Aluminum Alloy Castings: Properties, Processes And Applications – J. Gilbert Kaufman, Elwin L. Rooy

 

 

 

 

 

 

SELECTED CONTENTS

Chapter 1: Introduction

  • Background and Scope
  • History
  • Advantages and Limitations of Aluminum Castings
  • Major Trends Influencing Increased Use of AluminumCastings
    • Technology
    • Recycling
  • Selecting the Right Aluminum Alloy and Casting Process

Chapter 2: Aluminum Casting Alloys

  • GeneralSpecifications
  • Alloy Designations
    • The Aluminum Association (AA) Casting AlloyDesignation System
    • Aluminum Association Casting Temper DesignationSystem
    • Evolution of Designation System; Cross-Reference toOlder Designations
    • The UNS Alloy Designation System
    • International Casting Alloy Designations
    • Nomenclature System for Aluminum Metal-MatrixComposites
  • Composition Groupings
    • Aluminum-Copper
    • Aluminum-Silicon-Copper
    • Aluminum-Silicon
    • Aluminum-Silicon-Magnesium
    • Aluminum-Magnesium
    • Aluminum-Zinc-Magnesium
    • Aluminum-Tin
  • Effects of Alloying Elements
    • Antimony
    • Beryllium
    • Bismuth
    • Boron
    • Cadmium
    • Calcium
    • Chromium
    • Copper
    • Iron
    • Lead
    • Magnesium
    • Manganese
    • Mercury
    • Nickel
    • Phosphorus
    • Silicon
    • Silver
    • Sodium
    • Strontium
    • Believe
    • Titanium
    • Zinc
  • Alloy Groupings by Application or Major Characteristic
  • General-Purpose Alloys
  • Elevated-Temperature Alloys
  • Wear-Resistant Alloys
  • Moderate-Strength Alloys with Low Residual Stresses
  • Bearings
  • High-Strength Alloys

Chapter 3: Aluminum Casting Processes

  • History
  • Casting Process Selection
    • Casting Design
    • Specification Requirements
    • Volume of Production
    • Costs
    • Quality
  • Casting Process Technology
    • Expendable and Nonexpendable Mold Processes
    • Pressure versus Gravity
    • Gating and Risering
  • Expendable Mold Gravity-Feed Casting Process and Its Variations
    • Sand Casting
    • Evaporative (Lost-Foam) Pattern Casting (EPC)
    • Shell Mold Casting
    • Plastic Casting
    • Investment Casting
    • Vacuum Mold (V-Mold) Casting
  • Nonexpendable (Permanent) Mold Gravity Feed Casting Process and Its Variations
    • Permanent Mold Casting
    • Low-Pressure Die Casting (LP), Pressure Riserless Casting (PRC)
    • Vacuum Riserless Casting (VRC)
    • Centrifugal Casting
    • Squeeze Casting
    • Semisolid Forming
  • Pressure Die Casting and Its Variations
    • Acurad Die Casting Process
    • High-Integrity Pressure Die Casting
    • Pore-Free Pressure Die Casting
    • Vacuum Die Casting
    • Rotor Casting
  • Premium Engineered Castings
    • Melt Processing
    • Melt Quality Assessment
    • Solidification
    • Solidification Rate
    • Mold Materials
    • Alloys
    • Aluminum-Silicon Eutectic Modification and Grain Refinement
    • Mold Filling
    • Quality Assurance
    • Relevance of Premium Casting Engineering
  • Other Process Technologies
    • Metallurgical Bonding
    • Cast Aluminum-Matrix Composites
    • Hot Isostatic Pressing (HIP)

Chapter 4: The Effects of Microstructure on Properties

  • Intermetallic Phases
  • Dendrite Arm Spacing
  • Grain Refinement
  • Aluminum-Silicon Eutectic Modification
  • Refinement of Hypereutectic Aluminum-Silicon Alloys

Chapter 5: The Influence and Control of Porosity and Inclusions in Aluminum Castings

  • Hydrogen Porosity
  • Shrinkage Porosity
  • Inclusions
  • Combined Effects of Hydrogen, Shrinkage, and Inclusions
  • Radiographic Inspection

Chapter 6: Hot Isostatic Pressing

  • The HIP Process
  • The Effect of HIP on Tensile Properties
  • The Effect of HIP on Fatigue Performance
  • Radiographic Inspection of HIPped Castings

Chapter 7: Heat Treatment of Aluminum Castings

  • Solution Heat Treatment
  • Quenching
  • Precipitation Heat Treating/Aging
    • Aluminum-Copper
    • Aluminum-Copper Magnesium
    • Aluminum-Silicon-Magnesium
    • Aluminum-Zinc-Magnesium
  • Annealing
  • Stability
  • Residual Stresses
  • Troubleshooting Heat Treatment Problems
    • Acceptance Criteria
    • Diagnosis

Chapter 8: Properties and Performance of Aluminum Castings

  • Compositions and Influence of Composition on Characteristics
  • Physical Properties of Aluminum Casting Alloys
  • Typical and Minimum Mechanical Properties of Aluminum Alloy Castings
    • Published Typical Mechanical Properties
    • Published Minimum and Design Mechanical Properties
    • Effects of Subzero and Elevated Temperatures on Mechanical Properties
    • Influence of Premium Practices and Emerging Casting Technologies on Mechanical Properties
  • Fatigue Properties of Aluminum Casting Alloys
    • Influence of Casting Quality on Fatigue Strength
    • Influence of Stress Raisers on Fatigue Strength of Aluminum Castings
    • Fatigue Strengths of Welded Aluminum Castings
    • Design Fatigue Strengths for Aluminum Castings
  • Fracture Resistance of Aluminum Alloys
    • Notch Toughness and Notch Sensitivity
    • Tear Resistance
    • Fracture Toughness
    • Interrelation of Measures of Fracture Resistance
  • Subcritical Crack Growth
    • Fatigue Crack Growth
    • Creep Crack Growth
    • Stress-Corrosion Crack Growth
  • Corrosion Resistance
    • Aluminum-Copper Casting Alloys (2xx.x)
    • Al-Si-Cu and/or Mg Casting Alloys (3xx.x)
    • Aluminum-Silicon Casting Alloys (4xx.x)
    • Aluminum-Magnesium Casting Alloys (5xx.x)
    • Aluminum-Zinc Casting Alloys (7xx.x)
    • Aluminum-Tin Casting Alloys (8xx.x)
  • Properties of Cast Aluminum Matrix Composites

PREVIEW