Selection of alumium for casting 1

[Gianfranco]

Hi to all,

In your opinion what is the best Al alloy for casting with this quality items:

1. Mechanical properties - Priority A
2. Weldability at TIG to Al 3003 - Priority A-
3. Machineability - Priority B
4. Cost - Priority B++

Have you any suggestions for a Metal Selectors (as for plastics) or may you advise me for updated reference books where find out a comprehnsive list of Aluminum alloys/Characteristics/Applications.

Thank you very much for your qualified help.

Gianfranco

 

[butelja]

What is the application? Is it at elevated temperature? Is it in a corrosive environment?

 

[Gianfranco]

Hi butelja,

The max working temperature ranges 100-120°C.
Thanks for the fast replay.

Gianfranco

 

[semisolid]

Look in the ASM metal handbook. My choice for the temperatue range indicated would be A356, 357 or C355.

 

[Gianfranco]

Thanks semisolid!

I haven't the ASM handbook at hand.
Let me summarize reporting the alloys as shown on Marks' Handbook:

A356 6,5-7,5Si 0,20-0,40Mg 0,20Fe 0,20Cu 0,20Ti
357 6,5-7,5Si 0,45-0,60Mg 0,15Fe 0,05Cu 0,20Ti
C355 4,5-5,5Si 0,40-0,60Mg 0,20Fe 1,0-1,5Cu 0,20Ti

A356 Temper T61 R=255MPa(37ksi) A=5%
357 Temper T6 R=310MPa(45ksi) A=3%
C355 Temper T61 R=276MPa(40ksi) A=3%

Are these alloys usable for die-casting?
What is the best in cost/quality ratio?

Butelja sorry, my answer was incomplete.
The application is the oil coolers (lubricants or process fluids) or, in others words, air-liquid aluminum heat exchangers.
Generally the working ambients are not corrosive.

Thanks for your help.

Gianfranco

 

[WKTaylor]

Gianfranco...

I agree with "Semisolid" that You need to get the "ASM Specialty Handbook: Aluminum and Aluminum Alloys"
ISBN: 0-87170-496-X [$175 mbrs or $218 non-mbrs +SH]

go to:

http://www.asm-intl.org

then to the "Bookstore" Tab and find this Book.

What You are doing requires detailed knowledge of aluminum alloys and aluminum processes... this is an outstanding reference!

Regards, Wil Taylor

 

[Fabrizio]

Hi, Gianfranco, now i am at home, but i work in a foundry and we develop alloys. Send me detailed information about what you want to do. When a go back to work i will ask also to other engineers. Bye, Fabrizio Fabrizio@libero.it

 

[Gianfranco]

Wil, Semisolid,

Thanks for your advises: I bought the ASM Specialty Handbook, Aluminum and Aluminum Alloys.

Fabrizio, I appreciated very much your availability but
your E-mail address seems not correct: please, send to lopad@tin.it an E-mail. Fabrizio you have the tech. infos in the previous messages. To facilitate you (and Wil, Semisolid and Butelja), I've summarized them as follows:

A. The application is the oil coolers (lubricants or process fluids) or, in others words, air-liquid aluminum heat exchangers.

B. Generally the working ambients are not corrosive.

C. The max working temperature ranges 100-120°C.

D. The selection of Al alloy for casting has these priorities:

1. Mechanical properties - Priority A
(the part shall resist to the pressure of 20-35 bar)

2. Weldability at TIG to Al 3003 - Priority A-

3. Machineability - Priority B

4. Cost - Priority B++

E. Wil and Semisolid adivise me the
A356 6,5-7,5Si 0,20-0,40Mg 0,20Fe 0,20Cu 0,20Ti
357 6,5-7,5Si 0,45-0,60Mg 0,15Fe 0,05Cu 0,20Ti
C355 4,5-5,5Si 0,40-0,60Mg 0,20Fe 1,0-1,5Cu 0,20Ti

with this properties:

A356 Temper T61 R=255MPa(37ksi) A=5%
357 Temper T6 R=310MPa(45ksi) A=3%
C355 Temper T61 R=276MPa(40ksi) A=3%

My further question is: what Alloy has the better cost/quality ratio for die-casting and permanent die-casting?

Thanks again to all.

Gianfranco

 

[WKTaylor]

Gianfranco..

1. The ASM Handbook on alunimum alloys should provide all info on castability, weldability, inter-alloy compatability, corrosion protection, etc You need for the engineering aspects of this job. I have this book and have used it extensively for simmilar problems [mostly repair].

2. Production questions, are a different animal. I believe You need to do the following:

Estimate production volume [qty/period, high and low estimates].

Contact a few highly relaible ALUMINUM casting vendors who produce parts in the quantities You are anticipating. Thoroughly discuss the part configuration, end-use, alloys under consideration, quality and dimensional requirements, tooling requirements and Your quantity estimates. The vendors will have a LOT to say regarding each aspect and may have additional analytical capability to project costs.

Make Your final decisions based on the engineering AND the vendor input.
Regards, Wil Taylor