Effects of runner system design on the mechanical strength of Al-7Si-Mg alloy castings

X. Dai, X. Yang, J. Campbell, J. Wood

Research output: Contribution to journalArticle

81 Citations (Scopus)

Abstract

Effects of runner systems on the mechanical strength of Al-7Si-Mg alloy castings have been investigated by employing different cross-sectional shapes of runners. Computational fluid dynamics (CFD) modelling was used to identify the flow behaviour and the oxide film distribution in the castings. The X-ray radiography was then used to examine the general distribution of defects in the castings from different running systems. Four-point bending method was applied. The scatter of bend strength results was quantified by Weibull statistics. The oxide films and casting defects existing on the fracture surface of the casting specimens were observed by scanning electron microscopy (SEM). Both of numerical and experimental results showed that the vortex-flow runner system (VR) could effectively control the ingate velocity and keep its value lower than 0.5 m s−1, avoiding the generation of surface turbulence and the consequential entrainment of oxide films. The results from both the experiment and simulation support the conclusion that the use of VR can produce castings with fewer oxide film inclusions and more reliable mechanical properties compared with the castings using conventional runner systems.
LanguageEnglish
Pages315-325
Number of pages10
JournalMaterials Science and Engineering: A
Volume354
Issue number1-2
DOIs
Publication statusPublished - 15 Aug 2003

Fingerprint

systems engineering
Strength of materials
Systems analysis
Oxide films
oxide films
Casting
Vortex flow
vortices
X ray radiography
Defects
defects
entrainment
radiography
computational fluid dynamics
Computational fluid dynamics
Turbulence
turbulence
Castings
Statistics
statistics

Keywords

  • aluminium castings
  • runner system design
  • casting defects
  • bend strength
  • computational fluid dynamics
  • weibull statistics

Cite this

Dai, X. ; Yang, X. ; Campbell, J. ; Wood, J. / Effects of runner system design on the mechanical strength of Al-7Si-Mg alloy castings. In: Materials Science and Engineering: A. 2003 ; Vol. 354, No. 1-2. pp. 315-325.
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Effects of runner system design on the mechanical strength of Al-7Si-Mg alloy castings. / Dai, X.; Yang, X.; Campbell, J.; Wood, J.

In: Materials Science and Engineering: A, Vol. 354, No. 1-2, 15.08.2003, p. 315-325.

Research output: Contribution to journalArticle

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AB - Effects of runner systems on the mechanical strength of Al-7Si-Mg alloy castings have been investigated by employing different cross-sectional shapes of runners. Computational fluid dynamics (CFD) modelling was used to identify the flow behaviour and the oxide film distribution in the castings. The X-ray radiography was then used to examine the general distribution of defects in the castings from different running systems. Four-point bending method was applied. The scatter of bend strength results was quantified by Weibull statistics. The oxide films and casting defects existing on the fracture surface of the casting specimens were observed by scanning electron microscopy (SEM). Both of numerical and experimental results showed that the vortex-flow runner system (VR) could effectively control the ingate velocity and keep its value lower than 0.5 m s−1, avoiding the generation of surface turbulence and the consequential entrainment of oxide films. The results from both the experiment and simulation support the conclusion that the use of VR can produce castings with fewer oxide film inclusions and more reliable mechanical properties compared with the castings using conventional runner systems.

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