1.

Introduction

Aluminum casting is a widely used manufacturing process that involves the

shaping of molten aluminum into a desired form by pouring it into a mold and
allowing it to solidify. It is a versatile and cost-effective method for producing
complex and intricate metal components with excellent strength-to-weight ratio.

Aluminum, known for its lightweight and corrosion-resistant properties, is a

popular choice for casting due to its numerous advantages. It has a low melting
point, making it relatively easy to melt and pour into molds. Aluminum also
exhibits good fluidity, allowing it to fill intricate mold cavities and reproduce fine
details.

The process of aluminum casting typically begins with the creation of a pattern,
which can be made from various materials such as wood, plastic, or metal. This
pattern is used to create a mold by either using sand, ceramic, or metal casting
methods. The molten aluminum is then poured into the mold cavity and left to cool
and solidify. Once solidified, the mold is removed, and the resulting aluminum
casting is cleaned, finished, and, if needed, undergoes additional processes like
machining or surface treatment. By Recycling aluminum chips, we can
significantly reduce the need for primary aluminum extraction, which requires
substantial energy and has environmental consequences. Recycling aluminum
chips not only conserves resources but also reduces greenhouse gas emissions
associated with aluminum production. We know that recycling is a collective
effort, and it's essential to encourage individuals, businesses, and industries to
participate in aluminum recycling programs.by doing so, we can promote
sustainability, protect our environment, and contribute to a more sustainable future.

2. Statement of the problem

In our workshop students and researchers execute a lot of experimental workshop

process in machine shop laboratory, such as machining process. But for the
practical machining experiment our university prepare the rod samples, the
aluminum samples have many defects, which makes the struggle on the produced
part so consequently we can’t use the product for reliable fitted operation.
 2.1. Defects that I have observed

When we comes to aluminum casting, there are several common defects that can
occur during the casting process porosity defect in aluminum casting refers to the
presence of air or gas pockets within the cast aluminum material. These pockets
are formed during the solidification process when the molten aluminum cools and
hardens. Porosity can occur due to various factors, including:
2.1.1. Inadequate Venting: If the mold does not have proper venting channels or
vents are blocked, the gases generated during solidification cannot escape, leading
to porosity.
2.1.2. High Moisture Content: Moisture in the mold or core material can vaporize
when exposed to the high temperatures of molten aluminum, resulting in gas
porosity.
2.1.3. Shrinkage: As the aluminum cools and solidifies, it undergoes a volumetric
contraction. If the mold does not allow for proper feeding of the molten metal to
compensate for this shrinkage, voids can form.

2.1.4. Impurities: Certain impurities or contaminants present in the aluminum alloy

can create gas when exposed to high temperatures, causing porosity during
solidification.
Porosity defects can weaken the casting and reduce its overall quality. They may
manifest as surface voids, internal gas pockets, or both. To mitigate porosity, it is
crucial to ensure proper mold design, adequate venting, use of dry mold materials,
and clean, high-quality aluminum alloys. Additionally, optimizing the pouring and
solidification processes can help minimize the formation of porosity defects in
aluminum castings.

again the chips that comes from machining operation’s removed as wastage.

3.1 Objective of the study

 Casting of defect free aluminum rod from aluminum chip

3.1.1 Specific objective

 Casting of aluminum rod workpice.

 Recycling aluminum chip in D.D.U
 Saving cost of aluminum rod that spent for students and researchers
aluminum rod workpice.
 Raw material saving.
 Improve the sample quality.

4 Materials and methods

The material to be used will be aluminum chips and scrap to be transformed into
rod, Aluminum chips, which are small pieces or shavings of aluminum, can indeed
be recycled. Recycling aluminum is an excellent way to conserve natural
resources, reduce energy consumption, and minimize environmental impact. The
recycling process for aluminum chips typically involves the following steps:

1. Collection: First, the aluminum chips are collected from our workshops and also
there is various sources in Dire Dawa, such as manufacturing facilities, machining
shops, or metalworking industries. These chips may be generated during processes
like drilling, milling, or turning, so currently there is different operations have been
performed by students and researchers for practice and part production in our
workshop which generates a lot of chips and wasted and removed for nothing
2. Sorting: The collected aluminum chips are then sorted to remove any
contaminants or impurities, such as dirt, oil, or other metals. This step is crucial to
ensure the quality of the recycled aluminum.

3. Shredding/Melting: After sorting, the aluminum chips are shredded into smaller
pieces or melted down, depending on the desired form of the recycled aluminum.
Shredding is often done for bulkier chips, while melting is suitable for smaller
chips or shavings.

4. Purification: in our workshop during machining of aluminium on lath and

milling operation we use lubricants for machine and coolants during machining, so
the aluminum chips contain any coatings or surface treatments, they may undergo a
purification process to remove these additional substances. This helps in obtaining
a purer form of aluminum for recycling.

5. Re-melting and Casting: The purified aluminum is then re-melted to form

molten aluminum, which can be cast into various shapes or products. This molten
aluminum can be used to create new aluminum sheets, ingots, extrusions, or other
aluminum-based products but for our starting purpose I focused only to cast rod.

6. Casting in the mold By recycling aluminum chips, we can significantly reduce

the need for primary aluminum extraction, which requires substantial energy and
has environmental consequences. Recycling aluminum chips not only conserves
resources but also reduces greenhouse gas emissions associated with aluminum
production.

7 extracting the casted rod sample after casting the rod workpice extracted from
the mold and prepared to our workshop machine shop for students and our staff
researchers.

4.1 Steps and design

Step-by-step breakdown of the process:

4.1.1. Mold Preparation: The permanent mold, also known as a die or tool, will
design to have the desired shape and features of the aluminum part. The mold is
typically made in two halves to allow for easy removal of the cast part. The mold is
thoroughly cleaned and coated with a mold release agent to prevent the aluminum
from sticking to the mold, so bellow there is some design consideration for our cast
sample.

A) desired sample geometry.

Area of the sprue = A=π r 2 = πx(1 cm2) = 3.14 cm2
2 2 3
The internal mold volume is V ¿ π r X h ¿ π (7 cm) X 40 cm = 6157.52cm
Getting system

Pouring in Casting

flow velocity:- the inlet velocity of the molten aluminum, so we can calculate
from the relation to height of getting basin, here Bernoulli's theory is used to
find the velocity of the molten aluminum at the base of the sprue.
Assumption When friction losses are ignored and the system is assumed to remain
at atmospheric pressure throughout

 Velocity, v =√ 2∗g∗h where h is the inlet height

v =√ 2∗981cm/ s∗20 cm = √ 39240 cm2 /s 2 = 198.09 cm/s

 volume flow rate Q

Q= A * v where A is the vacancy inlate area and v is velocity of the molten

 Q = 3.14 cm2 * 198.09 cm3/s = 622 cm3/s

The total mold filling time. MFT

MFT = cast volume / flow rate = V/Q = 6157.52cm3/622cm3/s = 9.89 second

Solidification Time

2. Preheating: The mold is preheated to a specific temperature to ensure better heat

transfer and control during the casting process. Preheating also helps in reducing
thermal shock to the mold.

3. Melting the Aluminum: Aluminum alloys, which are a combination of

aluminum with other metals, are melted in a furnace at temperatures ranging from
650 to 750 degrees Celsius (1200 to 1380 degrees Fahrenheit). The exact
temperature depends on the specific alloy being used.

4. Mold Filling: Once the aluminum has reached the desired temperature, it is
poured into the preheated mold. Gravity is often used to assist in filling the mold,
although in some cases, low-pressure or high-pressure methods can be employed.
The mold is designed with gating and riser systems to facilitate proper flow of the
molten aluminum and minimize the formation of defects.

5. Cooling and Solidification: After the mold is filled, the molten aluminum starts
to cool and solidify, taking the shape of the mold cavity. Cooling time is critical, as
it affects the mechanical properties of the cast part. The mold is typically cooled by
air or water circulation to accelerate the solidification process.

 The time t s required for a simple casting to solidify completely can be

calculated using Chvorinov’s rule: 𝑡

6. Mold Opening and Part Removal: Once the aluminum has solidified, the mold is
opened, and the cast part is removed. The part may require some additional
finishing processes such as trimming, machining, or surface treatments to achieve
the desired final specifications.
7. Mold Preparation for Next Cycle: After the part is removed, the mold halves are
cleaned and prepared for the next casting cycle. This may involve removing any
residual aluminum, inspecting the mold for wear or damage, and applying a fresh
mold release agent.

Casting aluminum in a permanent mold offers several advantages, including better

dimensional accuracy, improved surface finish, and shorter production cycles
compared to other casting methods. It is commonly used for various applications,
such as automotive components, aerospace parts, and consumer goods.

5. Conclusion

In conclusion, the casting of aluminum is a widely used and versatile

manufacturing process that offers numerous advantages. Aluminum casting allows
for the production of complex shapes, high dimensional accuracy, and excellent
surface finish. It is a cost-effective method for creating lightweight components for
the laboratory equipment’s with good strength-to-weight ratios. However,
successful aluminum casting requires careful attention to various factors. Proper
mold design, gating system, and cooling techniques are essential to ensure sound
castings. The selection of the appropriate aluminum alloy, considering factors such
as mechanical properties, corrosion resistance, and thermal conductivity, is crucial
for meeting specific application requirements. To achieve high-quality aluminum
castings, it is important to control and monitor the casting parameters such as
pouring temperature, solidification time, and cooling rate. This helps to minimize
defects like porosity, shrinkage, and distortion, ensuring the integrity and
functionality of the final product.

reference
1 Study of Porosity Defect in Aluminum Die Castings and its Evaluation and Control for Automotive
Applications
2 Die Casting Mold Design for Aluminum Alloy Shell of Instrument Yuanyuan Li1,a, Meng Wang1 ,
Yuchao Guo1 1 East University of Heilongjiang in Harbin, China

3 Recycling of Aluminum Chips in Die Casting Foundry Article in International Journal of Metalcasting ·
October 2021 DOI: 10.1007/s40962-021-00707-3

4 ALUCAST 2020 - Technical Volume

5 Experimental Investigation on Aluminium Gravity Die Casting , Krishnaraj Ramaswamy Dambi Dollo
University,Ethiopia 126 PUBLICATIONS 741 CITATIONS

6 APPLICATION OF DIE CASTING: A REVIEW PAPER , Harsimran Singh Sodhi Chandigarh University 91
PUBLICATIONS 379 CITATIONS

7 Lecture Notes on Advanced Foundry Technology (Mould and moulding sands) Lecturer: Dr Getahun
Tefera School of Mechanical and Industrial Engineering Dire Dawa University