Experimental Observation and Analytical Modeling of Melting and Solidification during Aluminum Alloy Repair by Turbulence Flow Casting

• Main Author: Muki Satya Permana
• Format: Article
• Language: English
• Published: Hasanuddin University 2015-10-01
• Series: International Journal on Smart Material and Mechatronics
• Subjects: Repair; Turbulence Flow Casting; Aluminum alloy; preheating temperature; pouring time; analytical model
• Online Access: http://siaka.unhas.ac.id/ijsmm/library/index.php?kategori=vol2no2&download=9136-7209-131-ijsmm-vol2no2.pdf

This paper presents an overview on the state of the art of applicable casting technology for applications in the field of repairing aluminum alloy components. Repair process on the Al alloy sample using similar metal has been carried out to investigate the micro-structural effect. Joining occurs as a result of convection heat transfer of molten flow into the sand mold which melts the existing base metal inside the mold and subsequent solidification. The analytical model has been developed to describe aluminum alloy component repair by turbulence flow casting. The model is designed based on heat transfer principle that can handle the phenomena of heat flow. The experimental result and analytical model analyses pointed out that joint quality are greatly affected by parameters of preheating temperature and duration of molten metal flow in the mold. To obtain a desired metallurgical sound at the joint, the optimum temperature and time were adjusted in order to obtain a similarity of microstructure between filler and base metal. This model is aimed to predict the use of the process parameter ranges in order to have the optimum parameters when it is applied to the experiment. The fixed parameters are flow rate, sand ratio, and pouring temperature. The process parameters are preheating temperature and pouring time. It is concluded that analytical modeling has good agreement with the experimental result.