Method of casting hypereutectic aluminum-silicon alloys using an

Details Method of casting hypereutectic aluminum-silicon alloys using an Method of casting hypereutectic aluminum-silicon alloys using an

1997-11-21

2000-02-15

Lin, Kuang Y.

Metal founding

Process

Shaping a forming surface

164120, B22C 904, B22D 2713

Patent

active

060241578

ABSTRACT:
A method of casting hypereutectic aluminum-silicon alloys in an evaporable foam casting process with the application of pressure during the solidification of the alloy. A pattern is formed from a polymeric material having a configuration of an article to be cast. The pattern is supported in an outer mold and unbounded sand surrounds the pattern and fills the cavities within the pattern. The pattern is contacted with a molten hypereutectic aluminum-silicon alloy containing 16% to 30% silicon and having less than 0.8% copper. The molten alloy decomposes the foam pattern with the vapors of decomposition being entrapped within the interstices of the sand. While the alloy is in the molten state, gas pressure is applied to the alloy in the magnitude of 5 to 12 atmospheres to produce a cast alloy having less than 0.03% porosity and a high cycle fatigue strength greater than 13 KSI.

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