Manufacturing Technology 2021, 21(5):725-734 | DOI: 10.21062/mft.2021.074

Comparison of the Porosity of Aluminum Alloys Castings Produced by Squeeze Casting

Andrzej Zyska ORCID..., Kinga Boroń ORCID...
Czestochowa University of Technology, Department of Metallurgy and Metal Technology, Al. Armii Krajowej 19, 42-200 Częstochowa, Poland

The results of researches on porosity and structure of castings from AlMg9, AlSi7Mg and AlCu4Ti alloys produced by squeeze casting and for comparison by gravity die casting are presented. The tests were carried out on 200x100x25mm plates squeeze casted under 90MPa pressure. Prior to the commencement of experimental studies, numerical simulations of solidification were made for the selected alloy (AlSi7Mg) in order to determine the potential locations of shrinkage porosity. As part of the study, the porosity distribution in the plate cast was assessed by taking samples for measurements from the center and edge of the casting. It was found that the area particularly vulnerable to the presence of shrinkage porosity is the central part of the casting and the zone extending from its center to the upper surface. Due to the wide temperature range of solidification of the examined alloys, diffused porosity occurs in castings, and the shape of the pores formed is conditioned on the solidification morphology. The average porosity of squeeze castings is two times smaller than gravity die castings and is at the level of 1.0-1.5% depending on the type of alloy. In addition, as a result of pressing, the shrinkage porosity in the central part of the plate is reduced and its distribution becomes uniform throughout the volume. High pressure acting on solidifying castings ensures a significant increase of grains density in microstructure and decrease of SDAS.

Keywords: Squeeze Casting, Aluminum Alloys, Porosity, Structure

Received: May 20, 2021; Revised: June 17, 2021; Accepted: July 2, 2021; Prepublished online: October 21, 2021; Published: November 25, 2021  Show citation

ACS AIP APA ASA Harvard Chicago IEEE ISO690 MLA NLM Turabian Vancouver
Zyska A, Boroń K. Comparison of the Porosity of Aluminum Alloys Castings Produced by Squeeze Casting. Manufacturing Technology. 2021;21(5):725-734. doi: 10.21062/mft.2021.074.
Share...
Download citation
  • BibTeX (.bib)
  • Bookends (.ris)
  • EasyBib (.ris)
  • EndNote (.enw)
  • EndNote 8 (.xml)
  • ISI WoS (.isi)
  • Medlars (.medlars)
  • Mendeley (.ris)
  • MODS (.xml)
  • Papers (.ris)
  • RefWorks (.txt)
  • RefManager (.ris)
  • RIS (.ris)
  • MS Word (.xml)
  • Zotero (.ris)
    • Open full article

    References

    1. SOBCZAK, J. (1993). Theoretical and practical foundations of liquid state squeeze casting processes for non-ferrous metals. In: Transactions of Foundry Research Institute, Vol. 41, pp. 161-236.
    2. SOBCZAK, J. DRENCHEV, L., ASTHANA, R. (2012). Effect of pressure on solidification of metallicmaterials. In: International Journal of Cast Metals Research, Vol. 25, pp. 1-14. Go to original source...
    3. HAJDASZ, M., DROZDOWSKI, R., DUNIANAZAR, T., WINNICKI, Z. (1996). A device for testing metal barocrystallization. In: Scientific Journals of the Maritime University of Szczecin, Vol. 52, pp. 25-31.
    4. GHOMASHCHI, M. R., VIKHROV, A.(2000). Squeeze casting: an overview. In: Journal of Materials Processing Technology, Vol. 101, pp. 1-9. Go to original source...
    5. ZHANG, W., ZHAO, Y., ZHANG, D., LUO, Z., YANG Ch., LI, Y. (2018). Effect of Si addition and applied pressure on microstructure and tensile properties of as-cast Al-5.0Cu-0.6Mn-1.2Fe alloys. In: Transactions of Nonferrous Metals Society of China, Vol. 28, pp. 1061-1072. Go to original source...
    6. SCHWAM, D., WALLACE, J. F., CHANG, Q., ZHU, Y. (2002). Optimization of the squeeze casting process for aluminum alloy parts. In: US Department of Energy Assistant Secretary for Energy Efficiency and Renewable Energy, p.5, Washington D.C. Go to original source...
    7. ZYSKA, A., KONOPKA, Z., ŁĄGIEWKA, M., NADOLSKI, M. (2013). Optimization of Squeeze Parameters and Modification of AlSi7Mg Alloy. In: Archives of Foundry Engineering, Vol. 13, pp. 113-116. Go to original source...
    8. CAMPBELL, J. (2011). Complete casting, Handbook, Metal Casting Processes, Metallurgy, Technique sand Design, pp. 142-185. Butterworth-Heinemann, Elsevier. Go to original source...
    9. DUDEK, P. (2017). Application of squeeze casting technology to obtain aluminum alloy castings. In: Transactions of Foundry Research Institute, Vol. 58, pp. 211-224.
    10. CHATTOPADHYAY, H. (2007). Simulation of transport processes in squeeze casting. In: Journal of Materials Processing Technology, Vol. 186, pp. 174-178. Go to original source...
    11. AHMAD, R., GETHIN, D.T., LEWIS, R.W.(2012). Design Element Concept of squeeze casting process. In: Applied Mathematical Modelling, Vol.36, pp. 4760-4788. Go to original source...
    12. PENNINGTON, J.N. (1988). Squeeze-cast parts approach performance of forgings. In: Modern Metal Vol. 44, pp. 52-60.
    13. ZYSKA, A., KONOPKA, Z., ŁĄGIEWKA, M., NADOLSKI, M. (2010). Characteristics of squeeze cast AlZn5Mg alloy castings. In: Archives of Metallurgy and Materials, Vol. 55, pp. 969-975.
    14. YANG, L.J. (2003). The effect of casting temperature on the properties of squeeze cast aluminium and zinc alloys. In: Journal of Materials Processing Technology, Vol. 140, pp. 391-396. Go to original source...
    15. ABOU EL-KHAIR, M.T. (2005). Microstructure characterization and tensile properties of squeeze-cast AlSiMg alloys. In: Materials Letters, Vol. 59, pp. 894- 900. Go to original source...
    16. WANG, F., MA, Q., MENG, W., HAN, Z. (2017). Experimental study on the heat transfer behavior and contact pressure at the casting mold interface in squeeze casting of aluminum alloy. In: International Journal of Heat and Mass Transfer, Vol. 112, pp. 1032-1043. Go to original source...
    17. HAN, ZH., HUANG, X., LUO, A., SACHDEV, A., LIU K.B. (2012). A quantitative model for describing crystal nucleation in pressurized solidification during squeeze casting. In: Scripta Materialia, Vol. 66, pp. 215-218. Go to original source...
    18. PASTIRCAK, R., MARTINEC, D., KANTORIKOVA, E. (2020). Influence of Semisolid Squeeze Casting Technology on Alpha Phase and Eutectic of AlSi7Mg0.3. In: Manufacturing Technology, Vol. 20, pp. 78-83. Go to original source...
    19. KUCHARIKOVÁ, L., TILLOVÁ, E., PASTIRČÁK, R., UHRÍČIK, M., MEDVECKÁ, D. (2019). Effect of Wall Thickness on the Quality of Casts from Secondary Aluminium Alloy. In: Manufacturing Technology, Vol. 19, pp. 797-801. Go to original source...
    20. MAJERNIK, J., GASPAR, S., GRYC, K., SOCHA, L. (2018). Changes in Eutectic Silumin Structure Depending on Gate Geometry and Its Effect on Mechanical Properties of Casting. In: Manufacturing Technology, Vol. 18, pp. 439-443. Go to original source...
    21. PODPROCKA, R., BOLIBRUCHOVA, D. (2018). The Role of Manganese in the Alloy Based on Al-Si-Mg with Higher Iron Content. In: Manufacturing Technology, Vol. 18, pp. 650-654. Go to original source...
    22. HREN, I., SVOBODOVA, J., MICHNA, Š. (2019). Analysis of Microstructure Changes for AlSi7Mg0.3 Alloy Caused by Modification. In: Manufacturing Technology, Vol. 19, pp. 767-771. Go to original source...
    23. SENTHIL, P., AMIRTHAGADESWARAN, K. S. (2013). Experimental Study and Squeeze Casting Process Optimization for High Quality AC2A Aluminium Alloy Castings. In: Arabian Journal for Science and Engineering, Vol. 39, pp. 2215-2225. Go to original source...
    24. PATEL, M.G.C., KRISHNA, P., PARAPPAGOUDAR, M.B. (2015). Prediction of Secondary Dendrite Arm Spacing in Squeeze Casting Using Fuzzy Logic Based Approaches. In: Archives of Foundry Engineering, Vol. 15, pp. 51-68. Go to original source...
    25. FLEMING, M.C. (1974). Solidification processing. In: Metallurgical Transactions B, Vol. 5, pp. 2121-2134. Go to original source...
    26. ANYALEBECHI, P.N. (1998). Analysis and thermodynamic prediction of hydrogen solution in solid and liquid multicomponent aluminum alloys , pp. 827-842. Light Metals, , The Minerals, Metals and Materials Society, Barry Welch.
    27. FELICELLI, S.D., POIRIER, D.R., SUNG, P.K. (2000). A Model for Prediction of Pressure and Redistribution of Gas-Forming Elements in Multicomponent Casting Alloys. In: Metallurgical and Materials Transactions B, Vol. 31B, pp. 1283-1292. Go to original source...
    28. GÓRNY, Z., Metals and alloys casting. Special casting methods -Vol. III, pp.152-178. Foundry Research Institute, Kraków.
    29. CHÉRIF, A., SOUISSI, S., BEN AMAR, M., BRADAI, CH., KHITOUNI, M. (2017). Effect of squeeze casting pressure on microstructure and mechanical properties of recycled aluminum alloy. In: Journal of the Tunisian Chemical Society, Vol. 19, pp. 198-207.
    30. SOUISSI, N., SOUISSI, S., LE NINIVEN, C., BEN AMAR, M., BRADAI, C., ELHALOUANI, F.(2014). Optimization of squeeze casting parameters for 2017 a wrought al alloy using Taguchi method. In: Metals, Vol. 4, pp. 141-154. Go to original source...
    31. GOURGUES-LORENZON, A.F., HAUDIN, J.M.(2010). Matériaux pour l'ingénieur, pp.81-92, Ecole des Mines, Paris.
    32. SOUISSI, S., SOUISSI, N., BARHOUMI, H., BEN AMAR, M., BRADAI, C., ELHALOUANI, F. (2019). Characterization of the Role of Squeeze Casting on the Microstructure and Mechanical Properties of the T6 Heat Treated 2017A Aluminum Alloy. In: Advances in Materials Science and Engineering, Vol. 2019, pp. 1-9. Go to original source...

    This is an open access article distributed under the terms of the Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0), which permits non-comercial use, distribution, and reproduction in any medium, provided the original publication is properly cited. No use, distribution or reproduction is permitted which does not comply with these terms.


    Return to the content