Material engineering

1. Casting processes
of Aluminum
alloysTeam No.7
Under Supervision:DR.Mohamed Ramadan

2. INTR
O
Aluminum is the most abundant metallic element in the earth's crust, of
which it forms nearly 8%. It always occurs as a compound, some of its
minerals being bauxite, cryolite, corundum, alunite, diaspore, turquoise,
spinel, and such silicates as kaolin, feldspar, and mica. Bauxite a
ferruginous aluminum hydroxide, is the basic raw material from which
the metal aluminum is produced.

3. Impurities
are removed from the bauxite
by chemical processing to make
alumina (aluminum oxide). The
bauxite is crushed, mixed in a
caustic soda (sodium hydroxide)
solution,
Electrolyzing
a solution of alumina in molten
fluorides makes aluminum; this
electrolysis takes place in
reduction pots or cells at a
reduction plant. Aluminum
reduction plants produce pure,
high quality primary aluminum
The important definitions:
Raw aluminum

4.  Aluminum alloys
1xxx
Aluminum - 99.00% or Greater
2xxx
Copper
3xxx
Manganese
4xxx
Silicon
5xxx
Magnesium
6xxx
Magnesium, Silicon
7xxx
Zinc

5.  Casting processes of
Aluminum Alloys
SAND
CASTING
DIE
CASTING
SEMI-SOLID
CASTING
SEQUEEZE
CASTING
COSWORTH
CASTING
LOW
PRESSURE
CASTING
Charging the furnace is the first step in the casting process.
The cast house is equipped with the following in order to
prepare a charge, which is a mixture of raw materials that are
melted down to make an alloy.

6. Sand Casting
 Definition
• is the most direct and low cost means of converting
metal into a desired shape. Aluminum castings are
virtually unlimited in their ability to provide users
with a wide range of advantages and applications.

7. Sand Casting
Advantages
• Can Only Cast Basic
Part Shape
• Castings Require
Secondary Machining
• casting defects
• Rough surface finish
• Bad casting
dimensions, because
of shrinkage
Disadvantages
 Sand Casting Suitability
• Multi-use
• Can make complex shapes , sizes
• Low cost
• we can use the sand to make
another mould
• Higher production rate
• can produce very large castings

8. Sand Casting
 General Setup
Shrinkage Consideration

9. Sand Casting
• a mold is created by placing the mixture of sand, clay and water on a pattern
• The gating system is placed inside, and a sprue is formed in order for the
molten alloy to be fed into the cast
• the sand mold has two or more parts, the upper part is known as the cope
while the bottom one is called the drag.
• the two halves are closed and clamped together and molten metal is then
poured into the mold
• and let the metal solidify
• When the part is removed the clay will have a cavity that corresponds to the
shape of the part
• So we can use the sand to make another mould
 Sand Casting Process

10. Sand Casting
 Final Castings
• Used Oxyacetylene Torch to
heat steel crucible that would
not suffer thermal shock.
• Cast aluminium and copper
alloys (not quite enough heat
input for copper)

11.  Applications :-
• Sand cast aluminum components are widely used in
the automotive and transportation industries
including aerospace.
• Parts commonly produced with sand casting
include the power-train, supports,
suspensions, casings, gears and many others.
Sand Casting
Engine soft

12. Die Casting
 What Is Aluminum Die Casting?
• Aluminum die casting is a manufacturing process
for producing accurately dimensioned, sharply
defined, smooth or textured-surface aluminum
parts through the use of reusable molds, called
dies.
• The aluminum die casting process involves the use
of a furnace, aluminum alloy, die casting machine,
and die.
• Dies that usually constructed with long-lasting,
quality steel have at least two sections to permit
removal of castings.

13. Die Casting
 How are Aluminum Die Castings Made?
• The aluminum casting dies that are created using
hardened tool steel must be made in at least two
sections so that castings can be removed.
• The aluminum die casting process is capable of
producing tens of thousands of aluminum castings in
quick succession.
• The dies are firmly mounted in the die casting
machine. The fixed half die is stationary. The other
one, injector die half, is movable.

14. Die Casting
• Aluminum die casting alloys are lightweight and
possess high dimensional stability for complex part
geometries and thin walls.
• Aluminum withstands good corrosion resistance and
mechanical properties as well as high thermal and
electrical conductivity, making it a good alloy for die
casting.
• Low-density aluminum metals are essential to the die
casting industry.
 Die Casting Suitability

15. Die Casting
 A manufacturing process that produces accurately,
defined, smooth and textured-surfaced metal parts
 Accomplished by forcing molten metals into a mold
form due to high-pressure systems
 Corrosion resistant
 Highly conductive
 Have a good stiffness and strength-to-weight ratio
 Based on rapid production
 Allows a high volume of die casting parts to be
produced very quickly
 Is more cost-effective than alternative casting
processes
Advantages Disadvantages
• Casting weight must be between 30
grams and 10 kg Casting must be
smaller than 600 mm (24 in.).
• High initial cost.
• Limited to high-fluidity metals.
• A certain amount of porosity is
common.
• Thickest section should be less than
13 mm (0.5 in.).
• A large production volume is needed
to make this an economical
alternative to other processes.

16. Die Casting
• Aluminum castings improve automotive fuel efficiency by
contributing to weight saving requirements
• Aluminum is used in a broad range of networking and
infrastructure equipment in the telecom and computing
industries because RF filter boxes and housings require heat
dissipation
• In handheld devices, aluminum castings provide EMI/RFI
shielding, rigidity, and durability with minimal weight
• Because of aluminum’s excellent electrical performance and
shielding properties, even in high-temperature environments,
die cast aluminum is ideal for electronic connectors and
housings
 Aluminum Die Casting Applications:

17. Die Casting
 Companies works :

18. Semi-solid casting
 INTRODUCTION
semi-solid metal (SSM) casting process is a recent casting technique which
combines the advantage of liquid metal casting with the advantage
of solid metal forging. This process is mainly used to cast complex products
with near net shapes and excellent dimensional accuracy. Semi solid metal
casting which is also known as thixocasting, rheocasting, thixoforming, or
thixomolding, etc. is suitable to cast non-ferrous metals
such as aluminum, copper,
or magnesium.

19. Semi-solid casting
 Process
• metal is melted at temperature where slurry remains at a
temperature between the solid and liquid state.
• The ideal temperature is up to to 10C at which the metal is
in a slurry state which is 30% to 60% solid.
• The metal which is melted and cooled, during which
dendrites that are formed are broken up.
• In this state the metal is further process into the desired
castings.
• To maintain uniform structure and quality of the castings,
care must be taken to to homogeneously distribute the
solid metal without liquid is segregated.

20. Semi-solid casting
Advantages
• Complex parts produced in near net shapes.
• Excellent mechanical performance.
• Thin walls can be caste can be done.
• Casting are heat treatable.
• No air entrapment during the casting
process.
• Low shrinkage during solidification.
• Uniform microstructure of the entire cast.

21. Semi-solid casting
• Semi-solid processing is ideally suited for the production of
large volume die casting components, including light weight,
high strength components for automobiles.
• For aluminum alloys typical parts include engine suspension
mounts, air manifold sensor harness, engine blocks and oil
pump filter housing.
• For magnesium alloys, semi-solid casting is typically used to
produce extremely thin walled castings, such as computer and
camera bodies.
• Because of this the process can be applied to rapid
prototyping needs and mass production.
 Application

22. Squeeze Casting
 Definition :
• The process was introduced in the United States in 1960
and has since gained
• Squeeze casting as liquid-metal forging, is a process
by which molten metal solidifies under pressure within
closed dies positioned between the plates of a hydraulic
press.
• The applied pressure and instant contact of the
molten metal with the die surface produce a rapid
heat transfer condition.

23. Squeeze Casting
 General Setup
• Die set positioned on hydraulic press, preheated
to 200–250°C and coated with a releasing agent
such as graphite. Accurate metering
of liquid metal into die cavity via a "launder".
• Press actuated to bring two parts of die set
together. Metal displaced to fill die cavity
and pressure held until solidification is complete.
• Press ram withdrawn. Die set separated.
Component ejected. Components heat-treated
and machined when necessary

24. Squeeze Casting
 Squeeze Casting Suitability
• Squeeze casting increase the metal’s functionality.
• One benefit is that the metal will typically be stronger
• the cooling method forms a better grain when
compared to other casting techniques.
• There is a tight seal and pressure between the two
dies, so less metal is able to evaporate, leading to
less shrinking during
Advantages:
Disadvantages
• Costs are very high due
to complex tooling
• No flexibility as tooling
is dedicated to specific
components
• Process needs to be
accurately controlled
which slows the cycle
• time down and
increases process costs.

25. Figure : Typical macro structures (a) macro segregation
only; (b) both macro segregation and shrinkage defects;
and (c) shrinkage defects only.
Squeeze Casting

26. • Squeeze casting is an economical .
• simple and convenient process.
• It has found extensive application in automotive industry
in producing aluminum front steering knuckles .
• chassis frames, brackets or nodes. High capacity
propellers for boat-engine
 Application of Squeeze Casting:
Squeeze Casting

27. Cos-worth casting
is a modern foundry process where zircon
sand is used instead of silicon for making
sand molds. And, counter-gravity pouring
technique is used to force the metal into the
mold. The famous automobile
manufacturers 'The Ford' selected the
process for its wind ston,Ontario plant.
 Definition

28. Cos-worth casting
 Process:
The sand casting process is used to prepare the mold
for cos worth process. But, instead of silicon, zircon
is used as the aggregate. When the mold is prepared
the molten metal is forced into the mold from the base,
using the gravity technique. No gating and feeder are
used for the metal pouring purpose, therefore blow
holes from chill, cores and adhesives are not created as
in conventional pouring methods.

29. Cos-worth casting
• Through programmable control, the
pumping capacity can be adapted to fill
the respective mold suitably.
• Zirconium is used for the molds as its
thermal expansion and contraction can
be predicted better in comparison
with quartz sand.
• The pressure which acts on the liquid
metal in the mold cavity is maintained
until the end of the solidification as in
the low pressure gravity die casting
process. The DISA matic process also
works with the same mold filling
methods. It differs from the Cos worth®
process due to a box less sand mold
production.
 General Setup

30. Cos-worth casting
 Casting have high integrity and dimensional issues
 No porosity formed therefore the castings are pressure tight
 Best suitable for high-integrity aluminum castings
 Improved metallurgical and mechanical properties
 Reduces fettling time and machining required
 Thinner section can be cast allowing the design of lighter, more robust
components
 High strength and ductility for the casted products.
 Advantages:

31. Cos-worth casting
• The cos worth process is used to cast non-ferrous
casting for medium to high production.
• The process is being used for casting component
mainly for aerospace and defense industries like
helicopter engines, helicopter winch drums, high
pressure refueling manifolds for tanker aircraft, gun
cradles, aluminum structural parts for airframes and
marine engines, etc.
 Application:

32. Low pressure Casting
the pressure die casting process consists of
injecting under high pressure a molten metal
alloy into a steel mold (or tool). This gets
solidified rapidly (from milliseconds to a few
seconds) to form a net shaped component. It is
then automatically extracted.
 Definition

33. Low pressure Casting
• 1-the internal cavity is spread with
lubricating material this closed , and
lubrication help to reduce the
temperature of the mold and
extracting the product
• 2-the molten metal is injected under
high pressure (10-175Mpa) , the
moment that the mold is filled the
pressure remains till the metal solidify
• 3- then the mold is opened and the part
is removed
 Process

34. Low pressure Casting
1-High speed production can be achieved as the whole process is
completely automated.
2-Possible to obtain fairly complex castings than that feasible by gravity die
casting due to the use of the movable cores.
3-Very small thicknesses can be easily filled as the liquid metal is injected
under high pressure.
4-Very good surface finish can be obtained &most of pressure die castings
can be directly electroplated without any further processing
 Advantages of Pressure Die Casting

35. Low pressure Casting
1-The die casting machines & tooling costs are very expensive.
2-Cannot be used for large castings as the casting machine capacity is limited.
3-It is not suitable for all materials because of the limitations of the die
materials & the alloys used must have a low melting point.
4-High porosity is common & heat treatment is difficult
 Disadvantages

36. Low pressure Casting

37. Names of group
And Tasks
Sayyed Khairy Salama
Die casting
Researcher
01
Hamdy hamada
Semi-solid casting
Researcher
Alsayyed fathy Khalf
Aluminum alloy
Researcher .
Shady Heshmat
Squeeze casting
Researcher
Abd-Alrhman Saleh
Sand casting
Researcher
Hussien Hamed Alsakary
Cos-Worth casting
Researcher
04
02
05
03
06
This Research
Osama Ahmed Nasr
Low pressure Casting
Researcher
07
Assem Hussien
Review Engineer08

38. References
• Aluminum Alloy Castings: Properties, Processes, and
Applications (J. Gilbert Kaufman ; Elwin L. Rooy)
• Sand Casting of Metals (Elizabeth Merten )
Department of Materials Science& Engineering
University of Washington