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AC4C
AC4C
2578 to 2583
#2009 Japan Foundary Engineering Society
National Institute of Advanced Industrial Science and Technology, Nagoya 463-8560, Japan
Kotobuki Kinzoku Kogyo Co. LTD., Seki 501-3928, Japan
The gravity die casting of the AC4C aluminum alloy was conducted when mechanical vibration was incorporated. The specimen with a
specication of 25 mm in diameter and 210 mm in length were solidied at various vibration frequencies so as to examine the eect of the
vibration on the grain size, the casting defect distribution, and mechanical properties. In comparison with the grains formed in the as-cast state
without vibration, the grains in the inner area of a specimen became ner after mechanical vibration. The columnar structure remained in its
outer region under all vibration frequency. The average density of specimen increased by imposition the mechanical vibration. The casting
defects involved in the specimen reduced and became smaller with the increase of vibration frequency. The scattering in mechanical properties
of specimens cast with mechanical vibration decreased because of the decrease in casting defects. [doi:10.2320/matertrans.F-M2009822]
(Received June 26, 2009; Accepted July 30, 2009; Published September 30, 2009)
Keywords: mechanical vibration, aluminum, alloy, casting defect, mechanical properties, rening, X-ray computed tomography
1.
Introduction
rene and homogenize the macrostructure and the microstructure. But, these grain rening agents induce some
problems not only in production but also in recycling. In
production, both the grain rening agent and the addition
process increase the cost of the nal product. In recycling, on
the other hand, the separation or removal of grain rening
agents becomes dicult and it is a cost-added process.
Because of the increasing concern on resource saving, energy
saving, and recycling, a new process to rene and homogenize the cast structure is required. The increase in solidication rate and the imposition of vibration or agitation68)
are known as a method to rene and homogenize the castings
structure.
The gravity and low-pressure die castings are mainly
applied to large and thick products, so it is dicult to
increase the solidication rate due to the thermal extraction
constraints. Regarding vibration and agitation processes,
ultrasonic vibration process,9,10) electromagnetic stirring
process,11,12) electromagnetic vibration process,13,14) and
mechanical vibration process have been reported. In the
ultrasonic vibration process, vibration area is very narrow,
and it is necessary to insert and remove the ultrasonic horn in
each casting. So the apparatus and casting process become
more complex. In the electromagnetic stirring and the
electromagnetic vibration, a huge equipment to generate
the magnetic eld is required, and the shape and size of
products are limited due to the size of an induction coil and a
magnet. In mechanical vibration process, on the other hand, a
large or special device is not needed and the mechanical
vibration can be readily imposed.
In this study, the columnar AC4C aluminum alloy rods
were cast using the gravity die casting technique when
mechanical vibration was imposed at the frequency range of
0157 Hz. The eects of mechanical vibration on grain size,
distribution of casting defects, and mechanical properties
were investigated.
Eects of Mechanical Vibration on Macrostructure and Mechanical Properties of AC4C Aluminum Alloy Castings
Movable mold
Fixed mold
2579
Riser side
Fixed base
Movable base
Pouring
cup
Riser
(>64.48)
7
6
140.01
Spring
Sprue
4
3
2
1
Product
(25 210mmL)
50 60 (80.52)
Vibrator
Vibration
(>R15)
22
Spring
Gate
Runner
Vibrator
(a) castings
65
Gate side
Fig. 2 Schematic drawing of (a) castings and (b) a tensile test specimen.
Vibration
2.2
Air pressure
(MPa)
0.2
0.3
0.4
0.47
Centrifugal force
(kN)
0.7
0.97
1.23
1.37
Frequency
(Hz)
112
132
148
157
Table 2
Si
Mg
Ti
Fe
Ni
Cu
Zn
Al
6.66
0.320
0.006
0.112
0.001
0.003
0.024
Bal.
2.
Experimental Procedure
2580
N. Omura et al.
1mm
Fig. 3 (a) A typical X-ray CT image of as-cast specimen and (b) the cross-sectional photograph corresponding to the area (a). (c) and (d)
show the enlarged view of the area with defects.
3.
Results
Figure 4 shows typical macrostructures of castings fabricated with or without mechanical vibration. In the specimen
cast without mechanical vibration, as shown in Fig. 4(a),
columnar structure and granular structure are observed in
their outer and inner region respectively. Similarly, in the
specimens cast with mechanical vibration, a mixed structure
consisting of columnar in the outer region and granular in the
inner region is observed. As seen above, there is no clear
dierence on the macrostructure by the addition of the
mechanical vibration. On the other hand, the grain size is
strongly aected by the mechanical vibration. By applying
vibration, the grain size, especially the granular structure
in the inner area becomes small. However, in this study, a
clear grain size reduction by the increase of the vibration
frequency is not observed.
Figure 5 presents the density of as-cast specimens at
dierent vibration frequency. The calculated density of this
material estimated by the chemical composition measured
using spectroscopic analysis is 2679 (kg/cm3 ) and is indicated by the solid line in the Fig. 5. The density of the
specimen cast without vibration varies with positions and
indicates a remarkably low value at some positions. In the
specimens cast with vibration, the position of very low
Eects of Mechanical Vibration on Macrostructure and Mechanical Properties of AC4C Aluminum Alloy Castings
(a) 0 Hz
(b) 112 Hz
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(c) 132 Hz
5mm
(d) 148 Hz
(e) 157 Hz
Fig. 4 Macrostructures of specimens cast under dierent vibration frequencies of (a) 0 Hz, (b) 112 Hz, (c) 132 Hz, (d) 148 Hz and
(e) 157 Hz.
riser side
2690
Calculated value (2679)
Density, /kgm-3
2680
Position
1 (gate side)
2
3
4
5
6
7 (riser side)
Average
2660
2650
2640
2670
112
132
148
157
Frequency, f/Hz
Fig. 5
the solidied shells form and grow at the surface of riser and
pouring cup.15) In this process, it is also considered that the
riser works eectively because the formation and growth of
the solidied shell are inhibited by vibration.
Figure 7 represents the ultimate tensile strength (UTS) and
the elongation of as-cast specimens. It should be noted that
the UTS and the elongation of specimens at 0 Hz scattered
widely. On the other hand, the UTS and the elongation of
specimens cast with vibration hardly scatter. Furthermore,
these properties slightly increase by the imposition of
mechanical vibration. The UTS and the elongation of
vibrated specimen are independent on the vibration frequency, and about 170 MPa and 4.5%, respectively.
112Hz
157Hz
4.
Discussion
N. Omura et al.
200
10.0
180
9.0
160
8.0
140
7.0
120
6.0
100
5.0
80
4.0
3.0
60
40
U.T.S
Elongation
20
Elongation, /%
U.T.S, u /MPa
2582
2.0
1.0
0.0
0
0
112
132
148
157
Frequency, f/Hz
Conclusions
5mm
5mm
(a) Fracture surface
Fig. 8 (a) Fracture surface of the specimen cast without vibration after tensile test. (b) X-ray CT image corresponding to fracture area (a).
The dotted circle shows the size of specimen for tensile test.
Eects of Mechanical Vibration on Macrostructure and Mechanical Properties of AC4C Aluminum Alloy Castings
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