Browse Topic: Casting alloys
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].
Fly ash is a light byproduct produced when pulverized coal is burnt in suspension-fueled furnaces in power plants. Separating the recovered fly ash from the exhaust gases. Due to its distinct physical and chemical properties, it is utilized in a wide variety of industrial and building applications. These applications include the production of cement and concrete, the stabilization of liquid waste, and hydraulic mining backfill. Fly ash has the potential to enhance the physical and mechanical properties of aluminum castings, as well as reduce their costs and increase their densities, all while lowering their prices. This research investigated the effect of fly ash incorporation on the mechanical properties of the aluminum casting alloy ZA8. Investigated were the cast and heat-treated varieties of unreinforced ZA8 and its metal matrix composite of 15% ferrous, 20% nickel, 10% fly ash, and 10% magnesium carbide. According to the results, the quantity of fly ash in the melt affected the tensile and impact properties of the metal matrix composite. The loss of magnesium atoms in the matrix, which contributes to the strength of solid solutions, and porosity both contribute to the lower mechanical properties and impact resistance of the metal matrix composite.
This specification provides requirements and procedures for gas-pressure leak testing of parts.
This specification covers an aluminum alloy in the form of two types of welding wire.
The hot corrosion studies for the die-casted magnesium (Mg) silver (Ag) alloys are carried out through the steam heating route. The Magnesium Silver (QE22A) alloy is fixed under the top lid of the pressure cooker (2 liters) and filled with water and 5% salt (NaCl) solution. The specimens are treated with different time intervals (10, 20, and 30 minutes), with the steam temperature maintained at 100°C around the specimen. The results showed an increase in the corrosion rate with the increase in the steaming time. Further, after the specimens have cooled down to room temperature, similar experiments are repeated for the second and third cycles. Here the formation of the oxide layers over the specimen has reduced the corrosion rate. The structural, surface study was carried out through scanning electron microscopy (SEM), X-ray diffraction (XRD), and energy-dispersive spectroscopy (EDS) to know the corrosion behavior on the specimen. From the microstructure, it is noticed that the average grain size increased with the increase in the time intervals. Through SEM images, detailed studies on the crack length and pitting width were carried out. Finally, a comparison of pure and corroded alloys is made and discussed in detail.
The effect of Portevin-Le Châtelier (PLC) effect and its influence on the mechanical properties of aluminum, have aroused interest in the scientific community, aiming possible applications in the industry. The respective effect has been commonly observed in the solid solution state in Al-Mg alloys. Therefore, the objective of this work is to analyze the effect of the PLC phenomenon on the mechanical properties of the material with additions of 2% and 6% of Mg in the base alloy of Al-0.18%. For this purpose, the alloys were cast in a muffle furnace and cast in copper mold (section of the properzi wheel), followed by cooling in water. Samples were cut and machined to 9.5 mm in diameter. Subsequently, they underwent sanding and polishing processes in order to obtain their macrostructures. The results obtained in this step show that Mg refined the grain structures. The tensile test was performed for mechanical characterization. The results showed that increasing Mg contents resulted in grain refining, tensile strength limit and elongation losses. In order to analyze the effect of PLC in the stress strain curves, a practical method was developed, which consists in amplifying the points of the curves, measuring the amplitude of the oscillations by zone and individual, from which it was concluded that the oscillations were more evident in the alloy with addition of 2% Mg.
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