morphology studies demonstrate homogeneous particle dispersion with reduced casting defects. Furthermore, the AZ91E alloy hybrid nanocomposite (HNC) exhibits superior tensile strength, impact strength, and hardness when compared to the monolithic AZ91E alloy, showcasing improvements of 18%, 23%, and 25%, respectively, which is suggested for automotive seat frame applications.
Manivannan, S., Venkatesh, R., Kaliyaperumal, Gopal, Karthikeyan, S., Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad, Karthikeyan, N.
Study on Grain Refinement Efficiency of Cast Aluminum Alloy via Aluminium Titanium Boron Addition2024-01-521812/10/2024
Grain refinement of aluminium and its alloys is a common industrial practice, particularly for automobile casting. The grain refines with titanium agent influence better mechanical behaviour such as higher yield and ultimate tensile strength rather than monolithic alloy. Present study, the halide salt method has been used to produce the Al-Ti-B grain refiners with different Ti/B ratios. The prepared grain refiner is added in A356 alloy and observed its grain refining efficiency. The addition of grain refiner to A356 aluminium alloy at different holding times, such as 10, 20, and 30 min, allowed it to solidify. It is found that 30 min of holding time with 5Ti1B improves the hardness (40%) and ultimate tensile strength (UTS) value (63.56%). A high degree of grain refinement was observed in a 30-minute holding time with 5Ti1B with improved grain refining efficiency of 3 %. Its microstructural observation and tensile properties helped us understand this grain refinement.
Venkatesh, R., Manivannan, S., Das, A. Daniel, Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad
Microstructural Characterization of Aluminium Alloys Used in Automotive Body Parts2024-28-015712/5/2024
To meet light-weighting and safety target of automotive vehicles, different Aluminium alloys are used in various body parts. Apart from conventional manufacturing process of gravity die casting (GDC), advanced manufacturing process such as low pressure die casting (LPDC), high pressure die casting (HPDC) and extrusion processes are also used to form complex automotive body parts. Steel parts are majorly used in automotive applications across world. However, steel has limitations with respect to light-weighting. To achieve light-weighting, now a days, there is trend to use these complex Aluminium parts in automotive industry to replace steel and integrate multiple parts into a single one. Aluminium has emerged as great potential for light-weighting and reducing complexity of handling multiple parts at an automotive plant. There is a challenge to identify suitable etchant for microstructural characterization of Aluminium alloy parts that can be made through various manufacturing processes. This paper discusses Aluminium alloy’s microstructural characterization, suitable etchant selection, identification of alloy and its manufacturing process.
Deshmukh, Mansi, Jain, Vikas, Misal, Swapnali, Paliwal, Lokesh
Elevated Temperature Tensile Properties of CastingsAMS2361F (Current)12/4/2024
This specification establishes a procedure for designating minimum elevated temperature tensile property requirements of castings by means of this AMS number and a series of dash numbers.
AMS F Corrosion and Heat Resistant Alloys Committee
Stress-Rupture Properties of CastingsAMS2362E (Current)12/4/2024
This specification establishes a procedure for designating minimum stress-rupture property requirements of castings by means of this AMS number and a series of dash numbers.
AMS F Corrosion and Heat Resistant Alloys Committee
Room Temperature Tensile Properties of CastingsAMS2360F (Current)12/4/2024
This specification establishes a procedure for designating minimum room temperature tensile property requirements of castings by means of this AMS number and a series of dash numbers.
AMS F Corrosion and Heat Resistant Alloys Committee
Recent Developments on Aluminum 7075-Based Composite with Industrial Waste Fly Ash by Stir Casting and Their Applications05-18-02-000911/7/2024
Recent developments in manufacturing techniques and the development of Al7075 metal matrix composites (MMCs) with reinforcements derived from industrial waste have been steadily gaining popularity for aerospace and automobile applications due to their outstanding properties. However, there are still a lot of limitations with these composite materials. A great deal of research has been done to create new Al7075 MMC materials with the use of economic fly ash (FA) that possesses superior mechanical properties, corrosion resistance, density, and cycle cost. This review outlines different synthesis techniques used in the development of Al7075 MMCs using stir casting. Effects of FA along with other reinforcements on the mechanical, wear, machining, and microstructural properties of the composite are also discussed. Finally, a summary of the application of FA-based MMCs and a recap of the previous discoveries and challenges are reported. Future scope and potential areas of application are also discussed. This will inspire the potential researchers to understand the benefits of using FA as a reinforcement and carry out researches on this area that will be beneficial for the society economically as well as environmentally.
Kumar, Randhir, Mondal, Sharifuddin
Rings, Sealing, Cast Leaded-Tin Bronze, 80Cu - 16Sn - 5Pb As CastAMS7320H (Current)10/1/2024
This specification covers a cast leaded-tin bronze in the form of sealing rings (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Bronze Alloy, Sand Castings, 85Cu - 11Al - 3.6Fe, Solution Heat Treated and TemperedAMS4873G (Current)9/10/2024
This specification covers an aluminum bronze alloy in the form of sand castings (see 8.5).
AMS D Nonferrous Alloys Committee
Uniaxial Stress and Strain Analysis of a Notched Component Made of Cast Irons05-18-01-00018/2/2024
This article investigates the deformation mechanics of cast iron and its implications for notch analysis, particularly in the automotive industry. Cast iron’s extensive use stems from its cost-effectiveness, durability, and adaptability to various mechanical demands. Gray, nodular, and compacted graphite cast irons are the primary types, each offering unique advantages in different applications. The presence of graphite, microcracks, and internal porosity significantly influences cast iron’s stress–strain behavior. Gray and compacted cast iron display an asymmetrical curve, emphasizing low tensile strength and superior compression performance due to graphite flakes and crack closures. Nodular cast iron exhibits a symmetrical curve, indicating balanced mechanical properties under tension and compression. The proposed simplified macrostructural approach, based on monotonic stress–strain, aims to efficiently capture graphite and crack closure effects, enhancing compressive strength and stiffness. By employing the Neuber and Molski–Glinka methods for notch analysis, we assume nominally elastic behavior of notched components. This represents a novel application for gray and compacted cast iron, aiding in predicting material fatigue life, as demonstrated in other materials with asymmetrical behavior.
LaCourt, Cameron, Lee, Yung-Li, Gu, Randy
Magnesium Alloy, Sand Castings 4.5Zn - 0.75Zr (ZK51A-T5) Precipitation Heat TreatedAMS4443J (Current)7/15/2024
This specification covers a magnesium alloy in the form of sand castings.
AMS D Nonferrous Alloys Committee
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