Aluminum Green Sand Castings

Aluminum Green Sand Castings

Aluminum Green Sand Castings ASTM A319 Material Product Description and Process Aluminum Green Sand Castings ASTM A319 Material Production process: aluminum sand casting process Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc. Surface treatment process:...

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Aluminum Green Sand Castings ASTM A319 Material

Product Description and Process

Aluminum Green Sand Castings ASTM A319 Material

Production process: aluminum sand casting process

Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc.

Surface treatment process: anodic oxidation, Dacromet coating, powder coating etc.


Product Material and Uses

Normally produce with ZL101, ZL101A, ZL102, ZL104, ZL106, ZL107, ZL109, ASTM A356 T6, A319, A413, LM6, LM20, LM25, etc.

The aluminum casting products are widely used for electronic industry, auto-car parts, railway parts, electric motor parts, aero craft parts, watercraft parts, medical treatment equipment, communication system, other machinery components, etc. 


Aluminum Sand Casting from the Numerical Simulation Perspective

A simulation model that optimizes the process and layout of sand casting requires a complete fluid-dynamics simulation, including the change of a laminar flow of molten metal to an undesired turbulent flow. The model should also account for the natural air permeability of the mold, allowing gases and steam created by the casting process to easily escape, thanks to the good permeability of sand molds and cores. Some typical process parameters and their corresponding outcomes to be included in the model are:

The risk of inclusion in the case of a turbulent  vortex and molten metal velocity above the suggested 0.5 m/s range;

The temperature changes during the filling process in order to predict the emergence of cold shuts.

Possible overheating where the cores touch the metal caused by the low heat absorption of the sand which could result in surface defects such as sinks;

Different cooling rates as these can generate a high level of residual stress and significant casting distortion.


Mastering the Sand Casting Process through Simulation

Using engineering simulation to optimize the sand casting process for aluminum and light alloys, we can lead foundries to “zero defect” manufacturing resulting in the dimensional conformity of the objects produced. Engineering simulation can help with:

Optimizing the gating system design to avoid filling defects caused by turbulence.

Avoiding the presence of shrinkage porosities by acting on the process variables and feeder geometry right at the design stage.

Reducing casting trials.

Predicting the local microstructure and mechanical properties.

The proper evaluation of casting deformation and residual stress.

And all of this can be achieved while shortening the time to market of the final product.


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