Transcript Aluminium alloy castings: the EU StaCast guide to

Aluminium alloy castings:
the EU StaCast guide
to defects classification,
mechanical potential
and design issues
Edited by
Franco Bonollo and Giulio Timelli
Assomet Servizi Srl
AIM - Associazione Italiana di Metallurgia
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Aluminium alloy castings:
the EU StaCast guide
to defects classification,
mechanical potential
and design issues
Edited by
Franco Bonollo and Giulio Timelli
Assomet Servizi Srl
AIM - Associazione Italiana di Metallurgia
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Contents
Introduction
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The Partners of StaCast
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CHAPTER 1
Public survey on European foundries producing Aluminium alloy
castings
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1. Questionnaire for Al foundries
1.1 Background
1.2 Architecture of the Questionnaire
2. Results from Questionnaire: Companies
2.1 Number of Questionnaires correctly filled
2.2 Reliability and validity of answers received
2.3 Foundry profiles
2.4 Non-Foundries Companies and Institutions profiles
3. Results from Questionnaire: Data on Production
3.1 Production and processes
3.2 Used alloys
3.3 Application fields
3.4 Category of castings
4. Results from Questionnaire: Knowledge and use of CEN Standards
4.1 Knowledge and use of CEN Standards on Al alloys
5. Results from Questionnaire: Need for new EU Standards
5.1 New CEN Standards
6. Results from Questionnaire: Defects Analysis
6.1 Gas/Air porosity
6.2 Inclusions
6.3 Shrinkage
6.4 Cracks
6.5 Filling-related defects
6.6 Metal-Die interaction
6.7 Extent of Measurement/Quantification of defects
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7. Results from Questionnaire: Frequency of Defects
7.1 Frequency of defects
7.2 Frequency of defects and size company
7.3 Frequency of defects and process
8. Final Remarks and Reccomandations
Annex 1.1: Collection of Full Data
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1. Introduction
2. Development of a CEN Technical Report on Defect and
mperfections Classification
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2.1 Previous classifications of defects and imperfections
2.2 An improved classification of defects and imperfections
3. Survey of Defects and Imperfections
3.1 Internal Defects and Imperfections
3.2 Surface Defects and Imperfections
3.3 Geometry Defects and Imperfections
4. Dictionary of defects of die casting processes
5. References
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CHAPTER 3
Survey on Mechanical Potential of Al-based Casting Alloys
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1. Introduction
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2. Survey of Reference Dies and Castings to check Mechanical
Potential of Al Foundriey Alloys
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CHAPTER 2
Classification and Survey of Defects and Imperfections in Al-alloy
castings
2.1 High Pressure Die Casting
2.2 Low Pressure Die Casting
2.3 Gravity Die Casting
3. Survey of Stress vs Strain Curves of Al Foundry alloys cast in
Reference Dies
3.1 High Pressure Die Casting
3.2 Gravity Die Casting
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4. Current and former Standards for testing Mechanical Properties
of Al Foundry Alloys
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4.1 ASTM International B-108
4.2 AFNOR NF A 57-702
4.3 UNI 3039
5. Final Remarks
6. References
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CHAPTER 4
Guidelines for Mechanical Design of Al-alloy cast components
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1. Introduction
2. Quality and Defects & Imperfections in Al-Si alloys castings
2.1 Introduction
2.2 Quality and Defects & Imperfections
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3. Correlations among Process Parameters, Defects & Imperfections
and Mechanical behaviour in Al-Si alloys castings
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3.1 Introduction
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3.2 Influence of casting defects on microstructural and tensile
properties
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3.3 Influence of process parameters on microstructural and
tensile properties
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4.2 How to consider effect of casting defects & imperfections on
static mechanical properties
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4.3 Using Weibull statistics approach to control the reliability of
the casting
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3.4 Remarks
4. Some Guidelines for Design of Aluminium Alloys Castings
4.1 General Considerations
5. References
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