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Materials Today: Proceedings 4 (2017) 10987–10993 www.materialstoday.com/proceedings

AMMMT 2016

Mechanical Characterization and Microstructure analysis of Al

C355.0 by Sand Casting, Die Casting and Centrifugal Casting
Techniques.
Santosh M V* , Suresh K R, Kiran Aithal S
Department of Mechanical engineering, NMIT Bangalore, Karnataka, India

Abstract

In this study, mechanical properties of aluminium alloy C355.0 was investigated for Sand Casting, Die Casting and Centrifugal Casting
Technique. Mechanical properties like tensile test was performed using PC2000 software, and Brinell hardness test was performed. Die casting
was observed to have good tensile and hardness properties compared to sand and centrifugal castings Microstructure analysis was done by Nikon
Microscope LV150with Clemax Image Analyser. From the observation die casting had uniform distribution of silicon. Wear behavior of the alloy
studied using sliding wear test. Good wear specific wear rate was found in all the casting but the best was observed in die casting at 20N load.
© 2017 Elsevier Ltd. All rights reserved.
Selection and Peer-review under responsibility of Advanced Materials, Manufacturing, Management and Thermal Science
(AMMMT 2016).

Keywords: Die casting; sand casting; centrifugal casting; mechanical and sliding wear properties.

1. Introduction

Aluminum is light and possesses high strength it is an important metal in automotive and aerospace
industries. Generally pure aluminum does not fit the standards of the industries, therefore, they are alloyed with
silicon, copper, magnesium and many other metals to increase strength and other properties on the aluminum among
them Al-Si-Cu-Mg alloy system is one them. Al-Si-Cu-Mg system is the most used alloy group in the industries
because of excellent castability and mechanical properties. The applications are from aerospace to automobile to
household industries. Therefore this alloy system is very important among them C355.0 in one the alloy. The main
alloying ingredient are silicon and copper, the increase in silicon content will increase the hardness of the alloy

* Corresponding author. Tel.: +91-948-118-8859;

E-mail address: santoshmv9632@gmail.com

2214-7853 © 2017 Elsevier Ltd. All rights reserved.

Selection and Peer-review under responsibility of Advanced Materials, Manufacturing, Management and Thermal Science (AMMMT 2016).
10988 Santosh M V/ Materials Today: Proceedings 4 (2017) 10987–10993

system and increase in copper upto strength (yield and ultimate) increased[1-10, 13]. Also with the increase in load
and sliding distance volume loss increased but friction co-efficient was constant for the sliding distance, but also
friction co-efficient diminishes with longer sliding distance[11,12].

In this paper, an attempt is made to compare mechanical characteristics of different casting techniques that
are generally used in industries namely gravity die casting, sand casting. Also since in automotive industries friction
wear plays an important role sliding wear behavior are also analyzed.

2. Materials

The chemical composition of aluminum alloy C355.0 is shown in the Table 1. Properties of Aluminum are
shown Table 2. Aluminum has a FCC crystal structure with lattice parameters a=0.405nm and atomic radius
R=0.143nm. Aluminum C355.0 is a hypoeutectic alloy because %wt. of silicon is less than 12%.

Table 1 Chemical Composition of C355.0 alloy, %wt.

Elements % wt.
Cu 1.32
Mg 0.34
Si 5.05
Fe 0.15
Mn 0.01
Ni 0.02
Zn 0.01
Pb 0.01
Sn 0.01
Ti <0.01
Other(Total) 0.05
Al 93.05

Table 2 Properties of Aluminum

Properties Values
Density 2.67g/cc3
Melting Point 557-613°C
Elastic Modulus 72.4GPa
Poisson’s Ratio 0.33

3. Methodology

3.1. Casting Techniques

Fabrication of the alloy was carries out in three casting techniques namely gravity die casting, sand casting and
centrifugal casting. The alloy was melted to 800°C in a graphite crucible. For gravity die casting a die of diameter
12mm height of 25mm was used. In sand casting mold with diameter 12mm and height of 15mm was prepared and
molten metal was poured to obtain casting. In centrifugal casting a cylinder was obtained of outside diameter 60mm
and height 120mm.

3.2. Microstructure Study

The surface for microstructure study was prepared by etching a surface using 220, 400, 600, and 1000 grade
papers and further polished by Keller’s solution i.e., 0.5% of HF in 50ml of H2O. It was observed using Nikon
Microscope LV150 with Clemex Image Analyser.
 Santosh M V/ Materials Today: Proceedings 4 (2017) 10987–10993 10989

3.3. Tensile Test

The tensometer used was run by DC servo motors and accompanied with PC2000 software. From the obtained
casting tensile specimen were machined according to ASTM E8 standards. The dimensions are gauge diameter
6.25mm and gauge length of 25mm with overall length 50mm.

3.4. Wear Test

Wear specimen were machined according to ASTM G99 standards. Dry sliding wear test was conducted
different load conditions at room temperature. The diameter was of 10mm and length 30mm. The surface etched
with 600 grade paper to fit standards of the pin-on-disc apparatus used in the investigation.

3.5. Hardness Test

Hardness test was conducted using Brinell Hardness Equipment with load 250kg-f with indentation ball diameter
10mm was applied for 30sec. The indentation was made on the surface which as measured by traveling microscope
and BHN was calculated by the measured indentations.

4. Results and Discussions

4.1. Microstructure Evaluation

4.1.1. Die Casting

In die casting the silicon particles are uniform distributed among the primary phase and α-Al matrix is found.
Fig. 1 shows the un-etched surface of the as-cast obtained. The size of dendrite size and inter-dendrite arm spacing
is small because of faster and uniform cooling rate as shown in fig. 2.

Fig. 1 Unetched surface of Die Casting at 100X. Fig. 2 Keller’s etched surface of Die Casting at 100X.

4.1.2. Sand Casting

The fig. 3 shows the un-etched surface of the sand casting technique. From the observation of fig 4 the dark dots
are the existence of the porosity and impurities during casting process. From fig. 4 it is observed that the dendritic
and inter-dendrite space is small. The investigation of fig. 4 the solid solution of α-Al matrix is found and an
intermetallic secondary phase of β-Si. The β-Si phase is observed as large flakes, needles and fibrous precipitations
10990 Santosh M V/ Materials Today: Proceedings 4 (2017) 10987–10993

for the variation of Cu concentration. Since the Si needles exist there are chances of notching to occur which
decreases the mechanical properties.

Fig. 3 Unetched surface of Sand Casting at 100X. Fig. 4 Keller’s etched surface of Sand Casting at 100X.

4.1.3 Centrifugal Casting

Porosity in centrifugal casting is shown in the fig. 5. The silicon is unevenly distributed in the primary phase. A
large amount of Al2Cu is formed in the secondary phase along with α-Al matrix. Since the Si needles exist there are
chances of notching to occur which decreases the mechanical properties. The dark spots in fig. 6 shows scattered
magnesium.

Fig. 5 Unetched surface of Centrifugal Casting at 100X. Fig. 6 Keller’s etched surface of Centrifugal Casting at 100X.
 Santosh M V/ Materials Today: Proceedings 4 (2017) 10987–10993 10991

4.2 Hardness Test

Fig. 7 Hardness Test

BHN was calculated by measuring the indentation diameter which was made on the surface. An average was
taken of three indentations and shown fig. 7. Centrifugal casting had high hardness because it was found to be
ductile in nature when compared to die casting which had least hardness which good ductile property as shown in
section 4.3.

4.3 Tensile Test

Fig. 8 shows the variation in the strength of castings fabricated. Best strength was obtained in gravity die casting
and worst in centrifugal casting. Uniform distribution of silicon and less impurities and good casting techniques
increased the strength, whereas, porosity, blowholes present in centrifugal casting had least strength. On the other
hand, in sand casting porosity, bad casting technique and the presence of silicon needles which causes notching
effect had moderate strength. The % elongation of the specimen is shown in fig. 9. The engineering ultimate
strength of die casting was better by 57% compared to centrifugal casting and by 47% to that of sand casting.

Fig. 8 Tensile Test

10992 Santosh M V/ Materials Today: Proceedings 4 (2017) 10987–10993

Fig. 9 %Elongation of the specimen

4.4. Wear Test

Specific wear rate remains constant irrespective of load in sand and centrifugal casting. The sliding distance used
is 2500m with sliding speed of 763rpm for 10min with track diameter of 100mm and wear test normal load was
conducted for 10N, 20N and 30N. Fig 10 shows the specific wear rate of aluminum C355.0. From fig.10 it can be
observed that specific wear rate reduces for increases in load.

Fig. 10 Specific wear rate

5. Conclusion

From the investigation on the casting techniques following conclusion was drawn:
• Microstructure evaluation showed that in die casting fine eutectic silicon dispersed in the inter-dendritic
region and fine precipitation of alloy elements in Al solid solution. In sand and centrifugal casting method
needles dispersed in the inter-dendritic region was found.
• Best hardness of 74HB was found in die casting and least 53HB in sand casting. Centrifugal casting had a
good hardness with 69HB.
• Strength of Al C355.0 was best obtained using die casting method where engineering stress was found to
be 212MPa.
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• Die casting had good specific wear rate compared to sand and centrifugal casting. Also specific wear rate
decreases with increases in load.

Overall best casting method is die casting which provides good strength and wear properties. Even with high
initial cost for the manufacture of the die on the longer run for mass production die casting is favorable.

6. Acknowledgement
We thank Dr. H.C.Nagaraj, Principal and Management of Nitte Meenakshi institute of Technology, Bangalore,
India for motivating and providing research facilities at the institute.

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