Abstract

The effects of the casting design and reduced pressure in the flask on the density of an aluminum alloy casting in the expendable pattern casting (EPC) process were investigated experimentally. An aluminum alloy plate was cast by the EPC process, and the casting density was measured in order to evaluate the casting defect. The casting density tends to decrease, as the melt velocity is higher. The reason for this may be the increase of an involvement the liquid resin by the thermal decomposition of the model to the molten metal. In the case of bottom pouring, the casting density with reduced pressure is larger than that with no reduced pressure. In the case of top pouring, the casting density was larger than that for the bottom pouring, and the effect of the reduced pressure condition was not significant. From the result of observing the casting by an X-ray computed tomography (CT) imaging, the reason for the decrease in density of the casting may be a void by the residual resin defect.

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