ASM Handbook, Volume 15: Casting (2008)

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SELECTED CONTENTS (what applies to aluminium):

Applications and Specification Guidelines

History and Trends of Metal Casting

Principles of Liquid Metal Processing

  • Chemical Thermodynamics and Kinetics
  • Thermodynamic Properties of Aluminum-Base and Copper-Base Alloys
  • Gases in Metals
  • Aluminum and Its Alloys
  • Inclusion-Forming Reactions
    • Inclusion Types
    • Physical Chemistry
    • Control of Inclusions
    • Inclusions in Nonferrous Alloys

Melting and Remelting

  • Electric Arc Furnace Melting
  • Cupola Furnaces
  • Induction Furnaces
  • Vacuum Induction Melting
  • Electroslag Remelting
  • Vacuum Slag Remelting
  • Scull melting
  • Electron Beam Melting
  • Plasma Melting and Heating
  • Crucible Furnaces
  • Reverberatory and Stack Furnaces
    • Furnace Types
    • Reverberatory Furnace Practice
    • Molten Metal Circulation

Molten Metal Processing and Handling

  • Transfer and Treatment of Molten Metal—An Introduction
    • Launders
    • Tundishes
    • Molten-Metal Pumps
    • Pouring and Dosing
  • Degassing
    • Aluminum Foundry Degassing
  • Molten-Metal Filtration
    • Sources of Inclusion
    • Removal of Inclusions
    • Filter Characteristics
    • Types of Molten-Metal Filters
    • In-Mold Filtration
    • In-Furnace Filtration of Molten Aluminum
    • Filtered Metal Quality
  • Aluminum Fluxes and Fluxing Practice
    • Aluminum Fluxing
    • Categories of Fluxes
    • Foundry Practices
  • Modification of Aluminum-Silicon Alloys
    • Heat Treated Castings
    • Porosity and Shrinkage Formation
    • Modification Mechanisms
    • Eutectic NucleationEutectic Grain Structure
    • Recommended Foundry Practices
    • Growth of Silicon Eutectic
    • Effect of Other Elements
    • Summary
  • Grain Refinement of Aluminum Casting Alloys
    • Measurement of Grain Size
    • Mechanisms of Grain Refinement
    • Boron as a Grain Refiner
    • Best Practices for Grain Refinement
    • Benefits of Grain Refinement
    • Concluding Remarks
  • Refinement of the Primary Silicon Phase in HypereutecticAluminum-Silicon Alloys
    • Importance of Primary Silicon Refinement
    • Accomplishing Primary Silicon Refinement

Principles and Practices of Shape Casting

  • Shape Casting Processes—An Introduction
  • Patterns and Patternmaking
  • Casting Practice—Guidelines for Effective Production of Reliable Castings
  • Rule 1: Good-Quality MeltRule 2: Liquid Front Damage
  • Rule 3: Liquid Front Stop
  • Rule 4: Bubble Damage
  • Rule 5: Core Blows
  • Rule 6: Shrinkage Damage
  • Rule 7: Convection Damage
  • Rule 8: Segregation
  • Rule 9: Residual Stress
  • Rule 10: Location Points
  • Filling and Feeding System Concepts
  • Processing and Finishing of Castings

Expandable-Mold Casting Processes with Permanent Patterns

  • Introduction—Expendable Mold Processes with Permanent Patterns
  • Aggregates and Binders for Expendable Molds
  • Green Sand Molding
  • No-Bake Sand Molding
  • Coremaking
  • Slurry Molding
  • No-Bond Sand Molding

Expandable-Mold Casting Processes with Expendable Expendable

  • Introduction—Expendable Mold Processes with Expendable Expendable
  • Lost Foam Casting
  • Investment Casting
  • Replicast Molding

Centrifugal Casting

  • Centrifugal Casting
  • Horizontal Centrifugal Casting
  • Vertical Centrifugal Casting

Permanent Mold and Semipermanent Mold Processes

  • Permanent Mold Casting
  • Low-Pressure Die Casting
  • Low Pressure Counter Gravity Casting

High-Pressure Die Casting

  • High-Pressure Die Casting
  • Hot Chamber Die Casting
  • Cold Chamber Die Casting
  • Squeeze Casting
  • Vacuum High-Pressure Die Casting
  • Die Casting Tooling
  • Automation in High-Pressure Die Casting

Semisolid Casting

  • Semisolid Casting — Introduction and Fundamentals
  • Thixocasting
  • Rheocasting
  • Thixomolding

Casting of Nonferrous Alloys

  • Dross, Melt Loss, and Fluxing of Light Alloy Melts
    • Dross Formation
    • Influence of Melter Type on Dross Generation
    • Influence of Charge Materials on Melt Loss
    • Influence of Operating Practices on Melt Loss
    • Economic Implications of Dross
    • In-Plant Enhancement or Recovery of Dross Metallics
    • Ways to Reduce Dross Formation
  • Aluminum Alloy Ingot Casting and Continuous Processes
    • Ingot Forms
    • Molten-Metal Processing
    • Ingot Casting Processes
    • Continuous Processes
    • Solidification in the DC Process
    • Postsolidification Processes
    • Safety
  • Aluminum Shape Casting
    • Melting and Melt Handling
    • Casting Process Selection
    • Pressure Die Casting of Aluminum
    • Premium Engineered Casting

Nonferrous Alloy Castings

  • Aluminum and Aluminum Alloy Castings
  • Chemical Compositions
  • Effects of Alloying and Impurity Elements
  • Structure Control
  • Modification and Refinement of Aluminum-Silicon Alloys
  • Foundry Alloys for Specific Casting Applications
  • Heat Treatment
  • Welding
  • Properties of AluminumCasting Alloys

Quality Assurance, Nondestructive Evaluation, and Failure Analysis

  • Approaches to Measurement of Metal Quality
  • Metal Cleanliness Assessment Techniques
  • Nondestructive Testing of Components
    • Liquid Penetrant Inspection
    • Radiographic Inspection
    • Fluoroscopic Inspection and Automated
    • Defect Recognition
    • Ultrasonic Inspection
    • Eddy Current Inspection
    • Process-Controlled Resonant Testing
    • Leak Test
    • Electrical Conductivity Measurement
  • Casting Fracture Characteristics
    • General Fracture Examination
    • Fracture Features
  • Casting Failure Analysis Techniques and Case Studies
    • Introduction
    • Background Information
    • Planning and Sample Selection
    • Preliminary Examination
    • Material Evaluation
    • Data Analysis and Report Preparation
    • Case Studies
  • Common Defects in Various Casting Processes
  • Repair Welding of Nonferrous Castings
  • Quality Planning Tools and Procedures
  • Maintenance, Repair, Alterations, and Storage of Patterns and Tooling