Optimization of Centrifugal Casting Parameters of AlSi Alloy by using the Response Surface Methodology

Abstract

Centrifugal casting is one of the advanced casting branches widely used in the metallurgical industry in which the centrifugal force helps strengthen the workpiece material. The present work attempt to study the effect of the horizontal and vertical centrifugal casting parameters included the centrifugal mold rotation speeds and G-factors values on the quality of the product. The work has been completed with design and fabricated of a low cost horizontal and vertical centrifugal casting machine with the main accessories for producing a hypoeutectic aluminum silicone (AlSi) alloy (content 10 % Si) specimens. The experimental results were analyzed and improved by using the statistical computer program "Design Expert 11" and response surface methodology (RSM). The results showed that for vertical and horizontal casting processes, the finest surfaces quality was achieved when working at mold rotation speed from 520 to 690 and 950 to 1230 RPM, i.e., with an average value of the G-factor = 69 and 50, respectively. The proof stress values were increased with increasing the mold rotation speed up to (690 RPM) and (1230 RPM) or used the G-factor value of 87.99 and 60.96 gave an increase in proof stress by 6.7 and (20.62% for vertical and horizontal casting experiments compared with gravitational casting, respectively. The obtained tensile strengths values were improved by 38.6 and 45.41 %, compared with the gravitational casting, respectively; while the percentage elongations were reduced to 0.281and 0.291 %; which means decreased by 33.45 and 31.69 % for the vertical and horizontal centrifugal casting compared with the values obtained by gravitational casting experiments, respectively.All metals, alloys, nonmetals and virtually any material that can be liquidized and pourable can be cast by centrifugal casting processes for producing an isotropic and a dense product, including carbon and alloy steels, gray and ductile iron, stainless steels, copper, aluminum and magnesium alloys, nickel, cobalt and titanium based alloys and also nonmetals, including plastics, ceramics, glasses [1], by using a stainless steel, cast iron and graphite mold materials [2]. The process has become widely used for producing special castings tubes, pipes, rolls, cylinder liners and other axisymmetric parts [3][4][5]. The final quality of the products is depending upon the rate of solidification, the rotational speeds of the mold and the molten metal flow pattern [5].Centrifugal casting machines are categorized into three designs based on the operating of the mold Surface Methodology

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