Abstract
In this paper, the design and application of permanent mold casting technology reserving a significant place in the light alloy casting technology was conducted due to its convenience for mass production and industrial need. The metal tensile bar mold design, mold preheat temperature (100°C-150°C-200°C), thermal stress, fatigue and damage analyses were examined to be used in the casting experiments by using the finite element analysis. As well as the casting temperature and solidification time, the material flow analyses were conducted by using a computer-aided program. By producing the mold following the modeling and analyses studies, AA7075 aluminum alloy was melted at 800°C and casted in the permanent mold. Following the casting procedure, the tensile bars of aluminum alloys were prepared in conformity with the standards and their tensile and hardness tests were conducted. The general and fracture surface microstructure differences of experiment specimens were examined. As a result of modeling and analysis studies made in the computer environment, the surface stresses of specimen and runner regions which were significant in the mold design were calculated at 100, 150 and 200°C preheating temperatures. The most convenient mold lifetime was calculated by making fatigue calculations for permanent mold at 800°C. DOI: http://dx.doi.org/10.5755/j01.mech.24.4.19752
Highlights
The aluminium and its alloys are used in various casting-forging forming works and at heat treatment conditions
The metallic mold design was made by aiming at a single tensile test bar to use in the modelling and analyses of cast mold before the practices of melting and casting in the permanent mold (Fig. 3)
The post-melting and post-casting hardness measurements of aluminium alloy were conducted with REICHERTER brand BL 3 model test device pursuant to TS 139-1 EN ISO 6506-1 0 standards
Summary
The aluminium and its alloys are used in various casting-forging forming works and at heat treatment conditions It has been taking place in the metal market along with the iron and steel for more than 70 years. The permanent molds used in molding the aluminium alloys typically include a wide range of materials from a gray cast iron to high resistant tool steel. The demand for use of permanent mold technology has been gradually increasing [11] The programs such as cast modeling and analysis, etc. The permanent mold was produced following thermal stress, fatigue life and damage analyses with the permanent mold technology, tensile test bar mold design, modelling and analysis studies in the casting of Al alloys. The microstructure and mechanical properties of AA 7075 aluminium alloy after melting and casting process were examined
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