Thermal and mechanical behavior of Al-Si alloy cast using magnetic molding and lost foam processes

Abstract

Magnetic molding technology is an original alternative process aimed at improving the metallurgical quality and dimensional tolerances of the final components that are currently produced using the lost foam process. The initial development of the magnetic molding process took place at the same time as the lost foam process, more than 30 years ago, but the magnetic molding process has never achieved the same level of industrial development. The purposes of this study are to introduce the magnetic molding process and to define its advantages and characteristics. The comparative results obtained with both the lost foam and the magnetic molding processes for aluminum casting are given. The main factors involved in the magnetic molding process are also discussed.

Analysis of the Solidification and Microstructure of Two Aluminium Alloys Reinforced with TiB2 Particles

“…[7,8] The thermocouple measured the temperature of the material that was poured into it along the entire solidification process. The cups were produced by casting a plaster/water mixture into silicone moulds that had been obtained by casting a silicone rubber RTV-2 Elastosil M4541 from Wacker Chemie AG over commercial Quick Cup QC4011-type sand cups supplied by Heraeus Electro Nite Co.…”

Combined effects of mechanical vibration and wall thickness on microstructure and mechanical properties of A356 aluminum alloy produced by expendable pattern shell casting

“…In addition, the sand casting method is not easy to meet the demands of dimensional accuracy and surface finish required in precision castings. On the other hand, the LFC process has been regarded as a near net shape method for manufacturing complicated aluminum alloy precision castings [8][9][10]. However, the decomposition of the foam pattern during the pouring process may result in the gas porosity and slag inclusions [11,12], and its pouring temperature is higher than that of traditional cavity casting to overcome the heat absorption from the decomposition of the foam pattern.…”

Correlation of microstructure with mechanical properties and fracture behavior of A356-T6 aluminum alloy fabricated by expendable pattern shell casting with vacuum and low-pressure, gravity casting and lost foam casting

“…Lost foam casting (LFC) has been regarded as a near net shape method for manufacturing complicated aluminum and magnesium alloy precision castings at present [7][8][9]. However, the decomposition of the foam pattern during the pouring process may result in porosity and slag inclusion defects [10,11], and the pouring temperature of the LFC process is usually higher than that of traditional cavity casting.…”