TAILORING PROPERTIES TO REPRESENT HPDC TENSILE AND FATIGUE BEHAVIOUR IN ALUMINIUM-SILICON CAST ALLOY PROTOTYPES

University essay from Högskolan i Jönköping/JTH. Forskningsmiljö Material och tillverkning – Gjutning

Abstract:

The work presented aims to find alternatives for the prototyping of components by sand and plaster mold manufacturing processes that deliver properties similar to high pressure die casting (HPDC).

Sand and plaster test samples have been casted. The Al-7Si-0.35Mg alloy has been tested in as cast condition and in a heat treated condition; T5 for sand cast samples and T6 for those plaster cast. The Al-7Si-2Cu-0.35Mg alloy was also tested in as cast condition. Tensile, fatigue and hardness tests have been performed. Microstructural investigation comprising secondary dendrite arm spacing, defects, Fe-rich β-phases and Si size measurements has been performed on the different conditions. The results have been compared to available data for Al-9Si-3Cu-(Fe) alloy used in HPDC. The T5 heat treated sand cast condition has shown to have properties similar to HPDC. All other sand cast conditions, including the previously tested Al-9Si-3Cu-(Fe) alloy, have been shown to be reasonable alternatives.

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