Casting of Aluminum Alloy and Porous Metal

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (31 December 2022) | Viewed by 6249

Special Issue Editors


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Guest Editor
Faculty of Materials Science and Technology, VSB—Technical University of Ostrava, 708 00 Ostrava, Czech Republic
Interests: special casting methods; non-ferrous metals; aluminum alloys; metallic foams; foundry technology

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Guest Editor
Faculty of Materials Science and Technology, VSB—Technical University of Ostrava, 708 00 Ostrava, Czech Republic
Interests: special casting methods; non-ferrous metals; metallic foams; foundry technology

Special Issue Information

Dear Colleagues,

Aluminum and its alloys hold an important position among other non-ferrous metals due to their good physical and mechanical properties that predestine aluminum to be the most advantageous material for various application fields. In recent decades, the importance of aluminum alloy castings has increased, leading to the necessity to develop new diverse foundry processes and methods for production and, at the same time, enhance the properties of the manufactured aluminum alloys. Expanding the use of porous metals or metal foams with both artificially made closed or interconnected internal cavities—the pores—in their structure with different layouts, shapes, and sizes is providing new opportunities for foundry aluminum alloys to be a leading material for various applications. Their valued attributes result from the advantageous combination of aluminum alloy properties with the porous metal material qualities, and examples of these include high stiffness at low weight, sufficient strength or high breathability at high thermal conductivity, the ability to absorb impact energy, and acoustic damping ability.

This Special Issue will be devoted to theoretical and experimental observations in the field of simulations, research, and development of aluminum alloys for foundry purposes, with the aim of gathering and presenting advances in the numerous production technologies for aluminum castings and to address various aspects of their use in the field of porous metals. Articles from the academic or industrial sector that deal with the development of foundry production technologies for porous metals and metal foams, along with examination of their structure and properties, will also be highly appreciated.

Dr. Petr Lichý
Dr. Ivana Kroupová
Guest Editors

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Keywords

  • foundry
  • casting
  • aluminum alloy
  • metallic foam
  • porous metal
  • cellular structure

Published Papers (4 papers)

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Research

14 pages, 12762 KiB  
Article
Influence of HPDC Process Parameters on the Microstructure of EC Electromotor Housing
by Marek Brůna, Martin Medňanský, Marek Matejka and Radka Podprocká
Metals 2023, 13(2), 295; https://doi.org/10.3390/met13020295 - 01 Feb 2023
Viewed by 1359
Abstract
The mechanical properties of high-pressure die-casted parts are directly influenced by their microstructure. This article aims to evaluate the effect of the fast-shot speed on the structural component and overall microstructure for two geometrically different castings. The material used during experimental works is [...] Read more.
The mechanical properties of high-pressure die-casted parts are directly influenced by their microstructure. This article aims to evaluate the effect of the fast-shot speed on the structural component and overall microstructure for two geometrically different castings. The material used during experimental works is commonly known as the AlSi9Cu3(Fe) alloy. For experimental purposes, numerical simulations, microstructural and EDS analysis, the DAS index, length of eutectic Si plates and more were implemented. The simulations have shown the possibility of air entrapment in the filling chamber. Oxides, and consequently microporosity, were localized, which led to the selection of critical points of the casts for further observation and evaluation. With the use of the optical/scanning microscope and microhardness evaluation, the fast-shot speed value of 3.6 m.s−1 was selected as the most advantageous. Full article
(This article belongs to the Special Issue Casting of Aluminum Alloy and Porous Metal)
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15 pages, 5443 KiB  
Article
High-Speed and Low-Load Twin-Roll Casting of Al–5%Mg Strip
by Kazuki Yamazaki and Toshio Haga
Metals 2023, 13(1), 72; https://doi.org/10.3390/met13010072 - 27 Dec 2022
Cited by 2 | Viewed by 1364
Abstract
A conventional twin-roll caster usually casts strips at a speed slower than 2 m/min and a roll load greater than 2 kN/mm. A vertical-type high-speed twin-roll caster can cast aluminum alloy strips at a speed higher than 10 m/min and a roll load [...] Read more.
A conventional twin-roll caster usually casts strips at a speed slower than 2 m/min and a roll load greater than 2 kN/mm. A vertical-type high-speed twin-roll caster can cast aluminum alloy strips at a speed higher than 10 m/min and a roll load smaller than 550 N/mm due to the effect of the large thermal conductivity of copper alloy rolls, compared with that of steel rolls. However, the properties of an aluminum alloy strip cast at a roll load smaller than 140 N/mm and at a roll speed higher than 30 m/min are not clear. In this study, Al–5%Mg strips were cast at a roll speed of 30 m/min and roll loads of 2 and 88 N/mm using a vertical-type high-speed twin-roll caster. The effects of roll load on cracking at the strip surface, the tensile mechanical properties, and the microstructure were investigated. Rotating rolls were stopped during casting, and the progression of centerline segregation and the microstructure between the rolls was investigated. Centerline segregation and surface cracking were lower at 2 N/mm than at 88 N/mm. In the strip cast at 2 N/mm, elongation in the width direction was greater than that cast at 88 N/mm, due to decreased surface cracking. The results demonstrate that a very low roll load improves the properties of the cast strip. Full article
(This article belongs to the Special Issue Casting of Aluminum Alloy and Porous Metal)
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14 pages, 2901 KiB  
Article
Casting Process at Roll Bite in Strip Cast Using Vertical-Type High-Speed Twin-Roll Caster
by Toshio Haga and Yukihiro Kurahashi
Metals 2022, 12(7), 1169; https://doi.org/10.3390/met12071169 - 09 Jul 2022
Cited by 6 | Viewed by 1311
Abstract
The solidification process in strip casting using a vertical-type high-speed twin-roll caster was clarified by inserting a 0.1 mm diameter K-type thermocouple into a strip during casting. The roll speeds of the copper rolls were 10 m/min and 30 m/min, and the roll [...] Read more.
The solidification process in strip casting using a vertical-type high-speed twin-roll caster was clarified by inserting a 0.1 mm diameter K-type thermocouple into a strip during casting. The roll speeds of the copper rolls were 10 m/min and 30 m/min, and the roll loads were 5 kN and 20 kN. Al-Si alloys with a Si content of 2%, 6%, and 12% were used to investigate the influence of latent heat and viscosity in the semisolid state. The strip temperature increased after exiting the rolls. This indicated that the inside of the strip had not completely solidified at the roll bite, and secondary cooling was necessary to rapidly solidify the inside of the strip. The distance from the roll bite to the solidification starting position ranged from 30 mm to 63 mm. The cooling rate and degree of supercooling increased as the Si content decreased. The cooling rate ranged from 400 °C/s to 4000 °C/s. The cooling rate and degree of supercooling decreased as the viscosity of the semisolid increased. Full article
(This article belongs to the Special Issue Casting of Aluminum Alloy and Porous Metal)
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15 pages, 3869 KiB  
Article
Use of Molding Mixtures for the Production of Cast Porous Metals
by Ivana Kroupová, Martina Gawronová, Petr Lichý, Václav Merta and Filip Radkovský
Metals 2022, 12(7), 1134; https://doi.org/10.3390/met12071134 - 01 Jul 2022
Cited by 2 | Viewed by 1374
Abstract
This paper aims to present the possibility of producing cast porous metals (or metallic foams) in a low-tech way by the use of conventional foundry technologies, i.e., the common procedures and materials. Due to the technological and economic complexity of the production processes [...] Read more.
This paper aims to present the possibility of producing cast porous metals (or metallic foams) in a low-tech way by the use of conventional foundry technologies, i.e., the common procedures and materials. Due to the technological and economic complexity of the production processes of cast metallic foams, research into this material currently focuses on the development of less demanding technologies. The introduction of such production processes may help to exploit the full application potential of metallic foams. Within the framework of our proposed procedure, molding and core mixtures are used for the production of molds and filler material (space holder), also called precursors. It is the shape, size, and relative position of the individual precursors that determines the shape of the internal structure of the resulting metallic foam. The core mixture for the production of precursors is evaluated in terms of changes in properties with respect to storage time. Attention is focused on one of the most common bonding systems, furan no-bake. Casting tests are carried out for the possibility of making cast porous metals from aluminum alloy with different shapes of internal cavities depending on the different shapes of the filler material. The collapsibility of the cores after casting is evaluated for the test castings. The results show that even using commonly available materials and processes, cast metallic foams with complex internal structures can be produced. Full article
(This article belongs to the Special Issue Casting of Aluminum Alloy and Porous Metal)
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