Investigating the effects of gating design on mechanical properties of aluminum alloy in sand casting process
Abstract This research aims to analyze the effects of bottom and top gating configurations on mechanical properties of aluminum alloy 6063 T5 in sand casting process. The influence of three most effective process parameters including pouring temperature, runner area and ingate area have been investigated. Empirical models for both bottom and top gating configurations have been developed using response surface methodology (RSM) Analysis of variance (ANOVA) and confirmatory experiments have been used to measure adequacy and validity of developed models respectively. Bottom gating was observed as better configuration as compared to top gating configuration with 4.08% 18.78% higher ultimate tensile strength (UTS) and 5.98% 20.60% higher percentage elongation. This resulted due to splashes generated by top gating configuration which severely affected the fluidity of the melt with consequent effects on mechanical properties. Pouring temperature and ingate area have been identified as the most significant process parameters affecting ultimate tensile strength and percentage elongation. Ingate area, on the other hand influences the flow pressure and speed of melt which is required for mold filling. Micro hardness of the specimens has also been investigated to clarify the effects of gating configuration and input parameters on mechanical properties. To have a deeper insight of the findings, microstructural analysis of casted parts has also been carried out. The findings of this research will provide better insight of bottom and top gated sand casted parts and their effect on mechanical properties.