Cast Shop Technology: Shape Casting
Sponsored by: TMS Light Metals Division, TMS: Aluminum Committee
Program Organizers: Stephen Instone, Speira Gmbh; Mertol Gokelma, Izmir Institute of Technology; Samuel Wagstaff, Oculatus Consulting; Dmitry Eskin, Brunel University

Wednesday 2:00 PM
March 2, 2022
Room: 209A
Location: Anaheim Convention Center

Session Chair: Stephen Instone, Speira Gmbh

2:00 PM  
Energy Resilient Foundries: The "Small is beautiful" Projects: Mark Jolly1; Konstantinos Salonitis1; Emanuele Pagone1; Michail Papanikolaou1; Prateek Saxena1; 1Cranfield University
    Applying the concept of "small is beautiful" into a conservative relatively low technology manufacturing sector where the "economies of scale" argument has been used to build ever more so-called efficient process lines is a major challenge. The energy efficiency of the casting process has only been investigated in a limited fashion. The two “Small is Beautiful” projects aimed to introduce a new concept into foundries with regards the use of their resources. The new philosophy, "small is beautiful", starts by encouraging the use of high-quality feedstock, only melting what is required and only when it is required. Recycling of internal scrap is not necessarily acceptable but an aim for higher yields is. Applying counter gravity casting methods to improve yield and give enhanced quality is encouraged as is the recovery low grade heat from solidification. The present paper discusses the research undertaken and the key findings from the two projects.

2:25 PM  
NOW ON-DEMAND ONLY - The Effect of the Holding Time on the Microstructure of Gd-containing AlSi7Mg Alloys: Özen Gürsoy1; Giulio Timelli1; 1Department of Management and Engineering, University of Padova
    Among lanthanides, Gd addition has been expected to show a good achievement in changing the microstructure of the alloys for better performance in high-temperature applications. Nevertheless, there is a lack of information about the casting practice of Gd addition in terms of holding time and fading effect. In this study, the effective holding time and the fading effect of Gd in AlSi7Mg alloy have been investigated. After minor (0.1 wt. %) and major (0.5 wt. %) Gd additions, different holding times in the range between 15 and 200 minutes were examined. The chemical composition of the molten bath was frequently verified as a function of the holding time. Thermal analysis, macro- and microstructural investigations were performed. The results indicate how 45 minutes of holding time produce eutectic Si refinement. Longer holding times promote Gd settling leading to grain coarsening and formation of larger eutectic Si flakes.

2:50 PM  
NOW ON-DEMAND ONLY - Effects of Casting Temperature and Iron Content on the Microstructure of Hypoeutectic A380 Aluminum Alloy: Reza Haghayeghi1; Giulia Scampone2; Özen Gürsoy2; Giulio Timelli2; 1Volvo Truck; 2Padova University
    Casting temperature and iron content are among the most important factors in obtaining superior mechanical properties in hypoeutectic Al-Si alloys. An A380 aluminum alloy that is one of the most spread alloys in HPDC was selected for examining different iron contents and casting temperatures. The alloy with contents of about 0.8 and 1.2 wt.% Fe was cast at different temperatures in the range between 680°C and 1030°C. The outcome indicates that dendrite arm spacing does not change significantly at different temperatures or iron contents. From 820°C in low-Fe containing alloy and from 890°C in high-Fe containing alloy, the precipitation of harmful β-phase is suppressed. Moreover, blocky or Chinese script α-Fe compounds become the dominant phase throughout the microstructure. The results suggest A380 with lower Fe content at casting superheat of 100°C superheat would result in uniform microstructure and removal of detrimental β-phase.

3:15 PM  
NOW ON-DEMAND ONLY - Effect of Heat Treatment on Mechanical Properties of Er, Dy and Eu Modified A356 Alloy: Onur Ernam1; Tarik Sekban1; Oguzhan Tugan1; Kerem Dizdar2; Hayati Sahin2; Derya Dispinar2; 1Istanbul Technical University; 2Foseco
    The requirement for light weight in automative and aerospace applications has been the focus point in many studies. Lately, the effect of Rare-earth element addition to Al-Si alloys has begun to be investigated in detail. The aim is to establish higher tensile properties in thin sections. In this work, different ratios of Er, Eu and Dy were added to A356 alloy. T6 heat treatment was carried out with aging temperatures of 145, 160, 180 and 200C. 10 cylindrical bars were cast for statistical analysis. Weibull distributions were used to check the reproducibility of test results. It was found that Dy addition had made 356 more brittle while Er addition increased elongation at fracture. The toughness and reliability was found to be the highest in 0.1wt% Er added alloy.