Overview
FrançaisABSTRACT
Controlling the quality of castings is an absolute imperative for both suppliers and users. This article summarizes the typical defects and their remedies, the rules of the design of parts and tools as well as the potential of the numerical simulation of filling and solidification, which has become a major tool for quality in casting.
Read this article from a comprehensive knowledge base, updated and supplemented with articles reviewed by scientific committees.
Read the articleAUTHORS
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Michel GARAT: ESPCI engineer, private consultant, former R & D director of Aluminium Pechiney casting alloys and project manager Rio Tinto Alcan, Peyrins, France
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André LE NÉZET: ESF engineer, non-ferrous alloys casting expert, Renault, Rueil-Malmaison, France
INTRODUCTION
The quality of a cast part can be defined as its ability to satisfy the requirements specified in the customer's specifications. It depends on the design of the part by the client, and on the care taken in its production by the caster, who must master a large number of manufacturing parameters.
One of the keys to achieving this quality is to recognize and describe any anomalies or defects that may occur during the casting process, so that corrective action can be taken. Defects observed in aluminum alloy castings are similar to those encountered with other metals and alloys, though with some specific features, such as their high oxidizability in the liquid state and their tendency to dissolve hydrogen. These defects are examined in the first part of the article.
Part design must take into account the casting process used. The diversity of these processes in the case of aluminum alloys implies certain basic rules, the correct application of which is a prerequisite for obtaining quality parts. Digital techniques known as "virtual prototyping", which range from dimensional calculation to simulation of filling, solidification and cooling, enable improved part design and quality, as well as a significant reduction in costs and development times. This article describes the different types of defects and their origins, the means of repair, the design rules for avoiding them, and concludes with a discussion of numerical simulation of foundry processes, a major tool for rapidly achieving satisfactory quality.
The following articles complete the subject:
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Aluminium casting: defects and part design
Bibliography
Brochures and catalogs
Éditions Techniques des Industries de la Fonderie catalog and Centre Technique des Industries de la Fonderie brochures.
International bibliographic databases
Aluminium Metadex
Reviews
France
Fonderie magazine (CTIF and ATF, monthly)
Revue de Métallurgie (monthly)
Germany
Gießerei (monthly)
Gießerei-Praxis (monthly)
Gießerei Forschung (quarterly)
United States
Modern Casting (monthly)
Foundry...
Exhibitions and congresses
World
World Foundry Congress: every two years in a different country, usually at the end of the 3rd quarter.
France
Journées d'Études de l'Association Technique de Fonderie (ATF): in France, every year.
SF2M annual days organized by the French Society of Metallurgy and Materials: every year in October....
Patents
French National Institute of Industrial Property (INPI)
A large number of patents relating to aluminum alloy casting have been filed or are in the process of being filed around the world; an exhaustive list is virtually impossible to compile due to the constant filing of new patents, which means that they have to be constantly updated.
To obtain information on a given subject at...
Standardization
French and European standards. French Standards Association (AFNOR)
Standards NF EN ISO
- Geometric product specification (GPS) – Dimensional and geometric tolerances for molded parts. - NF EN ISO 8062 - (2007) :
- Aluminium and aluminium...
NF EN standards
Theses
BRACCINI (M.). – Optimization of castings: study of hot cracking phenomena in Al-Cu alloys. INP Grenoble (2000).
SAVELLI (S.). – Identification of mechanisms and quantitative approach to fatigue of cast aluminum model alloys. INSA Lyon (2000).
EVANS (W.J.), JONES (H.V.), SPITTLE...
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