CMR ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

PRODUCTION TECHNOLOGY LAB

PROJECT BASED LEARNING
MANUAL
The Effects of Solidification Rates on Porosity Formation
and Microstructure of Aluminum Alloy

Abstract

Aim of the project is to examine the effects of solidification

(cooling) rates on gas porosity and Microstructure formed in aluminum
alloy .This experiment is to conducted to study how gas pores and
other features of the microstructure formed in relation to the cooling
rate and how the mechanical properties of the alloy were affected as a
result.

Considering with four samples of the Al alloy, cooled at different rates,

a metallurgical microscope will be used to observe the micro surface of
the material.

Introduction

CASTING DEFECTS
POROSITY
Porosity is in the form of cavities caused due to gas entrapment during
solidification.

Causes of gas porosity

 Speed of metal pouring is too slow .
 Temperature of pouring metal is low.
 Presence of gas in metal.
 Mould is too hot.
 Presence of moisture
  Incomplete casting.
 Metal section is too thin
 Overheated moulds.

Remedies

 Regulate pouring temperature

 Reduce moisture and increase permeability of mould
 Control metal composition.
 Ensure effective degassing.
 Modify gating and risering.

Formation of Gas Porosity and Cast Microstructure of the

Aluminum Alloy
The formation of gas porosity in Al occurs because there are traces
of hydrogen gas bubbles (pores) within the material while it is
solidifying after the casting process. These pores do not form while the
material is solidifying because the solubility of hydrogen is much lower
in the solid state than it is in the liquid state. The rate at which the heat is
extracted determines the strength of the alloy. If the cooling rate is
comparatively high, then the pores are small but numerous. If the
cooling rate is low, then the pores are large but there are fewer of them.

The effects of solidification rates on gas porosity and the

microstructure of aluminum alloy A356 will be discussed in this paper.
The results of the experiment will attempt to verify that the solidification
rates have an effect on the formation of gas pores and the strength of
cast Al alloy. Also included in this paper will be a discussion on the
importance of the microscopy examination of the specimen over a range
of magnifications the applications of the metal in industry.
Porosity densities
Solidification rate : Various factors

 material of casting
 Thermal properties of mold (% moisture) and cast(K)

{ Porosity or permeability:

Porosity =f(sand grain size,grain shape, moisture,clay

components..

Sand is too fine, the porosity will be low}

 Geometrical relation between surface area and volume

Experimental Procedure

This experiment will be conducted using the following equipment

For Casting
Pattern preparation

Molding
 Melting

For Micro scopic observation

metallurgical microscope for optical microscopy

magnifications -5x, 10x, 50x,100x.

four samples of mounted, polished, and etched aluminum alloy for
observation

Results

Sand type % Cooling Sample Porosity-

moisture in Rate ID micro
mold structure
Green sand 8% water T1 ºC/s A
(Si, clay, water) 6% water T2 ºC/s B
Dry sand 2% water T3 ºC/s C
(when moisture 0% water T4 ºC/s D
removed)

Discussion

Conclusions