It is well established that the quality of the metal used to cast aluminium components has a large impact on the quality of the finished product, especially in relation to the mechanical properties and aesthetic appearance of the castings. The scope of the research presented in this paoper aims to investigate the sensitivity of casting performance to the quality of the metal used at a large scale manufacturing plant of A356 aluminium alloy road wheels. The effect of filtration of the metal prior to casting was quantified by conducting a series of casting trials using different filtration technologies and examining the resulting casting rejection rates to deterime any advantages. Effectiveness of the filters was also achieved by microscopically examining the used filters to determine the level of inclusion capture, and hence, to what extent they were refining the molten metal during casting. It was confirmed that the use of a sprue mesh at the entrance to the casting die effectively removes oxide film inclusions from the metal stream during casting, and can also act as a form of reinforcement during solidification. The use of ceramic foam filtration during the continual long term casting trial lead to a 63% reduction in the occurrence of leaking rims in the alloy wheels investigated. This clearly demonstrates the importance of making an effort to prevent oxide films from entering the castings in reducing the rate of costly rejects.
Quantifying the effects of filtration on the quality of low pressure permanent mould cast aluminium alloy wheels
Quantifizierung der Filterwirkung zur Qualitätsverbesserung beim Niederdruckkokillengießen von Aluminiumgussrädern
2003
12 Seiten, 9 Bilder, 3 Tabellen, 13 Quellen
Aufsatz (Konferenz)
Englisch
Cast aluminium alloy wheels for heavy duty trucks
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