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2006)
Abstract
This study investigated the effects of squeeze parameters on the properties of
squeeze castings and the optimum parameters for producing squeeze castings from Al-Si
alloy. It also compared the properties of the squeeze castings with those of chill
castings. Squeeze castings were made from Al-8%Si alloy using pressures of 25150MPa with the alloy poured at 650o, 700o and 750oC into a die preheated to 250oC.
Squeeze time was 30s. It was found that for a specific pouring temperature, the
microstructure of squeeze castings became finer; density and the mechanical properties
were increased with increase in pressure to their maximum values while further
increase in pressure did not yield any meaningful change in the properties. Compared
with chill casting process, squeeze casting enhanced the mechanical properties; it
increased the hardness, UTS, 0.2% proof stress and elongation of the alloy to optimum
values of HRF58.0, 232MPa, 156MPa and 3.8% respectively at squeeze pressure of
125MPa and pouring temperature of 700oC. The study concluded, among other things,
that optimum pouring temperature of 700oC and squeeze pressure of 125MPa are
suitable for obtaining sound Al-8%Si alloy squeeze castings with aspect ratio not
greater than 2.5:1.
Keywords: Squeeze casting, pouring temperature, squeeze pressure, molten alloy.
Introduction
Squeeze casting, compared with
traditional sand casting which dates back to
about 2000-3500B.C. (Amstead et al. 1979;
Rao 1992), is a relatively new casting
technology. It is a technology with a very
bright future, based on its applications and
advantages. Yue and Chadwick (1996)
described squeeze casting as a casting
process in which molten metal is solidified
under the direct action of a pressure that is
sufficient to prevent the appearance of either
gas porosity or shrinkage porosity as opposed
to all other casting processes in which some
residual porosity is left. They further
observed that the process is also known,
variously as liquid-metal forging, squeeze
forming, extrusion casting and pressure
crystallisation. Squeeze casting is also called
liquid pressing (Clegg 1991).
229
15
25
26
120
140
Fig. 1. Dimensions of produced castings; dimensions are in mm
Melting of Alloy
Melting of scrap was done in a 0.3kg
capacity crucible placed inside the furnace.
Fluxing was done at about 650oC by covering
the surface of the already molten alloy with
about 2% by weight of charge of proprietary
231
Eutec tic
Al alpha
232
Fig. 2. Micrograph of Al-8%Si alloy squeeze cast at a pouring temperature of 700oC and a
squeeze pressure of 75MPa (x 125)
Al alpha
Eutec tic
Density, g/cm3
Fig. 3.
2.88
2.86
2.84
2.82
2.8
2.78
2.76
2.74
2.72
2.7
T1=650oC
T2=700oC
T3=750oC
25
50
75
100
125
150
175
Fig. 4. Squeeze pressure versus density of squeeze cast Al-8%Si alloy density
at squeeze pressure of 0.1MPa refers to those of chill castings
233
65
Hardness, HRF
60
55
50
45
T1=650oC
40
T2=700oC
35
T3=750oC
30
0
25
50
75
100
125
150
175
Fig. 5.
234
250
225
200
175
150
T1=650oC
T2=700oC
T3=750oC
125
100
0
25
50
75
100
125
150
175
Fig. 6:
Proof Stress
155
145
135
125
T1=650oC
115
T2=700oC
105
T3=750oC
95
0
25
50
75
100
125
150
175
Fig. 7.
Relationship between squeeze pressure and proof stress of squeeze cast Al-8%Si
alloy; proof stress at squeeze pressure of 0.1MPa refers to those of chill castings
235
Elongation
The results of elongation of Al-8%Si
alloy chill castings as well as squeeze castings
are shown in Fig. 8. The percentages of
elongation for the squeeze castings varied
between 2.8 to 3.8% as compared to those for
chill castings which ranged from 2.4 to 2.7%.
The percentage elongation increased for
pouring temperature of 650oC from 2.7% at
atmospheric pressure of 0.1MPa to 3.4% at
75MPa and 100MPa and finally increased to
3.6% at 125MPa and 150MPa. For pouring
temperature of 700oC, the percentage
elongation increased from 2.4 to a maximum of
Elongation , %
3.8
3.6
3.4
3.2
3
2.8
2.6
2.4
T1=650oC
2.2
T3=750oC
T2=700oC
2
0
25
50
75
100
125
150
175
Fig. 8.
Conclusions
The following conclusions were made
based on the study:
1. The density of squeeze castings
increases with increases in pressure steeply and
then gradually until it becomes almost
constant. For a given pressure the density
increases with increases in temperature.
Generally, the density of squeeze castings is
higher than those of chill castings.
2. Squeeze casting helps to refine the
microstructures of castings and, thus, leads to
better mechanical properties of the castings.
References
Amstead, B.H.; Ostwald, P.F. and Begeman,
M.L. 1979. Manufacturing Processes, 7th ed.
John Wiley, New York, NY, USA.
Askeland, D.R. 1985. The Science and
Engineering of Materials. PWS Publ.,
Boston, MA, USA.
ASTM. 1990. 1990 Annual Book of ASTM
Standards, Section 3, Vol. 3.01 - MetalsMechanical Testing; Elevated and Low
Temperature Tests; Metallography, pp.151153. Amer. Soc. Testing and Materials,
Philadelphia, PA, USA.
Bracke, P.; Schurmans, H.; and Verhoest, J.
1984. Inorganic Fibres and Composite
Materials. Pergamon Press, Oxford, UK.
Clegg, A.J. 1991. Precision Casting Processes.
Pergamon, Oxford, UK.
Franklin, J.R.; and Das, A.A. 1984. Squeeze
casting A review of the status. Brit.
Foundryman 77:.150-8.
Li, Q.F.; and McCartney, G.D. 1994. A review
of reinforcement distribution and its
measurement in metal matrix composites. J.
Mat. Proc. Technol. 41:.249-62.
Lynch, R.F.; Olley, R.P.; and Gallagher, P.C.J.
1975a. Squeeze casting of brass and bronze,
Paper No.75-90. AFS Transactions 83: 561-8.
Lynch, R.F.; Olley, R.P. and Gallagher, P.C.J.
1975b. Squeeze Casting of aluminum. Paper
No.75-122. AFS Transactions 83: 755-60.
237