Effects of hollow sand mold on the microstructure and mechanical properties of a low pressure aluminum alloy casting
The hollow mold revolutionizes conventional dense mold design as it can optimize the solidification and cooling processes of casting and offer potential to improve performance of castings. In this paper, the effect of hollow mold structures on the microstructure and mechanical properties of a low pr...
| Main Authors: | , , , , |
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| Format: | Article |
| Language: | English |
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Elsevier
2024-01-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785423033343 |
| _version_ | 1827368302569062400 |
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| author | Baolin Liu Jinwu Kang Xin Yang Bo Zhang Yi Bian |
| author_facet | Baolin Liu Jinwu Kang Xin Yang Bo Zhang Yi Bian |
| author_sort | Baolin Liu |
| collection | DOAJ |
| description | The hollow mold revolutionizes conventional dense mold design as it can optimize the solidification and cooling processes of casting and offer potential to improve performance of castings. In this paper, the effect of hollow mold structures on the microstructure and mechanical properties of a low pressure thin-walled aluminum alloy conical cabin casting was investigated. A hollow mold combined by four sectors with different shell thicknesses was tactfully designed. The hollow mold structures delayed the cooling and solidification of casting. They significantly reduced the pore defect from 0.4 % to 0.03 % at the lower, from 0.68 % to 0.04 % at the middle and from 0.3 % to 0.03 % at the top, compared to dense mold. In the lower and middle areas of casting, improvements of 1.0 % and 1.1 % in mechanical properties were respectively achieved when applying 50 mm-thick-shell hollow sand molds compared with using dense sand mold, while an improvement of 1.1 % was achieved in the upper area of casting with 70 mm-thick-shell. This allows designers to create hollow molds with different shell thicknesses depending on the position in the casting to meet specific needs. For example, thin shell for the bottom to achieve high fluid flow and feeding while thick shell for the top for improved cooling. For castings with wall thickness of 10 mm–20 mm, the most effective shell thickness for the hollow mold is 50 mm–70 mm. The hollow mold provides the feasibility to differentiated semi-quantitatively control the solidification and cooling processes of castings, which can be applied in production of high-end castings in the future. |
| first_indexed | 2024-03-08T09:29:13Z |
| format | Article |
| id | doaj.art-ce617d2772724ab0b23da46b952af666 |
| institution | Directory Open Access Journal |
| issn | 2238-7854 |
| language | English |
| last_indexed | 2024-03-08T09:29:13Z |
| publishDate | 2024-01-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj.art-ce617d2772724ab0b23da46b952af6662024-01-31T05:44:22ZengElsevierJournal of Materials Research and Technology2238-78542024-01-012844884497Effects of hollow sand mold on the microstructure and mechanical properties of a low pressure aluminum alloy castingBaolin Liu0Jinwu Kang1Xin Yang2Bo Zhang3Yi Bian4School of Materials Science and Engineering, Key Laboratory for Advanced Materials Processing Technology, Tsinghua University, Beijing, ChinaSchool of Materials Science and Engineering, Key Laboratory for Advanced Materials Processing Technology, Tsinghua University, Beijing, China; Corresponding author.Beijing Hangxing Technology Development Co., Ltd., Beijing, ChinaBeijing Hangxing Technology Development Co., Ltd., Beijing, ChinaBeijing Hangxing Technology Development Co., Ltd., Beijing, ChinaThe hollow mold revolutionizes conventional dense mold design as it can optimize the solidification and cooling processes of casting and offer potential to improve performance of castings. In this paper, the effect of hollow mold structures on the microstructure and mechanical properties of a low pressure thin-walled aluminum alloy conical cabin casting was investigated. A hollow mold combined by four sectors with different shell thicknesses was tactfully designed. The hollow mold structures delayed the cooling and solidification of casting. They significantly reduced the pore defect from 0.4 % to 0.03 % at the lower, from 0.68 % to 0.04 % at the middle and from 0.3 % to 0.03 % at the top, compared to dense mold. In the lower and middle areas of casting, improvements of 1.0 % and 1.1 % in mechanical properties were respectively achieved when applying 50 mm-thick-shell hollow sand molds compared with using dense sand mold, while an improvement of 1.1 % was achieved in the upper area of casting with 70 mm-thick-shell. This allows designers to create hollow molds with different shell thicknesses depending on the position in the casting to meet specific needs. For example, thin shell for the bottom to achieve high fluid flow and feeding while thick shell for the top for improved cooling. For castings with wall thickness of 10 mm–20 mm, the most effective shell thickness for the hollow mold is 50 mm–70 mm. The hollow mold provides the feasibility to differentiated semi-quantitatively control the solidification and cooling processes of castings, which can be applied in production of high-end castings in the future.http://www.sciencedirect.com/science/article/pii/S2238785423033343Hollow moldLow pressure casting3D printingAluminum alloyCooling and solidificationMechanical properties |
| spellingShingle | Baolin Liu Jinwu Kang Xin Yang Bo Zhang Yi Bian Effects of hollow sand mold on the microstructure and mechanical properties of a low pressure aluminum alloy casting Journal of Materials Research and Technology Hollow mold Low pressure casting 3D printing Aluminum alloy Cooling and solidification Mechanical properties |
| title | Effects of hollow sand mold on the microstructure and mechanical properties of a low pressure aluminum alloy casting |
| title_full | Effects of hollow sand mold on the microstructure and mechanical properties of a low pressure aluminum alloy casting |
| title_fullStr | Effects of hollow sand mold on the microstructure and mechanical properties of a low pressure aluminum alloy casting |
| title_full_unstemmed | Effects of hollow sand mold on the microstructure and mechanical properties of a low pressure aluminum alloy casting |
| title_short | Effects of hollow sand mold on the microstructure and mechanical properties of a low pressure aluminum alloy casting |
| title_sort | effects of hollow sand mold on the microstructure and mechanical properties of a low pressure aluminum alloy casting |
| topic | Hollow mold Low pressure casting 3D printing Aluminum alloy Cooling and solidification Mechanical properties |
| url | http://www.sciencedirect.com/science/article/pii/S2238785423033343 |
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