Effect of pouring temperature on hot tearing susceptibility of Al-Cu cast Alloy: Casting simulation

Abstract

Al-Cu alloy more prone to hot tear in the foundry metals in casting process. It is widely using in structural, aerospace, marine and automotive industry. Defect-free casting is being challenge in the foundry. In the present investigation, the hot tearing of the molten Al-Cu cast alloy is reported by varying the pouring temperature at 700 °C, 750 °C and 780 °C by means of casting simulation. It has a direct impact on production cycle time, casting internal quality, material utilization, and gating design optimization. Simulation was performed by AutoCAST-X software; it enables directional solidification and feed metal paths. In the simulation set up have been considered green sand mould system with the wooden pattern, and the steel metallic cores are facilitated in the cavity to contrast the temperature while solidification process; as a result pouring temperature is subject to crack susceptibility. The results revealed that the dependence on pouring temperature is a key factor for the prediction of hot tearing susceptibility. The microscopic cracks were observed in casted part by simulation. The Casting simulation forecast the hot spot zone in casting solidification process to facilitate the riser for compensation of shrinkage allowance of molten metal. Simulation enhances the material utilization, quality of casting, productivity and optimization of gating design. The relation of pouring temperature was developed with solidification time.