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

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Effect of wall thickness on the quality of 1060 aluminium produced by sand casting.
Hudivhamudzimu Mugeri, Wallace Matizamhuka, Damilola Isaac Adebiyi, Jakobus Hendrik Deppinnar

Last modified: 2016-10-14


With the ever-increasing demand for thin walled castings in the automotive and aircraft manufacturing industries, quality is of utmost importance for optimal performance during service. Thin walled sections are more susceptible to filling defects due to inadequate metal filling. Metal fillability is mostly affected by wall thickness, casting temperature, thermal properties, and mould material. It is therefore important to reduce or eliminate the filling defects which are associated with thin walled sections. The aim of the present paper is to optimise the runner system for casting 1060 aluminium thereby improving fillability. This will investigate the filling defects which are associated with thin walled sections, thus affecting the quality of 1060 aluminium casting using sand casting process as a manufacturing process. Five test samples of thickness 1 mm, 1.5 mm, 2 mm, 2.5 mm and 3 mm were optimised with the use of MAGMAsoft at a casting temperature of 700 °C. The results show that complete filability was only obtained when the thickness was 3 mm.  A slight increase in wall thickness yielded a minimum of 12.5% and a maximum of 32% increase in fillability. It was observed that as the wall thickness increases, the chances of hot spot which will lead to shrinkage porosity upon solidification also increases. These results shows that wall thickness plays a big role in the fillability of thin walled sections.


fillability; runner system; sand casting; MAGMAsoft; hot spot and shrinkage porosity