Mould Filling Ability Characterisation of Cast Aluminium Alloys Using Design of Experiments

Abstract

Mould filling ability characteristic has been influencing the liquid metal flow, heat transfer, and solidification there by affecting the quality of aerospace castings. Mould filling is a critical parameter in the production of sound and quality castings, especially in the case of complex-shaped castings where section thickness is varying considerably. The mould filling ability of aluminium alloys LM6 and LM25 has been studied in the present investigation. Experimentation has been carried out using orthogonal array experimental layout. The process parameters studied in the present investigation are alloy composition, sand fineness, mould coating, and pouring temperature. The mould filling ability of selected aluminium alloy has been studied using pin test piece with cylindrical cores. The results from experimentation are analyzed to find the influence of the process parameters on mould filling ability. Based on the above, LM6 alloy has been found to have better mould filling ability characteristics and the analysis of variance has also revealed the same optimum factor combination.