Abstract
Squeeze casting is a pressure casting process in which molten metal is solidified under the direct action of a pressure. In squeeze casting, the relationship between the process parameters and the quality of the squeeze cast components is not fully understood; thus the need for more studies in this area of technology for better understanding of the process. The present work encompasses studying the effect of direct squeeze casting process parameters on the production of (3 and 20٪) volume fraction carbon fibers (CF) reinforced Al-Si matrix composites. The evaluated process parameters are squeeze pressure in the range (7.5-53) MPa, die preheating temperature (100,200,300)°C, pouring temperature (700,780)°C, squeeze time (30 sec.), and delay time (5 sec.). The results show a good distribution of the matrix between the carbon fibers when using higher casting pressures of (38 and 53MPa), lower pouring temperature of (700°C) and lower die temperatures of (100 and 200°C). Increasing the carbon fibers volume fraction had led to increasing the tensile strength. The using of higher pressure (53MPa), lower pouring temperature (700°C), and lower die temperature (200°C) have increased the ultimate tensile strength of the CF/Al-Si composites to (183MPa) when compared to that of the nonreinforced alloy which was (168MPa) because of the increased bonding, decreased shrinkage defects and fibers degradation based on the results. Also, UTS is increased at P=38MPa, Tp=700°C, and Td=100°C.
Highlights
The term squeeze casting can be applied to various processes in which the pressure is applied to a solidifying system, usually through a hydraulically activated ram
The results show a good distribution of the matrix between the carbon fibers when using higher casting pressures of (38 and 53MPa), lower pouring temperature of (700°C) and lower die temperatures of (100 and 200°C)
Any reactions other than those required for good bonding are usually undesirable. These composites have been marked by strengths well below those expected because at high temperature carbon fibers react with aluminum to form brittle aluminum–carbide at the interface between the fibers and aluminum matrix
Summary
The term squeeze casting can be applied to various processes in which the pressure is applied to a solidifying system, usually through a hydraulically activated ram. The widespread acceptance of carbon fiber-reinforced aluminum composite has been limited due to the various problems encountered during the fabrication of the composites [7]. It has been reported [7] that carbon fibers are difficult to be wetted by molten aluminum alloys. Any reactions other than those required for good bonding are usually undesirable These composites have been marked by strengths well below those expected because at high temperature carbon fibers react with aluminum to form brittle aluminum–carbide (hexagonal Al4C3 structure) at the interface between the fibers and aluminum matrix. The aim of this research is to preparing the carbon fibers reinforced Al-Si composites by squeeze casting and studying its tensile strength
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