In the present work, the fatigue behavior of lost foam cast aluminum alloy 356, in conditions T6 and T7, was investigated, under both zero and non-zero mean stress conditions, with either as- cast or machined surface finish. Lost foam casting is a highly versatile metalcasting process that offers significant benefits in terms of design flexibility, energy consumption, and environmental impact. Stress ratio effects in fatigue of lost foam cast aluminum alloy 356 In so doing, this method enables the sand to better support the refractory coat under metallostatic pressure during filling of the mold with molten metal. In comparison with the conventional method of sand filling and compaction, this method affords more nearly complete filling of the space around the refractory-coated foam mold pattern and more thorough compaction of the sand.
Overfelt, Ruel A.Īn improved method of filling a molding flask with sand and compacting the sand around a refractory-coated foam mold pattern has been developed for incorporation into the lost-foam metal- casting process. Improved Sand-Compaction Method for Lost-Foam Metal Castingīakhtiyarov, Sayavur I. With the increased emphasis on vehicle weight reduction, and given the high-strength-to-weight-ratio of magnesium, significant weight savings can be achieved by casting thin-wall (≤ 3 mm) engineering components from both aluminum- and magnesium-base alloys.« less Very limited research work has been performed with Al-Mg and Al-Cu type alloys. Most of the aluminum alloys poured using the lost foam process are based on the Al-Si system. Some of the unique advantages of using the lost foam casting process are closer dimensional tolerance, higher casting yield, and the elimination of sand cores and binders. This is especially true in Al-Mg and Al-Cu alloy systems that are prone to hot tearing when poured in rigid molds partially due to their longmore » freezing range. The use of un-bonded molding media in the lost foam process will impose less constraint on the solidifying casting, making hot tearing less prevalent. The lost foam casting process is a cost effective method for producing complex castings using an expandable polystyrene pattern and un-bonded sand. With the increased emphasis on vehicle weight reduction, production of near-net shape components by lost foam casting will make significant inroad into the next-generation of engineering component designs.
Energy-Saving Melting and Revert Reduction Technology (E-SMARRT): Lost Foam Thin Wall - Feasibility of Producing Lost Foam Castings in Aluminum and Magnesium Based AlloysĭOE Office of Scientific and Technical Information (OSTI.GOV)
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