Aluminium and its alloys have been widely used in the automotive industry for some time and A356 is one of the most popular aluminium alloys today in the sector. It contains approximately 7 wt.% Si and 0.3 wt.% Mg. Due to the defects that may be present in the cast parts, expected mechanical properties may not be reached and this alloy may perform in service under its potential. In a low pressure die casting, several precautions have to be taken in order to produce high quality and defect-free castings. Temperature of casting and the schemical composition of the melt is recorded continuously. Die temperature, pressure levels and their durations are optimized; degassing and fluxing operations are performed. Yet, regardless of the precautions, there could still be rejected parts. It is becoming clear that a good quality raw material is one of the most underrated points of the industry and that the starting material has a great effect on the final product and it should be taken in to account more seriously. Therefore, regarding the first rule of Campbell's 10 Rules of Casting, in this study, the quality of the starting material of supply chains for a wheel manufacturer was investigated. Chemical compositions were compared, fluidity tests, mechanical tests and bifilm indexes of these various sources and ingots were measured and a final quality index was proposed to create a reference for the quantification of quality of supplier's ingots. This new index was compared with the rejection rates.
Fracture pressure of six liquid metals, Pb, Al, Cu, Ni, Ti and Fe have been calculated at their melting points in three different ways; (i) by extrapolating molecular dynamic (MD) data reported in the literature for various temperatures to their melting points, (ii) by using the fracture pressure equation developed by Fisher and (iii) by using the work of nucleation suggested by Fletcher. Results have shown that the Fisher equation and MDs estimates agree closely, whereas the ones based on the work of nucleation are systematically lower than the other two. In all cases, calculated fracture pressures are several orders of magnitude different from those assumed in the literature, emphasizing the extent of weakening by extrinsic factors in liquid metals.
In situ composites have been studied mainly to eliminate wettability, porosity and non-uniform distribution of particulate problems in composite materials. Al-Mg 2 Si alloy are preferred choice of such group of alloys owing to the combination of light weight and improved mechanical properties. The morphology of Mg 2 Si is one of the key parameters for the wear properties. In this work, squeezed casting method was used to produce samples where porosity was aimed to be reduced and morphology of Mg 2 Si was altered. In addition, the wear properties of in situ A380-Mg 2 Si were investigated. It was found that as squeeze pressure was increased, porosity and size of Mg 2 Si was decreased and wear rate was increased.
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