SUNConferences, 17th Annual Conference of the Rapid Product Development Association of South Africa

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Effect of pouring temperature on the quality of 1060 aluminium produced by sand casting
Hudivhamudzimu Mugeri, Wallace Matizamhuka, Damilola Isaac Adebiyi, Kobus Dippenaar

Last modified: 2016-10-14

Abstract


Poor fillability in thin walled sections manifests itself in the form of discontinuities in the casting (i.e. misrun, shrinkage porosity, cold shuts) which have a negative impact on the component functionality. Thin walled sections are more susceptible to filling defects due to inadequate metal filling. The most critical factors affecting metal fillability include the wall thickness, pouring temperature, thermal properties, and mould material. For optimal performance the minimisation of defects associated with filling of thin walled sections is key. Thus the present study is focused on investigating the effect of pouring temperature on the quality of 1060 aluminium casting using sand casting process as a manufacturing process. This will investigate the filling defects which are associated with pouring temperature, thus affecting the quality of 1060 aluminium casting using sand casting process as a manufacturing process. At low pouring temperature viscosity is high and feeding distance is low promoting the formation of misrun defect. A 2mm test sample was optimised at six different casting temperatures of 7000C, 7300C, 7600C, 7900C, 8000C and 8600C using MAGMAsoft casting simulation software. The results showed that complete fillability was only obtained when casting temperature was 7900C. An increase in casting temperature by 30°C yielded minimum of 7% increase in fillability and maximum of 8.5% fillability increase. It was observed that as pouring temperature increases the risk of gas entrapment, porosity and bad surface finish due to splashing also increases. High backpressure and surface tension in thin walled sections played a big role in low fillability obtained. It is clear from the study that an increase in pouring temperature result in fillability increase when casting thin walled sections but its effect is not significant.


Keywords


Misrun; shrinkage porosity; coldshut; MAGMAsoft; pouring temperature; sand casting and simulation