From the point of view of economics and ecology, thin-wall ductile iron (TWDI) castings can compete in terms of mechanical properties with the light castings made of aluminum alloys. This article discusses the effect of technological factors on the cooling rate and physicochemical state of the liquid metal for preparing thin-wall castings with good mechanical properties and performance while avoiding casting defects. It describes a variety of defects that may appear during the production of TWDI castings, such as casting skin anomalies (e.g., flake graphite, graphite segregation), graphite clusters, exploded graphite, slag inclusions, shrinkage porosity, eutectic chill and secondary carbides, and cold shuts. The article reviews the tensile, fatigue, impact, and wear properties of TWDI castings. It provides information on the production and applications of TWDI castings.

This article provides a detailed discussion on the causes of formation of shrinkage porosity and gas porosity along with the methods involved in eliminating them. It discusses the process of porosity formation and the factors affecting porosity formation, including alloy composition, external pressure, and cooling conditions.

This article is an atlas of fractographs that helps in understanding the causes and mechanisms of fracture of cast aluminum alloys and in identifying and interpreting the morphology of fracture surfaces. The fractographs illustrate the brittle fracture, microvoid coalescence, fatigue striations, and microstructure of these alloys. The components considered include fractured sand-cast carrier trays, broken extension-housing yokes, helicopter tail-rotor drive assemblies, fractured bell-crank fittings, chain-hoist hooks, and automotive connecting rods.