A comprehensive efficiency evaluation of conventional and ablation sand casting on the example of the AlSi7Mg alloy impeller

Abstract

Ablation sand casting is a new technology for casting aluminum alloys which helps to achieve superior cooling trends during the solidification and results in eutectic microstructure, reduced degree of defects, and improved mechanical attributes. To further enhance the functionality, water-soluble binder-based sand molds are used in conjunction with appropriate control over process parameters for specialized applications such as complex and thin-walled impeller manufacturing. In this regard, the influence of key process parameters including binder ratio (BR), sand grain fineness number (AFS number), and pouring temperature (PT) is investigated thoroughly on the mechanical characteristics (ultimate tensile strength and hardness) and dimensional accuracy of the thin-walled impeller. Ablation sand casting revealed exceptionally enhanced mechanical properties and dimensional accuracy as compared to conventional sand casting. The AFS number and binder ratio were most significant for controlling the dimensional accuracy. Multi-response optimization through Grey Relational Analysis reveals the optimal setting PT = 800 ℃, ASF number = 45, BR = 5% for lower dimensional deviation, higher hardness, and ultimate tensile strength through conventional sand casting. While for ablation case, the optimal conditions PT = 850 ℃, ASF number = 40, BR = 9% are attained against desired attributes. The attributes are significantly improved through ablated sand casting, dimensional accuracy 31.6%, hardness 58.9% and ultimate tensile strength 41.82%, and fractography analysis depicted the ductile fracture surface. The current technology is drawing attention of industry because of its potential in producing castings with superior mechanical properties and improved internal integrity.

A Novel Approach of Optimum Time Interval Estimation for Al-7.5Si/Al-18Si Liquid–Liquid Bimetal Casting in Sand and Metallic Moulds

“…Otherwise, primary α-Al and eutectic are observed in the microstructure of M1 (Figure 2b). It is commonly known [37] that adding Si to pure Al significantly enhances the casting characteristics of aluminum alloys. Al-Si alloys' fluidity, hot tear resistance, and other casting properties are enhanced by adding up to about 25% Si.…”

“…A reduction in coefficient of thermal expansion and specific gravity are reported with additions of Si to Al alloys. Based on the relation between fluidity and cooling rate, the optimum range of Si content in Al-Si alloys can be assigned to metal casting processes, whereas a lower Si content (Si ≤ 7) is recommended for slow cooling rate sand casting and a higher Si content (Si ≥ 7) for gravity permanent mold casting [37].…”

Numerical Simulation of Sand Casting of Stainless Steel Pump Impeller

“…This method involves creating a mold from sand, into which molten metal is poured and allowed to solidify. However, its limitations in dimensional accuracy and surface finish compared to alternative manufacturing technologies highlight the need for ongoing advancements and innovations to improve the quality and efficiency of sand casting processes, ensuring its continued relevance in the modern manufacturing landscape [14][15][16][17][18].…”

Experimental Research Regarding the Effect of Mineral Aggregates on the Wear of Mixing Blades of Concrete Mixers

“…The research in [ 25 ] focuses on the distinct aspects of a new industrial process and its impact on engineering requirements, particularly the mechanical and microstructural characteristics of castings. The study also highlights the essential directions for further exploration of the potential of this emerging technology in producing high-quality castings.…”