Effect of evaporative pattern casting process parameters on the surface roughness of Al–7% Si alloy castings

Kumar, Sudhir; Kumar, Pradeep; Shan, H. S.

doi:10.1016/j.jmatprotec.2006.09.005

Cited by 86 publications

(46 citation statements)

References 4 publications

(5 reference statements)

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“…Lack of fit is non significant as it is desired. The normal probability plot of the residuals for penetration shown in Fig.4 reveals that the residuals are falling on the straight line, which means the errors are distributed normally [13]. All the above consideration indicates an excellent adequacy of the regression model.…”

Section: Checking Adequacy Of Modelmentioning

confidence: 75%

Modelling and Optimization of Gas Metal Arc Welding Using Response Surface Methodology

2016

Arimpie - 2016

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Abstract-GMAW is a complicated process with many interrelated parameters affecting the quality of the welded joint. The process variables with the maximum influence are the welding current, welding voltage, travel speed and arc efficiency. Response surface methodology was used to predict the weld penetration of gas metal arc welded mild steel. The experiments were conducted based on three factors, three-level, and central composite face centered design with full replications technique, and mathematical model was developed. The results obtained through response surface methodology were verified through a confirmation experiment.The welding parameters such as speed, welding current and voltage have been optimized for material AISI 1020 using GMAW process. To fortify the robustness of experimental design, a confirmation test was performed at selected optimal process parameter setting. Observations from this method may be useful for automotive sub-assemblies, shipbuilding and vessel fabricators and operators to obtain optimal welding conditions. Keywords-Gas metal arc welding, penetration, response surface methodology,central composite design.

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Section: Checking Adequacy Of Modelmentioning

confidence: 75%

Modelling and Optimization of Gas Metal Arc Welding Using Response Surface Methodology

2016

Arimpie - 2016

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Section: Pouring Temperaturementioning

confidence: 99%

“…Once the casting material melts, the prepared mold is poured. By experiment, it is determined that some aluminum alloys when poured into EPC mold at 650 C, quality casting is obtained [50,51].Effects of pouring temperature on the mechanical properties and microstructures of casting can be studied by observing a range of values and levels are taken within the range when the casting material is poured at the levels, opportunity is provided to compare results in terms of visual and mechanical examination of the casting obtained. The visual examination reveals some defects on the surface of the casting if they are existing.…”

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confidence: 99%

Evaporative Pattern Casting (EPC) Process

Omidiji¹

2018

Advanced Casting Technologies

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The chapter provides details of operations and activities in evaporative pattern casting (EPC) Process. The process was developed in the year 1956 to tackle some of the inadequacies of the traditional sand casting processes but has in itself some challenges that should be taken care of if sound castings would be obtained. The challenges come mainly from the evaporative pattern employed as pattern material in the process. The material makes the process to be sensitive to process variables such that proper and adequate control should be ensured to have castings of sound integrity. Some of the known process variables are pouring temperature, refractory coating, vibration and pattern and molding materials. In the whole the EPC is known to have edge over the traditional sand casting methods.Keywords: pattern, molding, casting, variables and coating History of evaporative pattern casting (EPC) processEvaporative pattern casting (EPC) Process is a sand molding process that makes use of evaporative patterns produced industrially by steam molding or machined out from a block of expandable polystyrene foam (EPS) [1,2]. The pattern is buried in the sand mold and the melted casting material is poured into the mold without removing pattern, unlike the traditional sand casting method that makes use of wooden, plastic and metallic pattern which is removed from the mold before molten metal is advanced.It was in 1956 that Shroyer made a documentation of his work on EPC where green sand was used as the molding material [3]. The author machined a shape from expanded polystyrene (EPS) and supported it inside a flask with bounded sand. Another researcher called Flemmings © 2018 The Author(s). Licensee IntechOpen. This chapter is distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/by/3.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.came up in 1964 to use unbounded silica grains for the process [1]. Foundry men later came to differentiate between the two; calling the first the full mold and the second the lost foam processes. The subtle difference only lied in the use of bounded (green) sand and loose sand.The process became known to foundry men in 1958 and many trade names have been formed to describe it [3]. They include styrecast, replicast, full mold, lost foam and evaporative process. A distinguishing feature of this type of sand process is that an evaporative pattern made of polystyrene foam is used [4]. It is coated with a coating developed from a refractory material usually silica or zircon sand before being buried in the mold. It is not removed from the mold once it is buried.After 1964, some works have been done by researchers to understand the variables that affect the process. Some works in the automotive industry have also been done. General motors have produced a number of automotive components with the method. This started in the year 1980 and they are still in the use of the p...

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“…Open cell metal foam is produced by pressure investment casting. The commercial names of the production methods are DUOCEL and Cellmet; 6101 and A356 aluminum alloys are produced by this method [9,27,38,57,64,65]. …”

Section: Investment Casting and Evaporative Pattern Castingmentioning

confidence: 99%

New Approaches to Aluminum Integral Foam Production with Casting Methods

Güner

Arikan

Nebioğlu

2015

Metals

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Abstract:Integral foam has been used in the production of polymer materials for a long time. Metal integral foam casting systems are obtained by transferring and adapting polymer injection technology. Metal integral foam produced by casting has a solid skin at the surface and a foam core. Producing near-net shape reduces production expenses. Insurance companies nowadays want the automotive industry to use metallic foam parts because of their higher impact energy absorption properties. In this paper, manufacturing processes of aluminum integral foam with casting methods will be discussed.

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Effect of evaporative pattern casting process parameters on the surface roughness of Al–7% Si alloy castings

Cited by 86 publications

References 4 publications

Modelling and Optimization of Gas Metal Arc Welding Using Response Surface Methodology

Modelling and Optimization of Gas Metal Arc Welding Using Response Surface Methodology

Evaporative Pattern Casting (EPC) Process

New Approaches to Aluminum Integral Foam Production with Casting Methods

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