Search results for: Aluminium Casting

Authors: Ch. Nerl, M. Wimmer, P. Hofer, E. Kaschnitz

Abstract:

The present article deals with a composite casting process that allows to produce bilayer AlSn6-Al strips based on the technique of horizontal continuous casting. In the first part experimental investigations on the production of a single layer AlSn6 strip are described. Afterwards essential results of basic compound casting trials using simple test specimen are presented to define the thermal conditions required for a metallurgical compound between the alloy AlSn6 and pure aluminium. Subsequently, numerical analyses are described. A finite element model was used to examine a continuous composite casting process. As a result of the simulations the main influencing parameters concerning the thermal conditions within the composite casting region could be pointed out. Finally, basic guidance is given for the design of an appropriate composite mould system.

Keywords: Aluminium alloys, composite casting, compound casting, continuous casting, numerical simulation

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Authors: Lenka Hurtalová, Eva Tillová, Mária Chalupová, Juraj Belan, Milan Uhríčik

Abstract:

The secondary alloy A226 is used for many automotive casting produced by mould casting and high pressure die casting. This alloy has excellent castability, good mechanical properties and cost-effectiveness. Production of primary aluminium alloys belong to heavy source fouling of life environs. The European Union calls for the emission reduction and reduction in energy consumption therefore increase production of recycled (secondary) aluminium cast alloys. The contribution is deal with influence of recycling on the quality of the casting made from A226 in automotive industry. The properties of the casting made from secondary aluminium alloys were compared with the required properties of primary aluminium alloys. The effect of recycling on microstructure was observed using combination different analytical techniques (light microscopy upon black-white etching, scanning electron microscopy - SEM upon deep etching and energy dispersive X-ray analysis - EDX). These techniques were used for the identification of the various structure parameters, which was used to compare secondary alloy microstructure with primary alloy microstructure.

Keywords: A226 secondary aluminium alloy, deep etching, mechanical properties, recycling foundry aluminium alloy.

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Authors: Satish Kumar, Arun Kumar Gupta, Pankaj Chandna

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The present work analyses different parameters of pressure die casting to minimize the casting defects. Pressure diecasting is usually applied for casting of aluminium alloys. Good surface finish with required tolerances and dimensional accuracy can be achieved by optimization of controllable process parameters such as solidification time, molten temperature, filling time, injection pressure and plunger velocity. Moreover, by selection of optimum process parameters the pressure die casting defects such as porosity, insufficient spread of molten material, flash etc. are also minimized. Therefore, a pressure die casting component, carburetor housing of aluminium alloy (Al2Si2O5) has been considered. The effects of selected process parameters on casting defects and subsequent setting of parameters with the levels have been accomplished by Taguchi-s parameter design approach. The experiments have been performed as per the combination of levels of different process parameters suggested by L18 orthogonal array. Analyses of variance have been performed for mean and signal-to-noise ratio to estimate the percent contribution of different process parameters. Confidence interval has also been estimated for 95% consistency level and three conformational experiments have been performed to validate the optimum level of different parameters. Overall 2.352% reduction in defects has been observed with the help of suggested optimum process parameters.

Keywords: Aluminium Casting, Pressure Die Casting, Taguchi Methodology, Design of Experiments

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Authors: O. Ualibek, C. Spitas, V. Inglezakis, G. Itskos

Abstract:

This study presents simulations of an aluminium melt containing an initially non-dispersed fly ash nanoparticle phase. Mixing is affected predominantly by means of forced extensional flow via either straight or slanted orifices. The sensitivity to various process parameters is determined. The simulated process is used for the production of cast fly ash-aluminium nanocomposites. The possibilities for rod and plate stock grading in the context of a continuous casting process implementation are discussed.

Keywords: Metal matrix composites, fly ash nanoparticles, aluminium 2024, agglomeration.

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Authors: Williams S. Ebhota, Freddie L. Inambao

Abstract:

This study investigates the use of centrifugal casting method to fabricate functionally graded aluminium A356 Alloy and A356-10%SiCp composite for hydro turbine bucket application. The study includes the design and fabrication of a permanent mould. The mould was put into use and the buckets of A356 Alloy and A356-10%SiCp composite were cast, cut and machined into specimens. Some specimens were given T6 heat treatment and the specimens were prepared for different examinations accordingly. The SiCp particles were found to be more at inner periphery of the bucket. The maximum hardness of As-Cast A356 and A356-10%SiCp composite was recorded at the inner periphery to be 60 BRN and 95BRN, respectively. And these values were appreciated to 98BRN and 122BRN for A356 alloy and A356-10%SiCp composite, respectively. It was observed that the ultimate tensile stress and yield tensile stress prediction curves show the same trend.

Keywords: A356 alloy, A356-10%SiCp composite, centrifugal casting, pelton bucket, turbine blade.

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Authors: Marco Actis Grande, Somlak Wannarumon

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This paper proposes the numerical simulation of the investment casting of gold jewelry. It aims to study the behavior of fluid flow during mould filling and solidification and to optimize the process parameters, which lead to predict and control casting defects such as gas porosity and shrinkage porosity. A finite difference method, computer simulation software FLOW-3D was used to simulate the jewelry casting process. The simplified model was designed for both numerical simulation and real casting production. A set of sensor acquisitions were allocated on the different positions of the wax tree of the model to detect filling times, while a set of thermocouples were allocated to detect the temperature during casting and cooling. Those detected data were applied to validate the results of the numerical simulation to the results of the real casting. The resulting comparisons signify that the numerical simulation can be used as an effective tool in investment-casting-process optimization and casting-defect prediction.

Keywords: Computer fluid dynamic, Investment casting, Jewelry, Mould filling, Simulation.

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Authors: Mehdi Modabberifar, Behrouz Raad, Bahman Mirzakhani

Abstract:

Flanges are widely used for connecting valves, pipes and other industrial devices such as gearboxes. Method of producing a flange has a considerable impact on the manner of their involvement with the industrial engines and gearboxes. By Using die casting instead of sand casting and machining for manufacturing flanges, production speed and dimensional accuracy of the parts increases. Also, in die casting, obtained dimensions are close to final dimensions and hence the need for machining flanges after die casting process decreases which makes a significant savings in raw materials and improves the mechanical properties of flanges. In this paper, a typical die of an industrial helical gearbox flange (size ISO 50) was designed and die casting process for producing this type of flange was simulated using ProCAST software. The results of simulation were used for optimizing die design. Finally, using the results of the analysis, optimized die was built.

Keywords: Die casting, finite element, flange.

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Authors: Gurmeet Singh Cheema, Navjotinder Singh, Gurjinder Singh, Amardeep Singh Kang

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Aluminium and its alloys have excellent corrosion resistant properties, ease of fabrication and high specific strength to weight ratio. In this investigation an attempt has been made to study the effect of different post weld heat treatment methods on the mechanical and metallurgical properties of TIG welded joints of the commercial aluminium alloy. Three different methods of post weld heat treatments are solution heat treatment, artificial ageing and combination of solution heat treatment and artificial aging are given to TIG welded aluminium joints. Mechanical and metallurgical properties of As welded joints of the aluminium alloys and post weld heat treated joints of the aluminium alloys were examined.

Keywords: Aluminium Alloys, Post weld Heat Treatment, TIG welding.

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Authors: O. Srihakulung, Y. Soongsumal

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Among the chemicals used for ammunition production, TNT (Trinitrotoluene) play a significant role since World War I and II. Various types of military weapon utilize TNT in casting process. However, the TNT casting process for warhead is difficult to control the cooling rate of the liquid TNT. This problem occurs because the casting process lacks the equipment to detect the temperature during the casting procedure This study presents the temperature detected by infrared camera to illustrate the cooling rate and cooling zone of curing, and demonstrates the optimization of TNT condition to reduce the risk of air gap occurred in the warhead which can result in the destruction afterward. Premature initiation of explosive-filled projectiles in response to set-back forces during gunfiring cause by casting defects. Finally the study can help improving the process of the TNT casting. The operators can control the curing of TNT inside the case by rising up the heating rod at the proper time. Consequently this can reduce tremendous time of rework if the air gaps occur and increase strength to lower elastic modulus. Therefore, it can be clearly concluded that the use of Infrared Cameras in this process is another method to improve the casting procedure.

Keywords: Infrared camera, TNT casting, warhead, curing.

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Authors: Saeid Norouzi, Ali Shams, Hassan Farhangi, Alireza Darvish

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Hot tear cracking and residual stress are two different consequences of thermal stress both of which can be considered as casting problem. The purpose of the present study is simulation of the effect of casting shape characteristic on hot tearing and residual stress. This study shows that the temperature range for simulation of hot tearing and residual stress are different. In this study, in order to study the development of thermal stress and to predict the hot tearing and residual stress of shaped casting, MAGMASOFT simulation program was used. The strategy of this research was the prediction of hot tear location using pinpointing hot spot and thermal stress concentration zones. The results shows that existing of stress concentration zone increases the hot tearing probability and consequently reduces the amount of remaining residual stress in casting parts.

Keywords: Hot tearing, residual stress, simulation, investment casting.

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Authors: A. Chellil, A. Nour, S. Lecheb, H. Mechakra, L. Addar, H. Kebir

Abstract:

This paper present a mechanical characteristics on fatigue crack propagation in Aluminium Plate based on strain and stress distribution using the abaqus software. The changes in shear strain and stress distribution during the fatigue cycle with crack growth is identified. In progressive crack in the strain distribution and the stress is increase in the critical zone. Numerical Modal analysis of the model developed, prove that the Eigen frequencies of aluminium plate were decreased after cracking, and this reduce is nonlinear. These results can provide a reference for analysts and designers of aluminium alloys in aeronautical systems.

Therefore, the modal analysis is an important factor for monitoring the aeronautic structures.

Keywords: Aluminium alloys, plate, crack, failure.

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Authors: Pei-Hsing Huang, Wei-Ju Huang

Abstract:

Investment casting is commonly used in the production of metallic components with complex shapes, due to its high dimensional precision, good surface finish, and low cost. However, the process is cumbersome, and the period between trial casting and final production can be very long, thereby limiting business opportunities and competitiveness. In this study, we replaced conventional wax injection with stereolithography (SLA) 3D printing to speed up the trial process and reduce costs. We also used silicone molds to further reduce costs to avoid the high costs imposed by photosensitive resin.

Keywords: Investment casting, stereolithography, wax molding, 3D printing.

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Authors: J. Uka, B. McKay, T. Minton, O. Adole, R. Lewis, S. J. Glanvill, L. Anguilano

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Effective heat treatment conditions to obtain maximum aluminium swarf recycling are investigated in this work. Aluminium swarf briquettes underwent treatments at different temperatures and cooling times to investigate the improvements obtained in the recovery of aluminium metal. The main issue for the recovery of the metal from swarfs is to overcome the constraints due to the oxide layers present in high concentration in the swarfs since they have a high surface area. Briquettes supplied by Renishaw were heat treated at 650, 700, 750, 800 and 850 ℃ for 1-hour and then cooled at 2.3, 3.5 and 5 ℃/min. The resulting material was analysed using SEM EDX to observe the oxygen diffusion and aluminium coalescence at the boundary between adjacent swarfs. Preliminary results show that, swarf needs to be heat treated at a temperature of 850 ℃ and cooled down slowly at 2.3 ℃/min to have thin and discontinuous alumina layers between the adjacent swarf and consequently allowing aluminium coalescence. This has the potential to save energy and provide maximum financial profit in preparation of swarf briquettes for recycling.

Keywords: Aluminium, swarf, oxide layers, recycle, reuse.

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Authors: M. Ramachandra, G. Dilip Maruthi, R. Rashmi

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This paper aims to study the corrosion property of aluminum matrix nanocomposite of an aluminum alloy (Al-6061) reinforced with zirconium dioxide (ZrO₂) particles. The zirconium dioxide particles are synthesized by solution combustion method. The nanocomposite materials are prepared by mechanical stir casting method, varying the percentage of n-ZrO₂ (2.5%, 5% and 7.5% by weight). The corrosion behavior of base metal (Al-6061) and Al/ZrO₂ nanocomposite in seawater (3.5% NaCl solution) is measured using the potential control method. The corrosion rate is evaluated by Tafel extrapolation technique. The corrosion potential increases with the increase in wt.% of n-ZrO₂ in the nanocomposite which means the decrease in corrosion rate. It is found that on addition of n-ZrO2 particles to the aluminum matrix, the corrosion rate has decreased compared to the base metal.

Keywords: Al6061 alloy, corrosion, solution combustion, stir casting, Potentiostat, Zirconium Dioxide.

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Authors: Taneli Eisto, Venlakaisa Hölttä, Katrine Mahlamäki, Janne Kollanus, Marko Nieminen

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Early supplier involvement (ESI) benefits new product development projects several ways. Nevertheless, many castuser companies do not know the advantages of ESI and therefore do not utilize it. This paper presents reasons why to utilize ESI in casting industry and how that can be done. Further, this paper presents advantages and challenges related to ESI in casting industry, and introduces a Casting-Network Collaboration Model. The model presents practices for companies to build advantageous collaborative relationships. More detailed, the model describes three levels for company-network relationships in casting industry with different degrees of collaboration, and requirements for operating in each level. In our research, ESI was found to influence, for example, on project time, component cost, and quality. In addition, challenges related to ESI, such as, a lack of mutual trust and unawareness about the advantages were found. Our research approach was a case study including four cases.

Keywords: Casting Industry, Collaboration Model, EarlySupplier Involvement, New Product Development.

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Authors: Balwinder Singh

Abstract:

The present research is a paper on the characterization of aluminum alloy-6063 hybrid metal matrix composites using three different reinforcement materials (SiC, red mud, and fly ash) through stir casting method. The red mud was used in solid form, and particle size range varies between 103-150 µm. During this investigation, fly ash is received from Guru Nanak Dev Thermal Plant (GNDTP), Bathinda. The study has been done by using Taguchi’s L9 orthogonal array by taking fraction wt.% (SiC 5%, 7.5%, and 10% and Red Mud and Fly Ash 2%, 4%, and 6%) as input parameters with their respective levels. The study of the mechanical properties (tensile strength, impact strength, and microhardness) has been done by using Analysis of Variance (ANOVA) with the help of MINITAB 17 software. It is revealed that silicon carbide is the most significant parameter followed by red mud and fly ash affecting the mechanical properties, respectively. The fractured surface morphology of the composites using Field Emission Scanning Electron Microscope (FESEM) shows that there is a good mixing of reinforcement particles in the matrix. Energy-dispersive X-ray spectroscopy (EDS) was performed to know the presence of the phases of the reinforced material.

Keywords: Reinforcement, silicon carbide, fly ash, red mud.

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Authors: Mohammad Syed Ali Molla, Mohammed Azim, Mohammad Esharuzzaman

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Centrifugal-casting machine is used in manufacturing special machine components like multi-layer journal bearing used in all internal combustion engine, steam, gas turbine and air craft turboengine where isotropic properties and high precisions are desired. Moreover, this machine can be used in manufacturing thin wall hightech machine components like cylinder liners and piston rings of IC engine and other machine parts like sleeves, and bushes. Heavy-duty machine component like railway wheel can also be prepared by centrifugal casting. A lot of technological developments are required in casting process for production of good casted machine body and machine parts. Usually defects like blowholes, surface roughness, chilled surface etc. are found in sand casted machine parts. But these can be removed by centrifugal casting machine using rotating metallic die. Moreover, die rotation, its temperature control, and good pouring practice can contribute to the quality of casting because of the fact that the soundness of a casting in large part depends upon how the metal enters into the mold or dies and solidifies. Poor pouring practice leads to variety of casting defects such as temperature loss, low quality casting, excessive turbulence, over pouring etc. Besides these, handling of molten metal is very unsecured and dangerous for the workers. In order to get rid of all these problems, the need of an automatic pouring device arises. In this research work, a robot assisted pouring device and a centrifugal casting machine are designed, developed constructed and tested experimentally which are found to work satisfactorily. The robot assisted pouring device is further modified and developed for using it in actual metal casting process. Lot of settings and tests are required to control the system and ultimately it can be used in automation of centrifugal casting machine to produce high-tech machine parts with desired precision.

Keywords: Casting, cylinder liners, journal bearing, robot.

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Authors: Mukuna P. Mubiayi, Esther T. Akinlabi

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Friction Stir Welding is a solid state welding technique which can be used to produce sound welds between similar and dissimilar materials. Dissimilar welds which include welds between the different series of aluminium alloys, aluminium to magnesium, steel and titanium has been successfully produced by many researchers. This review covers the work conducted in the above mentioned materials and further concludes by showing the need to fully understand the FSW process in order to expand the latter industrially.

Keywords: aluminium, dissimilar materials, FSW, hardness, magnesium, microstructure, steel, tensile test, titanium

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Authors: M. Khodai, S. M. H. Mirbagheri

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In the Lost Foam Casting process, melting point temperature of metal, as well as volume and rate of the foam degradation have significant effect on the mold filling pattern. Therefore, gas generation capacity and gas gap length are two important parameters for modeling of mold filling time of the lost foam casting processes. In this paper, the gas gap length at the liquidfoam interface for a low melting point (aluminum) alloy and a high melting point (Carbon-steel) alloy are investigated by the photography technique. Results of the photography technique indicated, that the gas gap length and the mold filling time are increased with increased coating thickness and density of the foam. The Gas gap lengths measured in aluminum and Carbon-steel, depend on the foam density, and were approximately 4-5 and 25-60 mm, respectively. By using a new system, the gas generation capacity for the aluminum and steel was measured. The gas generation capacity measurements indicated that gas generation in the Aluminum and Carbon-steel lost foam casting was about 50 CC/g and 3200 CC/g polystyrene, respectively.

Keywords: gas gap, lost foam casting, photographytechnique.

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Authors: Ömer Faruk Baykoç, Ümit Sami Sakalli

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In this paper, we propose a fuzzy aggregate production planning (APP) model for blending problem in a brass factory which is the problem of computing optimal amounts of raw materials for the total production of several types of brass in a period. The model has deterministic and imprecise parameters which follows triangular possibility distributions. The brass casting APP model can not always be solved by using common approaches used in the literature. Therefore a mathematical model is presented for solving this problem. In the proposed model, the Lai and Hwang-s fuzzy ranking concept is relaxed by using one constraint instead of three constraints. An application of the brass casting APP model in a brass factory shows that the proposed model successfully solves the multi-blend problem in casting process and determines the optimal raw material purchasing policies.

Keywords: Aggregate production planning, Blending, brasscasting, possibilistic programming.

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Authors: U. Achutha Kini, S. S. Sharma, K. Jagannath, P. R. Prabhu, Gowri Shankar M. C.

Abstract:

Aluminium matrix composites with alumina reinforcements give superior mechanical & physical properties. Their applications in several fields like automobile, aerospace, defense, sports, electronics, bio-medical and other industrial purposes are becoming essential for the last several decades. In the present work, fabrication of hybrid composite was done by Stir casting technique using Al 6061 as a matrix with alumina and silicon carbide (SiC) as reinforcement materials. The weight percentage of alumina is varied from 2 to 4% and the silicon carbide weight percentage is maintained constant at 2%. Hardness and wear tests are performed in the as cast and heat treated conditions. Age hardening treatment was performed on the specimen with solutionizing at 550°C, aging at two temperatures (150 and 200°C) for different time durations. Hardness distribution curves are drawn and peak hardness values are recorded. Hardness increase was very sensitive with respect to the decrease in aging temperature. There was an improvement in wear resistance of the peak aged material when aged at lower temperature. Also increase in weight percent of alumina, increases wear resistance at lower temperature but opposite behavior was seen when aged at higher temperature.

Keywords: Hybrid composite, hardness test, wear test, heat treatment, pin on disc wear testing machine.

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Authors: P. Meethum, C. Suvanjumrat

Abstract:

Many aluminum motorcycle parts produced by a high pressure die casting. Some parts such as fuel caps were a thin and complex shape. This part risked for porosities and blisters on surface if it only depended on an experience of mold makers for mold design. This research attempted to use CAST-DESIGNER software simulated the high pressure die casting process with the same process parameters of a motorcycle fuel cap production. The simulated results were compared with fuel cap products and expressed the same porosity and blister locations on cap surface. An average of absolute difference of simulated results was obtained 0.094 mm when compared the simulated porosity and blister defect sizes on the fuel cap surfaces with the experimental micro photography. This comparison confirmed an accuracy of software and will use the setting parameters to improve fuel cap molds in the further work.

Keywords: Aluminum, die casting, fuel cap, motorcycle.

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Authors: L. Mahnicka

Abstract:

The alumosilicate ceramics with mullite crystalline phase are used in various branches of science and technique. The mullite refractory ceramics with high porosity serve as a heat insulator and as a constructional materials [1], [2]. The purpose of the work was to sinter high porosity ceramic and to increase the quantity of mullite phase in this mullite, mullite-corundum ceramics. Two types of compositions were prepared at during the experiment. The first type is compositions with commercial alumina and silica oxides. The second type is from mixing these oxides with 10, 20 and 30 wt.%. of kaolin. In all samples the Al2O3 and SiO2 were in 2.57:1 ratio, because that was conformed to mullite stechiometric compositions (3Al2O3.2SiO2). The types of alumina oxides were α-Al2O3 (d50=4µm) and γ-Al2O3 (d50=80µm). Ratios of α-: γ-Al2O3 were (1:1) or (1:3). The porous materials were prepared by slip casting of suspension of raw materials. The aluminium paste (0.18 wt.%) was used as a pore former. Water content in the suspensions was 26-47 wt.%. Pore formation occurred as a result of hydrogen formation in chemical reaction between aluminium paste and water [2]. The samples were sintered at the temperature of 1650°C and 1750°C for one hour. The increasing amount of kaolin, α-: γ-Al2O3 at the ratio (1:3) and sintering at the highest temperature raised the quantity of mullite phase. The mullite phase began to dominate over the corundum phase.

Keywords: Alumina, Kaolin, Mullite-corundum, Porous refractory ceramics

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Authors: M. Jalali Azizpour, S.Norouzi H. Mohammadi Majd

Abstract:

In this paper, the babbitting of a bearing in boiler feed pump of an electromotor has been studied. These bearings have an important role in reducing the shut down times in the pumps, compressors and turbines. The most conventional method in babbitting is casting as a melting method. The comparison between thermal spray and casting methods in babbitting shows that the thermal spraying babbitt layer has better performance and tribological behavior. The metallurgical and tribological analysis such as SEM, EDS and wet chemical analysis has been made in the Babbitt alloys and worn surfaces. Two type of babbitt materials: tinbase and lead-base babbitt was used. The benefits of thermally sprayed babbitt layers are completely clear especially in large bearings.

Keywords: Thermal spray, Babbitting, Bonding, Bearing, BFP, CWP

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Authors: M. Heikkinen, A. Sarpola, H. Hellman, J. Rämö, Y. Hiltunen

Abstract:

Independent component analysis (ICA) is a computational method for finding underlying signals or components from multivariate statistical data. The ICA method has been successfully applied in many fields, e.g. in vision research, brain imaging, geological signals and telecommunications. In this paper, we apply the ICA method to an analysis of mass spectra of oligomeric species emerged from aluminium sulphate. Mass spectra are typically complex, because they are linear combinations of spectra from different types of oligomeric species. The results show that ICA can decomposite the spectral components for useful information. This information is essential in developing coagulation phases of water treatment processes.

Keywords: Independent component analysis, massspectroscopy, water treatment, aluminium sulphate.

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Authors: Kartikaningsih Danis, Yao-Hui Huang

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Various techniques including conventional and advanced have been employed for the boron treatment from water and wastewater. The electrocoagulation involves an electrolytic reactor for coagulation/flotation with aluminium as anode and cathode. There is aluminium as coagulant to be used for removal which may induce secondary pollution in chemical coagulation. The purpose of this study is to investigate and compare the performance between electrocoagulation and chemical coagulation on boron removal from synthetic wastewater. The effect of different parameters, such as pH reaction, coagulant dosage, and initial boron concentration were examined. The results show that the boron removal using chemical coagulation was lower. At the optimum condition (e.g. pH 8 and 0.8 mol coagulant dosage), boron removal efficiencies for chemical coagulation and electrocoagulation were 61% and 91%, respectively. In addition, the electrocoagulation needs no chemical reagents and makes the boron treatment easy for application.

Keywords: Electrocoagulation, chemical coagulation, aluminum electrode, boron removal.

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Authors: Myoung-Gon Yoon, Jung-Ho Moon, Tae Kwon Ha

Abstract:

Tensile specimens of nonflammable AZ91D Mg alloy were fabricated in this study via cold chamber die-casting process. Dimensions of tensile specimens were 25mm in length, 4mm in width, and 0.8 or 3.0mm in thickness. Microstructure observation was conducted before and after tensile tests at room temperature. In the die casting process, various injection distances from 150 to 260mm were employed to obtain optimum process conditions. Distribution of Al₁₂Mg₁₇ phase was the key factor to determine the mechanical properties of die-cast Mg alloy. Specimens with 3mm of thickness showed superior mechanical properties to those with 0.8mm of thickness. Closed networking of Al₁₂Mg₁₇ phase along grain boundary was found to be detrimental to mechanical properties of die-cast Mg alloy.

Keywords: Non-flammable magnesium alloy, AZ91D, die-casting, microstructure, mechanical properties.

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Authors: H. Harada, S. Nishida, T. Nagumo, M. Endo, H. Watari

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This study was aimed for investigating of manufacturing high aluminum content Mg alloys using a horizontal twin roll caster. Recently, weight saving has been key issues for lighter transport equipments as well as electronic component parts. As alternative materials to aluminum alloys, developing magnesium alloy with higher strength has been expected. Normally high Aluminum content Mg alloy has poor ductility and is difficult to be rolled because of its high strength. However, twin roll casting process is suitable for manufacturing wrought Mg alloys because materials can be cast directly from molten metal. In this study, manufacturing of high aluminum content magnesium alloy sheet using the roll casting process has been carried out. Effects of manufacturing parameter, such as roll velocity, pouring temperature and roll gap, on casting was investigated. A microscopic observation of the crystals of cross section of as cast strip as well as rolled strip was conducted.

Keywords: AZ91, AZ111, AZ121, Magnesium alloys, Twin roll casting

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Authors: Chil-Chyuan Kuo, Chen-Hsuan Tsai

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This study presents a cost-effective approach for rapid fabricating modeling platforms utilized in fused deposition modeling system. A small-batch production of modeling platforms about 20 pieces can be obtained economically through silicone rubber mold using vacuum casting without applying the plastic injection molding. The air venting systems is crucial for fabricating modeling platform using vacuum casting. Modeling platforms fabricated can be used for building rapid prototyping model after sandblasting. This study offers industrial value because it has both time-effectiveness and cost-effectiveness.

Keywords: Vacuum casting, fused deposition modeling, modeling platform, sandblasting, surface roughness.

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Authors: K. Kalaiselvan, A. Elango

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To achieve reliable welds with minimum distortion for the fabrication of components in aerospace industry laser beam welding is attempted. Laser welding can provide a significant benefit for the welding of Titanium and Aluminium thin sheet alloys of its precision and rapid processing capability. For laser welding, pulse shape, energy, duration, repetition rate and peak power are the most important parameters that influence directly the quality of welds. In this experimental work for joining 1mm thick TI6AL4V and AA2024 alloy and JK600 Nd:YAG pulsed laser units used. The distortions at different welding power and speed of titanium and aluminium thin sheet alloys are investigated. Test results reveal that increase in welding speed increases distortion in weldment

Keywords: Laser Beam Welding, Titanium, Aluminium alloy sheets and distortion.

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