Optimization of the Casting Parameters of a Squeeze Cast Aluminum Alloy Composite using Taguchi Method

Abstract

A lot of attention has been on aluminum and its alloy due to its wide
range of industrial applications and qualities likes low density, good
formability, high conductivity, high specific rigidity, excellent
corrosion resistance, high castability and attractive tensile strength.
The most common problems associated with casting are some forms
of imperfections which are voids, cracks, and inclusions with varying
degree of relative stiffness. Optimizing squeeze casting parameters
will eliminate these forms of imperfection which forms the basis of
this study. An optimization technique for squeeze casting process
parameters based on Taguchi method is reported in this project.
Squeezed casts were prepared using three different parameters at
three different levels. The settings of these parameters were
determined using the Taguchi L9 orthogonal array giving nine runs
and squeezed cast specimens were tested to obtain their hardness
and tensile strength. The optimum parameter combination was
obtained using the analysis of signal-to-noise (S/N) ratio. The
optimized process parameter obtained for hardness was A2 – 38.79,
B3 – 38.88, C2 – 38.80 corresponding to pouring temperature at
6500C, mould temperature at 7000C and squeeze pressure at
2000Pa. While that of tensile strength was A1 – 40.15, B2 – 40.89,
C1 – 40.89 corresponding to pouring temperature at 6500C, mould
temperature at 7000C and squeeze pressure at 3000Pa. Finally
based on the tensile strength and hardness test carried out the
optimum level process parameters was found to be 40.89N/mm2 and
38.88HB.