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Premium-quality castings are those which are guaranteed to show a specified high level of mechanical properties. The properties currently being achieved represent significant improvements over those which can be achieved in conventional aluminum-alloy castings and approach the properties currently obtainable in wrought aluminum alloys. These property advances are largely the result of improved casting technique and design. These castings are gradually finding acceptance and usage in aerospace applications, thanks to integrated efforts between the casting producers and their customers. (Author).
J. G. (Gil) Kaufman is currently president of his consulting company, Kaufman Associates.
Extensive research on the structure and properties of cast aluminum and magnesium alloys ha% been applied to foundry practice. The term 'premium quality' is used to describe castings with reliably high mechanical properties and high integrity of the product, guaranteed by the foundry. In production, conventional equipment and manufacturing techniques may be used, but rigid control of metal purity, alloy composition, melt quality, solidification conditions and heat treatment is essential to achieve and maintain high reliability of properties in designated areas of the casting, which are graded according to design and service considerations. Examples of the excellent properties that have been obtained in aluminum and magnesium alloy castings are listed.
This practical guide to product and process engineering of various aluminum castings emphasizes process and material characteristics; product-process-alloy integration; manufacturing aspects of aluminum casting; product design features; tooling design, feeding and gating design; product quality needs and specifications; and more.
This program was accomplished in two phases, I and II. Both phases were conducted in two parts, A and B. Phase IA established the status of premium quality aluminum foundry technology and identified the need for user-design documentation. Phase IB demonstrated the foundry processing effects that are major contributors to casting properties of aluminum castings. Phase IIA established foundry process control and inspection procedures needed to optimize casting properties. Phase IIB incorporated these procedures into a comprehensive test program. The object of this test program was to establish reliable design information and documentation for the design and procurement of premium quality aluminum castings.
Based on the positive response from the co-author's presentations on the casting characteristics and mechanical properties of aluminum alloys for producing structural castings during a 2015 AFS webinar, this data was expanded into a book. This book emphasizes factors affecting the structure and mechanical properties - such as the influence of alloying elements including impurities, casting processes, gating and risering design, phase diagrams, melt treatment to improve the quality of the liquid metal- and solidification characteristics including grain refinement and modification, heat treatment, etc. Design engineers, manufacturing engineers, casting engineers, foundry metallurgists and other foundry staff and management working in the premium quality production of structural castings will benefit from this book. In addition, the book is aimed at both undergraduate and post-graduate students interested in casting technology.