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AVAILABLEONLINEATWWWSCIENCEDIRECTCOMSCIENCEDIRECTMATERIALSTODAYPROCEEDINGS420171098710993WWWMATERIALSTODAYCOM/PROCEEDINGSAMMMT2016MECHANICALCHARACTERIZATIONANDMICROSTRUCTUREANALYSISOFALC3550BYSANDCASTING,DIECASTINGANDCENTRIFUGALCASTINGTECHNIQUESSANTOSHMV,SURESHKR,KIRANAITHALSDEPARTMENTOFMECHANICALENGINEERING,NMITBANGALORE,KARNATAKA,INDIAABSTRACTAMMMT2016KEYWORDSDIECASTINGSANDCASTINGCENTRIFUGALCASTINGMECHANICALANDSLIDINGWEARPROPERTIES1INTRODUCTIONALUMINUMISLIGHTANDPOSSESSESHIGHSTRENGTHITISANIMPORTANTMETALINAUTOMOTIVEANDAEROSPACEINDUSTRIESGENERALLYPUREALUMINUMDOESNOTFITTHESTANDARDSOFTHEINDUSTRIES,THEREFORE,THEYAREALLOYEDWITHSILICON,COPPER,MAGNESIUMANDMANYOTHERMETALSTOINCREASESTRENGTHANDOTHERPROPERTIESONTHEALUMINUMAMONGTHEMALSICUMGALLOYSYSTEMISONETHEMALSICUMGSYSTEMISTHEMOSTUSEDALLOYGROUPINTHEINDUSTRIESBECAUSEOFEXCELLENTCASTABILITYANDMECHANICALPROPERTIESTHEAPPLICATIONSAREFROMAEROSPACETOAUTOMOBILETOHOUSEHOLDINDUSTRIESTHEREFORETHISALLOYSYSTEMISVERYIMPORTANTAMONGTHEMC3550INONETHEALLOYTHEMAINALLOYINGINGREDIENTARESILICONANDCOPPER,THEINCREASEINSILICONCONTENTWILLINCREASETHEHARDNESSOFTHEALLOYINTHISSTUDY,MECHANICALPROPERTIESOFALUMINIUMALLOYC3550WASINVESTIGATEDFORSANDCASTING,DIECASTINGANDCENTRIFUGALCASTINGTECHNIQUEMECHANICALPROPERTIESLIKETENSILETESTWASPERFORMEDUSINGPC2000SOFTWARE,ANDBRINELLHARDNESSTESTWASPERFORMEDDIECASTINGWASOBSERVEDTOHAVEGOODTENSILEANDHARDNESSPROPERTIESCOMPAREDTOSANDANDCENTRIFUGALCASTINGSMICROSTRUCTUREANALYSISWASDONEBYNIKONMICROSCOPELV150WITHCLEMAXIMAGEANALYSERFROMTHEOBSERVATIONDIECASTINGHADUNIFORMDISTRIBUTIONOFSILICONWEARBEHAVIOROFTHEALLOYSTUDIEDUSINGSLIDINGWEARTESTGOODWEARSPECIFICWEARRATEWASFOUNDINALLTHECASTINGBUTTHEBESTWASOBSERVEDINDIECASTINGAT20NLOAD2017ELSEVIERLTDALLRIGHTSRESERVEDSELECTIONANDPEERREVIEWUNDERRESPONSIBILITYOFADVANCEDMATERIALS,MANUFACTURING,MANAGEMENTANDTHERMALSCIENCE221478532017ELSEVIERLTDALLRIGHTSRESERVEDSELECTIONANDPEERREVIEWUNDERRESPONSIBILITYOFADVANCEDMATERIALS,MANUFACTURING,MANAGEMENTANDTHERMALSCIENCEAMMMT2016CORRESPONDINGAUTHORTEL919481188859EMAILADDRESSSANTOSHMV9632GMAILCOM10988SANTOSHMV/MATERIALSTODAYPROCEEDINGS420171098710993SYSTEMANDINCREASEINCOPPERUPTOSTRENGTHYIELDANDULTIMATEINCREASED110,13ALSOWITHTHEINCREASEINLOADANDSLIDINGDISTANCEVOLUMELOSSINCREASEDBUTFRICTIONCOEFFICIENTWASCONSTANTFORTHESLIDINGDISTANCE,BUTALSOFRICTIONCOEFFICIENTDIMINISHESWITHLONGERSLIDINGDISTANCE11,12INTHISPAPER,ANATTEMPTISMADETOCOMPAREMECHANICALCHARACTERISTICSOFDIFFERENTCASTINGTECHNIQUESTHATAREGENERALLYUSEDININDUSTRIESNAMELYGRAVITYDIECASTING,SANDCASTINGALSOSINCEINAUTOMOTIVEINDUSTRIESFRICTIONWEARPLAYSANIMPORTANTROLESLIDINGWEARBEHAVIORAREALSOANALYZED2MATERIALSTHECHEMICALCOMPOSITIONOFALUMINUMALLOYC3550ISSHOWNINTHETABLE1PROPERTIESOFALUMINUMARESHOWNTABLE2ALUMINUMHASAFCCCRYSTALSTRUCTUREWITHLATTICEPARAMETERSA0405NMANDATOMICRADIUSR0143NMALUMINUMC3550ISAHYPOEUTECTICALLOYBECAUSEWTOFSILICONISLESSTHAN12TABLE1CHEMICALCOMPOSITIONOFC3550ALLOY,WTELEMENTSWTCU132MG034SI505FE015MN001NI002ZN001PB001SN001TI001OTHERTOTAL005AL9305TABLE2PROPERTIESOFALUMINUMPROPERTIESVALUESDENSITY267G/CC3MELTINGPOINT557613CELASTICMODULUS724GPAPOISSONSRATIO0333METHODOLOGY31CASTINGTECHNIQUESFABRICATIONOFTHEALLOYWASCARRIESOUTINTHREECASTINGTECHNIQUESNAMELYGRAVITYDIECASTING,SANDCASTINGANDCENTRIFUGALCASTINGTHEALLOYWASMELTEDTO800CINAGRAPHITECRUCIBLEFORGRAVITYDIECASTINGADIEOFDIAMETER12MMHEIGHTOF25MMWASUSEDINSANDCASTINGMOLDWITHDIAMETER12MMANDHEIGHTOF15MMWASPREPAREDANDMOLTENMETALWASPOUREDTOOBTAINCASTINGINCENTRIFUGALCASTINGACYLINDERWASOBTAINEDOFOUTSIDEDIAMETER60MMANDHEIGHT120MM32MICROSTRUCTURESTUDYTHESURFACEFORMICROSTRUCTURESTUDYWASPREPAREDBYETCHINGASURFACEUSING220,400,600,AND1000GRADEPAPERSANDFURTHERPOLISHEDBYKELLERSSOLUTIONIE,05OFHFIN50MLOFH2OITWASOBSERVEDUSINGNIKONMICROSCOPELV150WITHCLEMEXIMAGEANALYSERSANTOSHMV/MATERIALSTODAYPROCEEDINGS4201710987109931098933TENSILETESTTHETENSOMETERUSEDWASRUNBYDCSERVOMOTORSANDACCOMPANIEDWITHPC2000SOFTWAREFROMTHEOBTAINEDCASTINGTENSILESPECIMENWEREMACHINEDACCORDINGTOASTME8STANDARDSTHEDIMENSIONSAREGAUGEDIAMETER625MMANDGAUGELENGTHOF25MMWITHOVERALLLENGTH50MM34WEARTESTWEARSPECIMENWEREMACHINEDACCORDINGTOASTMG99STANDARDSDRYSLIDINGWEARTESTWASCONDUCTEDDIFFERENTLOADCONDITIONSATROOMTEMPERATURETHEDIAMETERWASOF10MMANDLENGTH30MMTHESURFACEETCHEDWITH600GRADEPAPERTOFITSTANDARDSOFTHEPINONDISCAPPARATUSUSEDINTHEINVESTIGATION35HARDNESSTESTHARDNESSTESTWASCONDUCTEDUSINGBRINELLHARDNESSEQUIPMENTWITHLOAD250KGFWITHINDENTATIONBALLDIAMETER10MMWASAPPLIEDFOR30SECTHEINDENTATIONWASMADEONTHESURFACEWHICHASMEASUREDBYTRAVELINGMICROSCOPEANDBHNWASCALCULATEDBYTHEMEASUREDINDENTATIONS4RESULTSANDDISCUSSIONS41MICROSTRUCTUREEVALUATION411DIECASTINGINDIECASTINGTHESILICONPARTICLESAREUNIFORMDISTRIBUTEDAMONGTHEPRIMARYPHASEANDALMATRIXISFOUNDFIG1SHOWSTHEUNETCHEDSURFACEOFTHEASCASTOBTAINEDTHESIZEOFDENDRITESIZEANDINTERDENDRITEARMSPACINGISSMALLBECAUSEOFFASTERANDUNIFORMCOOLINGRATEASSHOWNINFIG2FIG1UNETCHEDSURFACEOFDIECASTINGAT100XFIG2KELLERSETCHEDSURFACEOFDIECASTINGAT100X412SANDCASTINGTHEFIG3SHOWSTHEUNETCHEDSURFACEOFTHESANDCASTINGTECHNIQUEFROMTHEOBSERVATIONOFFIG4THEDARKDOTSARETHEEXISTENCEOFTHEPOROSITYANDIMPURITIESDURINGCASTINGPROCESSFROMFIG4ITISOBSERVEDTHATTHEDENDRITICANDINTERDENDRITESPACEISSMALLTHEINVESTIGATIONOFFIG4THESOLIDSOLUTIONOFALMATRIXISFOUNDANDANINTERMETALLICSECONDARYPHASEOFSITHESIPHASEISOBSERVEDASLARGEFLAKES,NEEDLESANDFIBROUSPRECIPITATIONS10990SANTOSHMV/MATERIALSTODAYPROCEEDINGS420171098710993FORTHEVARIATIONOFCUCONCENTRATIONSINCETHESINEEDLESEXISTTHEREARECHANCESOFNOTCHINGTOOCCURWHICHDECREASESTHEMECHANICALPROPERTIESFIG3UNETCHEDSURFACEOFSANDCASTINGAT100XFIG4KELLERSETCHEDSURFACEOFSANDCASTINGAT100X413CENTRIFUGALCASTINGPOROSITYINCENTRIFUGALCASTINGISSHOWNINTHEFIG5THESILICONISUNEVENLYDISTRIBUTEDINTHEPRIMARYPHASEALARGEAMOUNTOFAL2CUISFORMEDINTHESECONDARYPHASEALONGWITHALMATRIXSINCETHESINEEDLESEXISTTHEREARECHANCESOFNOTCHINGTOOCCURWHICHDECREASESTHEMECHANICALPROPERTIESTHEDARKSPOTSINFIG6SHOWSSCATTEREDMAGNESIUMFIG5UNETCHEDSURFACEOFCENTRIFUGALCASTINGAT100XFIG6KELLERSETCHEDSURFACEOFCENTRIFUGALCASTINGAT100XSANTOSHMV/MATERIALSTODAYPROCEEDINGS4201710987109931099142HARDNESSTESTFIG7HARDNESSTESTBHNWASCALCULATEDBYMEASURINGTHEINDENTATIONDIAMETERWHICHWASMADEONTHESURFACEANAVERAGEWASTAKENOFTHREEINDENTATIONSANDSHOWNFIG7CENTRIFUGALCASTINGHADHIGHHARDNESSBECAUSEITWASFOUNDTOBEDUCTILEINNATUREWHENCOMPAREDTODIECASTINGWHICHHADLEASTHARDNESSWHICHGOODDUCTILEPROPERTYASSHOWNINSECTION4343TENSILETESTFIG8SHOWSTHEVARIATIONINTHESTRENGTHOFCASTINGSFABRICATEDBESTSTRENGTHWASOBTAINEDINGRAVITYDIECASTINGANDWORSTINCENTRIFUGALCASTINGUNIFORMDISTRIBUTIONOFSILICONANDLESSIMPURITIESANDGOODCASTINGTECHNIQUESINCREASEDTHESTRENGTH,WHEREAS,POROSITY,BLOWHOLESPRESENTINCENTRIFUGALCASTINGHADLEASTSTRENGTHONTHEOTHERHAND,INSANDCASTINGPOROSITY,BADCASTINGTECHNIQUEANDTHEPRESENCEOFSILICONNEEDLESWHICHCAUSESNOTCHINGEFFECTHADMODERATESTRENGTHTHEELONGATIONOFTHESPECIMENISSHOWNINFIG9THEENGINEERINGULTIMATESTRENGTHOFDIECASTINGWASBETTERBY57COMPAREDTOCENTRIFUGALCASTINGANDBY47TOTHATOFSANDCASTINGFIG8TENSILETEST10992SANTOSHMV/MATERIALSTODAYPROCEEDINGS420171098710993FIG9ELONGATIONOFTHESPECIMEN44WEARTESTSPECIFICWEARRATEREMAINSCONSTANTIRRESPECTIVEOFLOADINSANDANDCENTRIFUGALCASTINGTHESLIDINGDISTANCEUSEDIS2500MWITHSLIDINGSPEEDOF763RPMFOR10MINWITHTRACKDIAMETEROF100MMANDWEARTESTNORMALLOADWASCONDUCTEDFOR10N,20NAND30NFIG10SHOWSTHESPECIFICWEARRATEOFALUMINUMC3550FROMFIG10ITCANBEOBSERVEDTHATSPECIFICWEARRATEREDUCESFORINCREASESINLOADFIG10SPECIFICWEARRATE5CONCLUSIONFROMTHEINVESTIGATIONONTHECASTINGTECHNIQUESFOLLOWINGCONCLUSIONWASDRAWNMICROSTRUCTUREEVALUATIONSHOWEDTHATINDIECASTINGFINEEUTECTICSILICONDISPERSEDINTHEINTERDENDRITICREGIONANDFINEPRECIPITATIONOFALLOYELEMENTSINALSOLIDSOLUTIONINSANDANDCENTRIFUGALCASTINGMETHODNEEDLESDISPERSEDINTHEINTERDENDRITICREGIONWASFOUNDBESTHARDNESSOF74HBWASFOUNDINDIECASTINGANDLEAST53HBINSANDCASTINGCENTRIFUGALCASTINGHADAGOODHARDNESSWITH69HBSTRENGTHOFALC3550WASBESTOBTAINEDUSINGDIECASTINGMETHODWHEREENGINEERINGSTRESSWASFOUNDTOBE212MPASANTOSHMV/MATERIALSTODAYPROCEEDINGS42017109871099310993DIECASTINGHADGOODSPECIFICWEARRATECOMPAREDTOSANDANDCENTRIFUGALCASTINGALSOSPECIFICWEARRATEDECREASESWITHINCREASESINLOADOVERALLBESTCASTINGMETHODISDIECASTINGWHICHPROVIDESGOODSTRENGTHANDWEARPROPERTIESEVENWITHHIGHINITIALCOSTFORTHEMANUFACTUREOFTHEDIEONTHELONGERRUNFORMASSPRODUCTIONDIECASTINGISFAVORABLE6ACKNOWLEDGEMENTWETHANKDRHCNAGARAJ,PRINCIPALANDMANAGEMENTOFNITTEMEENAKSHIINSTITUTEOFTECHNOLOGY,BANGALORE,INDIAFORMOTIVATINGANDPROVIDINGRESEARCHFACILITIESATTHEINSTITUTEREFERENCES1ZEREN,M2005EFFECTOFCOPPERANDSILICONCONTENTONMECHANICALPROPERTIESINALCUSIMGALLOYS,169,292298HTTP/DOIORG/101016/JJMATPROTEC2005030092LABISZ,K,KRUPISKI,M,DOBRZASKI,LA2009PHASESMORPHOLOGYANDDISTRIBUTIONOFTHEALSICUALLOY,372,3093163ELMADAGLI,M,PERRY,T,ALPAS,AT2007APARAMETRICSTUDYOFTHERELATIONSHIPBETWEENMICROSTRUCTUREANDWEARRESISTANCEOFALSIALLOYS,262,7992HTTP/DOIORG/101016/JWEAR2006030434DWIVEDI,SP,SHARMA,S,MISHRA,RK2014ADVANCEDMATERIALSA356ALUMINUMALLOYANDAPPLICATIONSAREVIEW,42,81865FCZERWINSKI,SKSHAHA,WKASPRZAK,JFRIEDMAN,ANDDLCHEN2016AGINGCHARACTERISTICSOFTHEALSICUMGCASTALLOYMODIFIEDWITHTRANSITIONMETALSZR,VANDTI,012031HTTP/DOIORG/101088/1757899X/117/1/0120316K