CONCLUSIONS

In this experimental study, the effect of temperature on the fluidity properties of the
aluminium alloy is measured by using spiral casting. The solidification behavior of cast MMCs
are also studied through the cooling curves that recorded experimentally for Al alloy (LM6) at
different modulus of the casting and compared. An attempt has been made to optimize the size of
the riser considering different sizes of plate castings (LM6 aluminium alloy) by using
conventional method (modulus method) and vector element method (VEM) based simulation
technique with experimental observations.

The following conclusions can be drawn after analyzing the data available from the experiments.

Study of Solidification Behaviour of LM6:

The eutectic solidification time changed with the modulus of the casting, the cooling curve
indicates that on decreasing the section modulus of the castings the eutectic solidification time
decreases i.e. in case of lowest modulus the eutectic solidification time is less compared to
highest modulus. This validates that the Chvorinov’s rule still applies to the solidification
process.

Study of Fluidity of LM6:

The castability of alloys is a measure of their ability to be cast with a given shape with a given
casting process. The fluidity limits the castability of alloys and their final properties, e.g., surface
finish and wall thickness. Poor or insufficient fluidity affects the soundness of cast products and
deteriorates their final quality, e.g., rejection of a shaped casting due to incomplete filling of the
mould. Due to the large production volumes involved in casting processes, small reductions in
the amount of casting defects can give large economical benefits.

Reliable fluidity data for both pure and commercial aluminium foundry alloys are not readily
available. However, such data are important in the optimization of mould filling calculations
during solidification. The term “fluidity” in the foundry is used to indicate the distance a molten
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metal can flow in a mould of a constant cross-sectional area before it solidifies. This definition is
different from the definition presented in physics which describes fluidity as the inverse of
viscosity, a fundamental temperature related property of a liquid. Fluidity testing can be carried
out in different ways. Since the first fluidity test in 1902, several equipments for fluidity testing
have been developed and modified. Currently, the most popular fluidity tests are the spiral-
shaped mould test and the vacuum fluidity test.

From the experiments it is proved that casting temperature and the thickness of cast parts are the
important parameters influencing fluidity. It is observed that on increasing the temperature the
fluidity of aluminium alloy (LM6) increases i.e. the castability of LM6 is better at higher pouring
temperature. From the results the statistical analysis enables to describe the castability by
following expressions,

L = 0.434Tp + 11.40g - 304, cm.

Where, L = Length of casting.

Tp = Pouring temperature.

g = Thickness of cast part.

Determination of Modulus method for LM6:

In Foundry, the primary way to control casting defects is through good mold design
considerations in the creation of the casting's mold, gating and risering system. The key is to
design a system that promotes directional solidification. Directional solidification, in casting
manufacture, means that the material will solidify in a manner that we plan, usually as uniformly
as possible with the areas farthest away from the supply of molten metal solidifying first and
then progressing towards the risers.

The proper design of riser /feeder required to achieve directional solidification is important
because improperly designed riser results either defective casting with shrinkage cavity or lower
yield. Hence, proper design of risering system and good control over the process parameters are
necessary for quality castings. However, the experimental routes are always better for design and
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development of mould and for arriving at the optimum process parameters. But, it is costly, time
consuming, and may be impossible in some cases. Therefore, casting simulation process is a
convenient way of proper design of risering system and analyzing the effect of various
parameters.

In steel casting, the relationship between modulus of casting and modulus of riser is Mr = 1.2Mc
but from the above experiments it has found that for LM6 (Aluminium alloy) the above relation
becomes Mr = 1.07Mc. Moreover the application of casting simulation softwares in the foundries
not only minimizes the wastages of resources but also enhances the quality and yield of castings,
which implies higher value addition and lower production cost. The simulated results are
compared to the experimental data, and it is observed that the simulated results are more or less
similar with experimental results.

Determination of neck sizes of LM6 Castings:

In sand casting process, the proper design of riser neck is also very important as like the design
of riser, as the improper design of riser neck imparts defective castings however the design of
riser is correct. So, in this experimental study the size of riser neck is optimized through casting
simulation process for aluminium alloy i.e. LM6 and also its effect in solidification behaviour of
aluminium alloy i.e. LM6 is studied.

In case of steel the neck diameter is generally 40% to 50% of riser diameter but from the above
experiments it is found that for LM6 aluminium alloy the minimum neck diameter is 35% of
riser diameter. Moreover the application of casting simulation softwares in the foundries not only
minimizes the wastages of resources required for final castings, but also improves the quality and
yield of castings, which implies higher value addition and lower production cost. The
experimental study represents the effect of sizes of risers and necks on the solidification
behaviour of the aluminium alloy castings. The simulated results are more or less similar with
experimental results.

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Determination of Shape Factor method for LM6

The NRL method is used to determine the riser size by calculating shape factor. This process is
used for steel only. From the above graph the volume of riser can be found easily as the volume
of casting is calculated from the aluminium alloy component sizes. So, for aluminium alloy we
can easily design the riser sizes by using the said graph. This data will provide a great help for
industrialists as well as academicians.

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