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Expendable mold casting
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Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2022
DOI: 10.31399/asm.tb.isceg.t59320323
EISBN: 978-1-62708-332-4
Abstract
This chapter provides an overview of key elements in controlling the casting process, systems to confirm the quality of outgoing components, and the steps needed to launch a novel product. The discussion also provides information on process control tools and techniques; incoming material control; process control of sand preparation and system maintenance; metallic charge materials; product quality control; and melting, metallurgical, and mechanical testing.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410091
EISBN: 978-1-62708-280-8
Abstract
This chapter is a collection of tables listing: cast alloy designations of Aluminum Association, along with their general applications; the chemical compositions of the frequently used alloys for gravity permanent molds, low-pressure permanent molds, squeeze castings, and die castings; the typical tensile properties of die cast alloys; and the designations of different heat treatments and their description. The tables also list the temperatures and times of typical heat treatment cycles for different permanent mold cast alloys; typical components in sand, gravity, and low-pressure permanent mold castings and die castings, the functional requirements of each process, and the corresponding suitable alloys and heat treatments; and alloys that are high vacuum die cast for structural castings. The chapter also presents examples of photomicrographs of some alloys cast by different processes.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.aceg.t68410029
EISBN: 978-1-62708-280-8
Abstract
This chapter discusses the advantages, limitations, and applications of various aluminum casting processes, namely green sand casting process, air set or no-bake molding process, vacuum molding process, evaporative foam casting process, and die casting process. The processes covered also include gravity permanent molding, low-pressure permanent molding, counter pressure, squeeze casting, investment casting, rapid prototype casting, cast forge hybrid, and semisolid metal processes.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2015
DOI: 10.31399/asm.tb.tpmpa.t54480161
EISBN: 978-1-62708-318-8
Abstract
Casting is the most economical processing route for producing titanium parts, and unlike most metals, the properties of cast titanium are on par with those of wrought. This chapter covers titanium melting and casting practices -- including vacuum arc remelting, consumable electrode arc melting, electron beam hearth melting, rammed graphite mold casting, sand casting, investment casting, hot isostatic pressing, weld repair, and heat treatment -- along with related equipment, process challenges, and achievable properties and microstructures. It also explains how titanium parts are produced from powders and how the different methods compare with each other and with conventional production techniques. The methods covered include powder injection molding, spray forming, additive manufacturing, blended elemental processing, and rapid solidification.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 June 2008
DOI: 10.31399/asm.tb.emea.t52240095
EISBN: 978-1-62708-251-8
Abstract
Almost all metals and alloys are produced from liquids by solidification. For both castings and wrought products, the solidification process has a major influence on both the microstructure and mechanical properties of the final product. This chapter discusses the three zones that a metal cast into a mold can have: a chill zone, a zone containing columnar grains, and a center-equiaxed grain zone. Since the way in which alloys partition on freezing, it follows that all castings are segregated to different categories. The different types of segregation discussed include normal, gravity, micro, and inverse. The chapter also provides information on grain refinement and secondary dendrite arm spacing and porosity and shrinkage in castings. It concludes with a brief overview of six of the most important casting processes in industries: sand casting, plaster mold casting, evaporative pattern casting, investment casting, permanent mold casting, and die casting.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140299
EISBN: 978-1-62708-335-5
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140039
EISBN: 978-1-62708-335-5
Abstract
In castings, microstructural features are products of metal chemistry and solidification conditions. The microstructural features, excluding defects, that most strongly affect the mechanical properties or aluminum castings are size, form, and distribution of intermetallic phases; dendrite arm spacing; grain size and shape; and eutectic modification and primary phase refinement. This chapter discusses the effects of these microstructural features on properties and methods for controlling them. The chapter concludes with a detailed examination of the refinement of hypereutectic aluminum-silicon alloys.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140047
EISBN: 978-1-62708-335-5
Abstract
Porosity in aluminum is caused by the precipitation of hydrogen from liquid solution or by shrinkage during solidification, and more usually by a combination of these effects. Nonmetallic inclusions entrained before solidification influence porosity formation and mechanical properties. This chapter describes the causes and control of porosity and inclusions in aluminum castings as well as the combined effects of hydrogen, shrinkage, and inclusions on the properties of aluminum alloys. In addition, it discusses the applications of radiography to reveal internal discontinuities in aluminum.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140055
EISBN: 978-1-62708-335-5
Abstract
Hot isostatic pressing (HIP) is a process refinement available to address internal porosity in castings. The HIP process may be used, in particular, for applications requiring very high quality and performance. This chapter discusses the principles, advantages, and disadvantages of HIP. It describes the effect of HIP on tensile properties and on the fatigue performance of aluminum alloy castings. In addition, the chapter discusses the processes involved in radiographic inspection of HIP-processed castings.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140061
EISBN: 978-1-62708-335-5
Abstract
The metallurgy of aluminum and its alloys offers a range of opportunities for employing heat treatments to obtain desirable combinations of mechanical and physical properties such that castings meet defined temper requirements. This chapter discusses the processes involved in solution heat treatment, quenching, precipitation hardening, and annealing of aluminum alloys. The effects of these processes on dimensional stability and residual stresses are also discussed. Troubleshooting and diagnosis of heat treating problems are covered in the concluding section of the chapter.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140069
EISBN: 978-1-62708-335-5
Abstract
This chapter reviews and provides data tables for the wide range of properties and performance characteristics that are possible with specific aluminum casting alloys and tempers. Properties and performance attributes addressed include casting and finishing characteristics; typical physical properties; typical and minimum (design) mechanical properties; fatigue strength; fracture resistance, including subcritical crack growth; and resistance to general corrosion and to stress-corrosion cracking. The chapter concludes with information on the properties of cast aluminum matrix composites.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140133
EISBN: 978-1-62708-335-5
Abstract
This data set presents aging response curves for a wide range of aluminum casting alloys. The aging response curves are of two types: room-temperature, or "natural," curves and artificial, or "high-temperature," curves. The curves in each group are presented in the numeric sequence of the casting alloy designation. The curves included are the results of measurements on individual lots considered representative of the respective alloys and tempers. The properties considered are yield strength, ultimate tensile strength, elongation, and Brinell hardness.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140175
EISBN: 978-1-62708-335-5
Abstract
This data set contains approximately 50 growth curves for a wide range of aluminum casting alloys at various temperatures. Growth curves are used to determine the dimensional changes that must be anticipated during service in applications where close dimensional tolerances are required. Hardness curves are provided for many of the alloys. The hardness values are from corresponding aging response studies in which measurements were made on individual lots considered representative of the respective alloys and tempers.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140193
EISBN: 978-1-62708-335-5
Abstract
The stress-strain curves in this data set are representative examples of the behavior of several cast alloys under tensile or compressive loads. The curves are arranged by alloy designation. Each figure cites the original source of the curve and provides pertinent background information as available. Compressive tangent modulus curves are presented for certain alloys. The effects of cyclic loading are given on several curves.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140211
EISBN: 978-1-62708-335-5
Abstract
This data set contains the results of uniaxial tensile tests of a wide range of aluminum casting alloys conducted at high temperatures from 100 to 370 deg C, subzero temperatures from -269 to -28 deg C, and room temperature after holding at high temperatures from 100 to 370 deg C. In most cases, tests were made of several lots of material of each alloy and temper. The results for the several lots were then analyzed together graphically and statistically, and the averages were normalized to the room-temperature typical values. For some alloys, "representative" values (raw data) rather than typical values are provided.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140243
EISBN: 978-1-62708-335-5
Abstract
This data set contains the results of uniaxial creep rupture tests for a wide range of aluminum casting alloys conducted at temperatures from 100 to 315 deg C. In most cases, tests were made of several lots of material of each alloy and temper, the results were analyzed, and the averages were normalized to the room-temperature typical values. For some alloys, "representative" values (raw data) rather than typical values are provided.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140253
EISBN: 978-1-62708-335-5
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140293
EISBN: 978-1-62708-335-5
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140301
EISBN: 978-1-62708-335-5
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.tb.aacppa.t51140001
EISBN: 978-1-62708-335-5
Abstract
This chapter first introduces the various factors that may alter the physical and mechanical properties of aluminum castings that are addressed in the other chapters in the book. Then, it presents the historical development of aluminum castings, followed by a discussion on the advantages and limitations of aluminum castings. Next, the chapter describes the major trends that are influencing the increased use of aluminum castings. Finally, it introduces the considerations involved in the selection of an appropriate aluminum alloy and casting process for a given application.