The Research on the Ablation Casting Technology for Aluminium Alloys

Dudek, P.; Fajkiel, A.; Reguła, T.

doi:10.4028/www.scientific.net/ssp.223.70

Cited by 20 publications

(26 citation statements)

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“…Also, gases also contribute to porosity which are blown to refrain from outgassing phenomena of mold materials for instance coatings and lubes [31]. Further, the porous phenomenon occurs with the precipitated bubbles because of dissolved gasses and similarly, with the shrinkage pores as a result of insufficient feeding [25]. The porosity formed during solidification process is categorized as shrinkage porosity (due to inefficient feeding and solidification shrinkage) and gas porosity (due to high proportion of dissolved gases).…”

Section: Response Surface Plots For Dimensional Deviationmentioning

confidence: 99%

“…To overcome these issues, the new developments in the castings especially in the sand molds are becoming popular due to the attainment of excellent engineering properties in final part. The castings are intensively cooled during the process of solidification and sand-molds are destructed using water spray/flow after solidification, known as ablation sand casting [25].…”

Section: Introductionmentioning

confidence: 99%

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A comprehensive efficiency evaluation of conventional and ablation sand casting on the example of the AlSi7Mg alloy impeller

Hafeez

Ahmed

Ali

et al. 2022

Int J Adv Manuf Technol

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Ablation sand casting is a new technology for casting aluminum alloys which helps to achieve superior cooling trends during the solidification and results in eutectic microstructure, reduced degree of defects, and improved mechanical attributes. To further enhance the functionality, water-soluble binder-based sand molds are used in conjunction with appropriate control over process parameters for specialized applications such as complex and thin-walled impeller manufacturing. In this regard, the influence of key process parameters including binder ratio (BR), sand grain fineness number (AFS number), and pouring temperature (PT) is investigated thoroughly on the mechanical characteristics (ultimate tensile strength and hardness) and dimensional accuracy of the thin-walled impeller. Ablation sand casting revealed exceptionally enhanced mechanical properties and dimensional accuracy as compared to conventional sand casting. The AFS number and binder ratio were most significant for controlling the dimensional accuracy. Multi-response optimization through Grey Relational Analysis reveals the optimal setting PT = 800 ℃, ASF number = 45, BR = 5% for lower dimensional deviation, higher hardness, and ultimate tensile strength through conventional sand casting. While for ablation case, the optimal conditions PT = 850 ℃, ASF number = 40, BR = 9% are attained against desired attributes. The attributes are significantly improved through ablated sand casting, dimensional accuracy 31.6%, hardness 58.9% and ultimate tensile strength 41.82%, and fractography analysis depicted the ductile fracture surface. The current technology is drawing attention of industry because of its potential in producing castings with superior mechanical properties and improved internal integrity.

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Section: Response Surface Plots For Dimensional Deviationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A comprehensive efficiency evaluation of conventional and ablation sand casting on the example of the AlSi7Mg alloy impeller

Hafeez

Ahmed

Ali

et al. 2022

Int J Adv Manuf Technol

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“…The technology is referred to as ablation casting [ 9 ]. The principle of the process operation was described in detail by J. Grassi et al [ 6 ] and P. Dudek et al [ 18 , 19 ]. The process is applicable to aluminium and magnesium alloys.…”

Section: Introductionmentioning

confidence: 99%

Effect of the Type of Inorganic Binder on the Microstructure and Properties of AlSi7Mg Alloy Castings Made by Ablation Casting Technology

Kamińska¹,

Angrecki²,

Puzio³

2022

Materials

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The results of studies on the effect that the type of binder and casting technology exert on the microstructure and properties of AlSi7Mg alloy castings are discussed in this paper. Comparative tests were carried out on three casting manufacturing technologies, i.e., conventional sand mould casting and cooling process, metal mould (die) casting, and sand mould casting with ablation breakdown of mould and cooling of castings. Moulds were made from four different sand mixtures with inorganic binders hardened by various technologies. The microstructure of test castings was examined at three different levels, i.e., in the upper part, central part, and lower part of each casting. The tensile test at room temperature was carried out in accordance with standards. The experimental results showed differences in the microstructure of castings. The differences resulted from changes in the crystallisation path due to the use of three different casting technologies, ensuring different rates of heat dissipation from castings; they were also due to the shape of castings. It has been shown that castings made by ablation technology are characterised by a high degree of the microstructure refinement (SDAS reduced by 18–30%), which gives higher strength properties than the properties of castings made in conventional sand moulds. Samples taken from castings made by the ablation technology in moulds with phosphate binder and microwave-hardened geopolymer binder were characterised by the mechanical properties comparable to gravity die castings.

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“…China is considered to be the precursor of ablation casting technology. This technique was used to produce dish handles from around 1600 BC [1].…”

Section: Introductionmentioning

confidence: 99%

“…At the Foundry Research Institute in Krakow, a modification of the casting stand for ablation casting was introduced [4][5]. The device construction allows for rotation and vertical plane movement, which ensures simultaneous removal of the moulding sand from the mould by a stream of water supplied from the nozzles and controlled directional cooling of the casting.…”

Section: Introductionmentioning

confidence: 99%

Archives of Metallurgy and Materials

Major-Gabryś

Hosadyna-Kondracka

Puzio

et al. 2020

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The ablation casting technology consists in pouring castings in single-use moulds made from the mixture of sand and watersoluble binder. After pouring the mould with liquid metal the mould is destructed (washed out) using a stream of cooling medium, which in this case is water. The process takes place while the casting is still solidifying.The following paper focuses on testing the influence of the modified ablation casting of aluminum alloy on casts properties produced in moulds with hydrated sodium silicate binder. The authors showed that the best kind of moulding sands for Al alloy casting will be those hardened with physical factors -through dehydration. The analysis of literature data and own research have shown that the moulding sand with hydrated sodium silicate hardened by dehydration is characterized by sufficient strength properties for the modified ablation casting of Al alloys. In the paper the use of microwave hardened moulding sands has been proposed.The moulds were prepared in the matrix specially designed for this technology. Two castings from the AlSi7Mg alloy were made; one by traditional gravity casting and the other by gravity casting using ablation.The conducted casts tests showed that the casting made in modified ablation casting technology characterizes by higher mechanical properties than the casting made in traditional casting technology. In both experimental castings the directional solidification was observed, however in casting made by ablation casting, dimensions of dendrites in the structure at appropriate levels were smaller.

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The Research on the Ablation Casting Technology for Aluminium Alloys

Cited by 20 publications

References 1 publication

A comprehensive efficiency evaluation of conventional and ablation sand casting on the example of the AlSi7Mg alloy impeller

A comprehensive efficiency evaluation of conventional and ablation sand casting on the example of the AlSi7Mg alloy impeller

Effect of the Type of Inorganic Binder on the Microstructure and Properties of AlSi7Mg Alloy Castings Made by Ablation Casting Technology

Archives of Metallurgy and Materials

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