Quantitative Feeder Design for Metal Castings

Casting simulation packages are used to check a design for its castability. A better starting design should need fewer simulation cycles to arrive at a defect-free component thus cutting computation and manpower costs. Quantitative design of the feeding system is done by an analysis of the solidification pattern of the 3D model of the cast component. A clustering algorithm uses the solidification time/temperature data from the simulation to divide the casting into 3D feeding sections. The sections are created by following hotspots surrounded by areas of decreasing solidification time. Feeders are built by the feeder design module of AutoCAST casting design software. The initial simulation as well as the efficacy of the rigging is tested through the advanced simulation module FLOW+ of AutoCAST X. An industrial case study illustrates the software pipeline in a virtual foundry trial.

Effect of Heat Treatment on Thermal Conductivity of Aluminum Die Casting Alloys

Thermal conductivity is an important property when high heat dissipation is a requirement during the use of the cast component. This study was carried out to study the effect of heat treatment on thermal conductivity of three common aluminum die casting alloys. Measurement of thermal conductivity was done by the Hot Disk method. A substantial increase in thermal conductivity was measured as a result of heat treatment. Microstructural changes due to heat treatment was examined by optical and scanning electron microscopy.

Analysis of the Age-Hardening T5 Treatment in a Al-7%Si-0.6%Mg-0.5%Cu Rheo-Cast Alloy

The tensile properties and the microstructure of an Al-7%Si-0.6%Mg-0.5%Cu rheo-cast component were investigated. The material underwent a T5 treatment, consisting in ageing at 160, 175 and 190°C for durations ranging from 0.5 to 48h. Tensile testing indicated that the T5 treatment resulted in a relatively good level of strength and in a comparatively low ductility. In order to improve ductility, maintaining as low as possible the cost of the final component, a single solution treatment at 500°C for 4h was subsequently applied. The tensile strength and ductility of the solution treated and aged material were higher than in the T5 condition. These differences were attributed to the microstructural evolution occurring during exposure at 500°C, in particular to the spheroidization of eutectic-Si and to a more homogeneous distribution of the precipitates.