ASM Handbook, Volume 15: Casting (2008)
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
