DOE Analysis of the Influence of Sand Size and Pouring Temperature on Porosity in LFC

Abstract:

Lost foam casting is a relatively new process in commercial terms and is widely used to produce defect free castings owing to its advantages like producing complex shape and acceptable surface finish. In the present research, experimental investigations in lost foam casting of aluminium-silicon cast alloy, LM6, were conducted. The main objective of the study was to evaluate the effect of different sand sizes and pouring temperatures on the porosity of thin-wall castings. A stepped pattern was used in the study and the focus of the investigations was at the thinnest 3 mm section. A full 2-level factorial design experimental technique was employed to plan the experiment and subsequently identify the significant factors which affect the casting porosity. The result shows that increasing in the pouring temperature decreases the porosity in the thin-wall section of casting. Finer sand size is more favourable than coarse size for LFC mould making process.

• Periodical: Applied Mechanics and Materials (Volumes 121-126)
• Pages: 2661-2665
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.121-126.2661
• Online since: October 2011
• Authors: S. Izman, Amirreza Shayganpour, M.H. Idris, Hassan Jafari
• Keywords: Full Factorial Design (FFD), LM6 Alloy, Lost Foam Casting, Porosity, Pouring Temperature, Sand Size

References

[1] K. Bokhyun and K. Yongsun: J. Mater. Sci. Technol. Vol. 23, p.119. (2007)

[2] S. Kumar, P. Kumar, H.S. Shan: Effect of evaporative pattern casting process parameters on the surface roughness of Al–7% Si alloy castings, J. Mater. Process. Technol. 182 (1-3), pp.615-623. (2007)

DOI: 10.1016/j.jmatprotec.2006.09.005

[3] Davies, W.D.G.A.P.J: the permeability of Lost Foam pattern coatings for Al alloy castings, J. Mater. Sci. (2008)

[4] P. Vijian, V.P. Arunachalam: Optimization of squeeze cast parameters of LM6 aluminum alloy for surface roughness using Taguchi method, J. Mater. Process. Technol. 180 p.161–166. (2006)

DOI: 10.1016/j.jmatprotec.2006.05.016

[5] K.V.B.S. Kalyan Kumar, S.K. Choudhury: Investigation of tool wear and cutting force in cryogenic machining using design of experiments, J. Mater. Process. Technol. Vol. 203, p.95–101. (2008)

DOI: 10.1016/j.jmatprotec.2007.10.036

[6] D.R. Gunasegaram, D.J. Farnsworth: Identification of critical factors affecting shrinkage porosity in permanent mold casting using numerical simulations based on design of experiments, J. Mater. Process. Technol. 209, p.1209–1219. (2009)

DOI: 10.1016/j.jmatprotec.2008.03.044

[7] G.O. Verran, R.P.K. Mendesb, L.V.O. Dalla Valentina: DOE applied to optimization of aluminum alloy die casting, J. Mater. Process. Technol. p.120–125. (2008)

[8] S. Izman, A. Shayganpour, M.H. Idris. Adv. Mat. Res. (2011), IN PRESS.

[9] X.Chen and J.E. Gruzleski: Int. J. Cast Metals Res, 9, 17. (1996)