MECHANICAL PROPERTIES

UNDER CONSIDERATION
• Hardness
• Tensile strength
• Ductility

COMPOSITION OF ALUMINUM
ALLOY LM 25:
Copper
Magnesium
Silicon
Iron
Manganese
Nickel
Zinc
Lead
Tin 0.15-0.2
0.20-0.65
6.5-7.5
0.45-0.55
0.35
0.15
0.05

Titanium 0.05-0.25

Aluminum Remainder

Chemical composition
Aluminium casting alloys
• Alloy designations:
• (i) Aluminium Association (AA)
system.
• (ii) Aluminium Association
casting Tamper Designation
system.
• (iii) American National Standards
Institute (ANSI ):
• (iv) The UNS Alloy Designation
System
 Contd………..

• (v)DIN AND ISO SYSTEM



 For example, 6181=AlSi1Mg0.8

 Variation of Mechanical
properties with percentage
composition of constituent
element
• Composition Grouping:There are 7
basic groups…….
• Aluminum- copper (2xx)
• Aluminum- silicon- copper (3xx)
• Aluminum-silicon-magnesium (3xx)
• Aluminum- silicon (4xx)
• Aluminum- magnesium (5xx)
• Aluminum- zinc-magnesium (7xx)
• Aluminum-tin (8xx)
 


 Aluminum-Copper
Aluminum-Copper have been used
extensively in wrought and cast
form where strength and toughness
are required. These alloy exhibit
strength and hardness at room and
elevated temperatures
Alloy of this types are susceptible to
solidification cracking and to
interdendritic shrinkage.
Copper-containing aluminum alloys
are less resistance to corrosion and
 Aluminum-Silicon-Copper
• Copper contributes to strengthening
and machinability and silicon
improves castability and reduces
hot shortness
• Al-Si-Cu alloys with less than 5-6%
Cu are heat-treatable, if Mg is
added then heat-treatment
response is enhanced

 Aluminum-Silicon-
Magnesium
• Excellent properties after heat
treatment, high Corrosion
resistance, and a low level of
thermal expansion
• While not as strong as high-strength
Al-Cu and Al-Si-Cu alloys.
 Aluminium-Silicon
• Binary aluminium-silicon alloys
exhibit excellent fluidity, castability,
and corrosion resistance. These
alloys display low strength and poor
machinability
• The strength, ductility, and
castabilityof hypoeutectic Al-Si
alloys can be further improved by
modification of Al-Si eutectic
through the controlled addition of
sodium and/ or strontium

 Aluminium-Magnesium
• Single phase binary alloys with
moderate to high strength and
toughness
• Most important characteristics is the
corrosion resistance including
exposed to sea-water and marine
application
• Excellent weldability , machinability and
attractive appearance
• But they require greater control of
temperature gradient
• Mg in Al-alloys increases the oxidation
rates
Aluminium-Zinc-Magnesium
• Rapid solidification in these alloys
can result in microsegretion of
magnesium-zinc phases that
reduces hardening potential.
• The cost of heat-treatment, high
residual stress levels and distortion
are avoided
• The castability of Al-Zn-Mg alloys is
poor, and good foundry practices
are required to minimize hot
tearing and shrinkage defects
 Aluminium-Tin
• Tin is the major alloying element in
compositions developed for bearing
application.
• Alloys containing 5.0 to 7.0% Sn are broadly
used in bearings and bushing in which low
friction, compressive strength, fatigue
strength, and resistance to corrosion are
important criteria
• Their light weight minimize loads in
reciprocating and heat dissipation
improves bearing life
• Al and tin are essentially immiscible before
and after solidification, tin is present in
dispersed form
• Parts may be plastically cold worked to
 Effects of Alloying Elements
(i) Antimony


• 0.10%, antimony refines the aluminum-

silicon eutectic.
• But a distinctly lamellar eutectic rather
than a fine fibrous structure
• It reacts with sodium or strontium to
form coarse intermetallics with
adverse effects on castability and
metallurgical structure
• Antimony is a heavy metal with
potential of toxicity and associated
with stibinegas (SbH3) formation
(ii) Beryllium
Additions of a few parts per million

beryllium can be effective in reducing

oxidation losses
At higher concentrations (>0.04% ),

beryllium affects the form and

composition of iron-containing
intermetallics, markedly improving
strength and ductility
Changing the morphology of the

insoluble phase from plate to nodular,

beryllium changes its composition,
(iii) Bismuth, Lead, and Cadmium
Bi,Pb, and Cd addition improves the

machinability of cast aluminum alloys,

at concentrations greater than 0.1%



 (iv) Boron


Boron combines with other metals to form



borides, such as AlB2 and TiB2

Titanium boride forms stable nucleation
sites that interact with active grain-
refining phases such as TiAl3 for grain
refinement
Metallic borides reduce tool life and form

coarse inclusions with detrimental

effects on strength and ductility.
Borides also contribute to sludging, the
(v) Sodium
Sodium modifies the Al-Si eutectic. In the
absence of phosphorus, recovered
concentration of 0.01% are effective
Sodium at less than 0.005% is
embrittling in Al-Mg alloys
Sodium is rapidly lost in molten Al
through its high vapour pressure
Sodium increases surface tension and
through addition methods can increase
hydrogen content
b ) Al - 13wt % Si - 0 . 01 % Na phase diagram
and micrograph
phase diagram and Micrograph a ) Al - 13wt % Si
6 Strontium


Strontium modifies the Al-Si eutectic. In

the absence of phosphorus, recovered
concentration range of 0.008% to
0.04% are effective
Lower concentrations are effective with

higher solidification rates

Higher addition levels are associated

with casting porosity

 


(vii) Phosphorus
As AlP , phosphorus nucleates and
3
refines primary silicon-phase
formation in hypereutectic Al-Si alloys
it coarsens the eutectic structure in

hypereutectic Al-Si alloys and

diminishes the effectiveness of
common modifiers



(viii) Tin
 

Tin is effective in improving antifriction

characteristics and is used in bearing

applications.it also improves
machinability

(ix) Titanium
Titanium is extensively used to refine

grain structure
TiB is necessary grain refinement
2

(x) Chromium
Chromium typically forms the

compound CrAl3, which display

extremely limited solid solubility and
is therefore useful in suppressing
grain-growth tendencies
It improves corrosion resistance
a) Without grain refinement
b) With grain refinement
 Effects of Major Alloying
Elements
(i) Silicon


• Improvement of casting characteristics

• Fluidity, hot tear resistance and feeding
characteristics
• For slow cooling rate processes such as plaster,
investment, and sand, the preferred range is 5 to
7%, for permanent mold 7 to 9%, and for die casting
8 to 12%
• It combines with Mg and forms an intermetallic
compound MgSi2
• Al-Si alloys differ from our "standard" phase diagram
in that aluminium has zero solid solubility in silicon
at any temperature. This means that there is no
beta phase and so this phase is "replaced" by pure
silicon (you can think of it as a beta phase, which
consists only of silicon).
• Therefore, for Al-Si alloys, the eutectic composition is
Phase Diagram of Al-Si
(ii)
 Magnesium


Mg is the basic for strength and

hardness development in heat treated
Al-Si alloys and is commonly used in
more complex Al-Si alloy containing
Cu, Ni and some other elements for
same purpose
The intermetallic compound MgSi
2
which acts as a hardening phase
display a useful solubility limit
 Variation of tensile
properties with Mg%
 Elongation vs Mg
percentage for 1.3mm thick
plate
(iii) Copper
It improves strength and hardness in

the cast and heat treated conditions

Alloys containing 4 to 5.5% Cu

respond most strongly to thermal

treatment
It reduces corrosion resistance and

increases stress-corrosion
It reduces hot tear resistance and

increases the potential for

interdendriticshrinkage
Aluminum-copper alloy containing 2
 Variation of tensile
properties with copper
content
(iv) Iron
Iron improves hot-tearing resistance

and decreases the tendency for die

sticking or soldering in die casting .
Increases in iron content decreased

ductility
The intermateilic phases FeAl ,
3
FeMnAl6, and α-AlFeSi. These
insoluble phases are responsible for
strength, especially at elevated
temperature, but also embrittlement
of the microstructure
Effect of Iron plus Silicon
impurities on Tensile
properties of Al
 (v) Manganese


In the absences of work-hardening, Mn

offers no significant in cast Al-alloys
High-volume fraction of MnAl
6 in alloy
containing more than 0.5% Mn may
beneficially influence internal
soundness

 Variation of tensile
properties of Al-alloy with
Mn %
(vi) Zinc
Zinc offers no significant benefits in

aluminium casting
Addition of Cu and/ or Mg, however,

zinc results in attractive heat-

treatable composition
Up to 3% Zn in die casting

compositions allows the use foe

lower-grade and wrought alloy scrap
 Variation of tensile
properties for Al-Mg alloy
with Zn
 CASTING

• Sand Casting
• Sand casting is the simplest method
of casting aluminium. Sand is made
into a mould by forming around a
wooden "pattern". The pattern is
removed, the sand mould
assembled and molten metal
poured in. The process is chosen for
small production runs, for complex
shape castings requiring intricate
cores or for very large castings
Sand Casting
 Gravity Die-Casting
• Castings are produced by pouring
molten metal into permanent metal
moulds. It is generally made from
cast iron. This process produces ‘
Chill Castings’
Gravity Die-Casting
 Low Pressure Die-
Casting
• This is a repetitive process where
identical parts are cast by injecting
molten metal under low pressure
into metal dies. This process
requires complex machinery and is
similar to high pressure die-casting
Low Pressure Die-
Casting
 High Pressure Die-
casting
• High pressure die- casting is a
repetitive process for casting
identical parts by injecting
Aluminium into metal moulds at
pressures in the order of 1000psi.
Complex machinery and expensive
tooling is required for this process.
It is characterized by very good
surface finish and dimensional
consistency. The advantage of this
system includes fast cycle times
and the convenience of melting the
High Pressure Die-
casting
 Diesel Furnace
• A diesel furnace is a piece of equipment that
produces heat by burning diesel. The diesel
used to power the furnace can be of
petroleum origin. It is used to make casting
specimens. We used a K- type thermocouple
to measure the temperature. Temperature
Range – 0 to 1100 ºC. We also used a multi
channel temperature indicator for mesuring
casting temperature.
• The highest temperature that can be obtained
in a diesel furnace (in workshop) is 950ºC.
The temperature required to melt LM 25 alloy
was around 700ºC to 750ºC. It took around
20- 25 minutes to melt the material. After
that we took it to a crusible(refractory
container) and with the help of laddle we
poured the molten metal into the mould. It
took 2-3 days to solidify the molten metal and
the specimen was obtained. The specimen
 BHN values comparision- graphite˂
metal˂ sand
Prepared Specimen
CASTING SIMULATION
USING PROCAST
 FIRST ITERATION
Ø CAST SPECIMEN SPECIFICATION.
Ø One test bars with dimensions of 12mm diameter, 52mm gage
length.
Ø Cast material is LM25.
Ø Two circular section of 20 mm diameter and length 20 mm,
test section diameter 12 mm and 52 mm gauge length.
Ø Top gate is designed for this iteration.



CASTING DESIGN.
 PROCESS PARAMTER SPECIFICATION

Parameter ’ s Magnitude

Metal velocity 0.1 m/sec

Casting pressure 1 atm (101325 pa )

Ambient temperature 30 deg Celsius

Film coefficient between casting 100 w/m*m*k

and mould
Melt temperature 715 deg Celsius

Die Material Sand Silica

Casting metal Al_AlSi7Mg

TET MESH GENERATION
PRECAST INITIALIZED.
CASTING MATERIAL ASSIGN
MOULD MATERIAL ASSIGN
DEFINING RUN PARAMTER
PROCAST SOLVER
FILL TIME
INTERPRETATION OF RESULT
Ø THIS SHOWS THE TIME WHICH IS
REQUIRED FOR
 THE MOLTEN METAL TO REACH AT A
PARTICULAR POINT.
Ø WE CAN KNOW AFTER WHAT TIME
MOLTEN METAL WILL REACH AT THE
INTERESTED POINT.
Ø IT IS USED FOR THE PREDICTION OF
CATING YIELD, IF FILL TIME FOR A
POINT IS MORE THAN
 THE SOLIDIFICATION TIME OF EARLY
POINT IN
FRACTION SOLID AT 70 SEC
INTERPRETATION OF RESULT
Ø THIS RESULT PREDICTES THE MASS
PERCENTAGE OF SOLID.
Ø THIS TELL’S HOW MUCH PERCENTAGE
OF SOLID IS PRESENT AT A GIVEN
TIME.
Ø LINK FOR ANIMATION.
PRESSURE VARIATIONAT 0.51 SEC
INTERPRETATION OF RESULT.
Ø THIS WILL TELL WHAT IS THE
PRESSURE AT EACH SECTION AT A
GIVEN TIME.
Ø THE VARIATION OF PRESSURE
DIRECTLY INFLUSENCE THE GRAIN
SIZE AND HENCE MECHANICAL
PROPERTIES.
Ø THE GRAIN SIZE CAN PREDICTED
FROM THE PRESSURE AT A POINT.
Ø LINK FOR ANIMATION.
MOULD TEMPERATURE AT 190 SEC
 INTERPRETATION OF RESULT
Ø THIS PREDICTES THE VARIATION OF
MOULD TEMPERATURE WITH TIME.
Ø THE POINTS WHERE THE
TEMPERATURE REACHES HIGH
VALUE WHICH CAN CAUSE HARM TO
FOUNDRYMAN.
Ø LINK FOR ANIMATION.

AIR ENTRAPMENT AT 0.57 SEC
INTERPRETATION OF RESULT
Ø THIS TELL’S THE ENTRAPED AIR AT A
GIVEN TIME
Ø THIS RESULT CAN BE USED TO
PREDICT THE LOCATIONS WHERE
AIR CAVITY CAN BE PRESENT IN
CASTING.
Ø AIR OR GAS VENT’S CAN BE
PROVIDED AT SUITABLE LOCATIONS
WHERE THIS AIR ENTRAPMENT IS
OCCURING.
Ø LINK FOR ANIMATION.
SOLIDIFICATION TIME.
INTERPRETATION OF RESULT
Ø IT PREDICT THE SOLIDIFICATION TIME
OF EVERY POINT.
Ø THE MAXIMAM SOLIDIFICATION TIME
AND MINIMUM SOLIDIFICATION
TIME CAN BE FOUND OUT.
Ø IF THE SOLIDIFICATION TIME OF A
POINT IS LESS THAN THE FILL TIME
OF A POINT AFTER IT THEN THE
RESULTING CASTING WILL HAVE
VOIDS.
TEMPERATURE Vs TIME GRAPH.
INTERPRETATION OF RESULT
Ø THIS GRAPH IS PLOTED BETWEEN
TEMPERATURE AND TIME.
Ø THIS GRAPH IS FOR NODAL GAP OF 50.
Ø EACH CURVE SHOWS THE
TEMPARATURE VARIATION OF A
PARTICULAR NODE WITH TIME.
Ø THIS GRAPH WILL BE USED TO KNOW
THE TEMPARATURE OF A PARTICULAR
NODE.
Ø GRAPH TELL THE TEMPARATURE AT
EACH POINT IN CASTING AND MOULD.
Ø LINK FOR ANIMATION.
TEMPARATURE VARIATION OF A NODE
INTERPRETATION OF RESULT
Ø THIS GRAPH SHOWS THE VARIATION
OF TEMPARATURE OF A NODE
WHICH IS IN CASTING WITH TIME
AND HENCE ITS SOLIDIFICATION
RATE CAN BE FOUND OUT.
Ø SOLIDIFICATION RATE INFLUENCE
THE HARDNESS.
FRACTION SOLID WITH TIME
INTERPRETATION OF RESULT
Ø THIS GRAPH SHOWS THE FRACTION
SOLID WITH NODAL GAP OF 50.
Ø IN ASINGLE GRAPH ALL THE POINT IN
CASTING ARE PLOTED WITH THERE
FRACTION SOLID WITH TIME.
VOID CREATED AFTER SOLIDIFICATION
 INTERPRETATION OF RESULT
Ø AFTER THE SOLIDIFICATION OF
CASTING THERE WILL BE A VOID AT
TOP MOST PORTION.
Ø VOID OCCURRED BECAUSE THE
MOLTEN METAL AT TOP SOLIDIFES AT
LAST.
Ø THIS CAN BE AVOIDED WITH
PROVIDING A SPUR OF SOME EXTRA
HEIGHT.
POROSITY
 INTERPRETATION OF RESULT
Ø THIS RESULT CAN TELL US ABOUT THE
LOCATION WHERE POROSITY WILL
OCCUR.
Ø POROSITY IS A MEASURE OF THE VOID
SPACES IN MATERIAL, AND IS A
FRACTION OF THE VOLUME OF
VOIDS OVER THE TOTAL VOLUME,
BETWEEN 0 TO 1 OR AS A
PERCENTAGE BETWEEN 0 TO 100.
Ø LINK FOR ANIMATION.
 CONCLUSION FOR DESIGN
Ø THIS DESIGN WHICH HAVE TOP
GATEING SYSTEM WILL HAVE
SHRINKAGE CAVITY, VELOCITY OF
MOLTEN METAL WILL CAUSE SAND
INCLUSION.
Ø THIS DESIGN HAS DRAWBACKS OF VOID
CREATION, SHRINKAGE POROSITY,
FILL TIME OF SOME SECTION ARE
MORE THAN THE SOLIDIFACTION TIME
OF PREVIOUS POINTS.
Ø NOW WE KNOW WHERE CASTING WILL
 SECOND ITERATION.
Ø SAME CASTING SPECIMEN
SPECIFICATION AS FIRST
ITERATION.
Ø THE GATING SYSTEM USED IS
BOTTOM GATE.
DEISGN OF CASTING.
 PROCESS PARAMTER SPECIFICATION

Parameter ’ s Magnitude

Metal velocity 0.2 m/sec

Casting pressure 10 atm (101325 pa )

Ambient temperature 30 deg Celsius

Film coefficient between casting 20 w/m*m*k

and mould
Melt temperature 715 deg Celsius

Die Material REFRACTORY GRAPHITE MOULD.

Casting metal Al_AlSi7Mg

VELOCITY OF MOLTEN METAL
 INTERPRETATION OF RESULT
Ø THIS SHOWS THE VELOCITY PROFILE
AND ITS MAGNITUDE AND HENCE
THE EFFECT ON MOULD BECAUSE
OF MOLTEN METAL FLOW.

FRACTION SOLID AT T=2.58 SEC
 INTERPRETATION OF RESULT
Ø AT THE TIME 2.58 SEC THE MOULD IS
NOT COMPLETELY FILLED AND TILL
THAT TIME ALL THE MOLTEN METAL
IS AT SAME POURING TEMPARATURE
BECAUSE THE MOULD IS A
REFACTORY MATERIAL WITH VERY
LESS FILM COEFFICIENT BETWEEN
INTERFACE.

VOID CREATION AT TIME 2.58 SEC
INTERPRETATION OF RESULT
Ø SINCE DURING THE TIME OF 2.58 SEC
THE MOULD IS NOT COMPLETELY
FILLED HENCE THERE WILL BE A
VOID AT THAT TIME.
Ø THIS VOID MAY NOT BE THERE IF
SIMULATION IS RUNNED FOR MORE
TIME.
TEMPARATURE VARIATION
INTERPRETATION OF RESULT
Ø SINCE THE MOULD IS A BAD
CONDUCTOR OF HEAT SO THERE
WILL BE VERY LESS HEAT TRANSFER
TO SURROUNDING AND MOLTEN
METAL WILL BE AT TEMPERATURE OF
POURING FOR TIME 2.58 SEC.
VARIATION OF TEMPARATURE.
INTERPRETATION OF RESULT
Ø THERE IS VERY LESS TEMPARATURE
VARIATION IN BOTH CASTING AND
MOULD BECAUSE THE MOULD
MATERIAL IS BAD CONDUCTORE OF
HEAT.
Ø THIS RESULT IS ONLY TILL TIME 2.58
SEC.
 CONCLUSION.
Ø SO FAR TILL TIME OF 2.58 SEC THERE IS
PROPER MOULD FILLING.
Ø NOTHING CAN BE CONCLUDED FROM
THIS SIMULATION BECAUSE THE
TIME OF SIMULATION IS NOT
ENOUGH TO FILL THE MOULD
COMPLETELY.
Ø BUT THERE IS WASTAGE OF MATERIAL
IN SPUR AND ALSO IT IS DIFFICULT
TO REMOVE THE RUNNER AND SPUR
FROM CASTING.
 ITERATION THIRD.
Ø CAST SPECIMEN SPECIFICATION.
Ø ONE TEST BARS WITH DIMENSIONS OF 12MM
DIAMETER, 52MM GAGE LENGTH.
Ø CAST MATERIAL IS LM25.
Ø TWO CIRCULAR SECTION OF 20 MM DIAMETER
AND LENGTH 20 MM, TEST SECTION
DIAMETER 12 MM AND 52 MM GAUGE
LENGTH.
Ø BRANCHED GATE IS DESIGNED FOR THIS
ITERATION.



CASTING DESIGN.
 PROCESS PARAMTER SPECIFICATION

Parameter’s Magnitude

Metal velocity 0.3 m/sec

Casting pressure 1 atm (101325 pa )

Ambient temperature 30 deg Celsius

Film coefficient between casting and mould 20 w/m*m*k

Melt temperature 715 deg Celsius

Die Material Refractory graphite

Casting metal Al_AlSi7Mg

 TEMPARATURE VARIATION.
AT TIME 30.8 SEC.



Ø AT TIME 30.8 SEC.

Ø AT TIME 160 SEC.

Ø AT TIME 160 SEC.

TEMPATURE Vs TIME
AIR ENTRAPMENT.
FRACTION SOLID AT T= 40 SEC
FRACTION SOLID Vs TIME.
PROSOITY.
SOLIDIFICATION TIME.
FILL TIME.
 CONCLUSION.
Ø THIS DESIGN IS BETTER THAN OTHER
AS THERE IS UNIFORM
SOLIDIFICATION TIME FOR
CASTING.

 STANDARDIZATION
• We need to standardize the data of LM25 using
the instruments available in the campus so
that we can compare this data with the
enhanced alloy to be produced.
Standardization or standardization is the
process of developing and agreeing upon
technical standards. A standard is a
document that establishes uniform
engineering or technical specifications,
criteria, methods, processes, or practices.
Some standards are mandatory while others
are voluntary. Voluntary standards are
available if one chooses to use them. Some
are de facto standards, meaning a norm or
requirement which has an informal but
dominant status. Some standards are de jure,
meaning formal legal requirements. Formal
standards organizations, such as the
International Organization for Standardization
 Metallographic Specimen
Preparation
Specimen Preparation


• The first step in specimen preparation is

selection and separation of samples from
the bulk material (sampling) is of special
importance. If the choice of a sample is
not representative of the material, it
cannot be corrected later.it is also difficult
to compensate later for improper
sectioning, because additional ,time
consuming corrective steps are necessary
to remove the initial damage.
• Sectioning should render a plane surface for
the following preparation without causing
critical changes in the material
Mounting
Mounting of specimens is usually

necessary to allow them to be handled

easily.it also minimizes the amount of
damage likely to be caused to the
specimen itself.
The mounting material used should not

influence the specimen as a result of

chemical reaction or mechanical
stresses.it should adhere well to the
specimen ,and if the specimen is to be
electro polished later in the
preparation then the mounting should
Grinding
Surface layers damaged by cutting
must be removed by grinding.
Mounted specimens are ground with
rotating discs of abrasive paper, for
example wet silicon carbide paper.
The coarseness of the paper is
indicated by a number: the number of
grains of silicon carbide per square
inch. So, for example, 180 grit paper is
coarser than 1200 grit.
The grinding procedure involves several
Polishing
Polishing discs are covered with soft
cloth impregnated with abrasive
diamond particles and an oily
lubricant or water lubricant. Particles
of two different grades are used : a
coarser polish-typically with diamond
particles 6 microns in diameter which
should remove the scratches
produced from the finest grinding
stage, and a finer polish-typically with
diamond particles 1 micron in
diameter, to produce a smooth
Specimen after
grinding
 HARDNESS TEST
• The Brinell hardness test is used to measure
the hardness of the composites. The
Brinell hardness test method consist of
indenting the test material with a 10 mm
diameter hardness steel ball subjected to
a load of 500 kg for softer materials. The
full load is normally applied for at least 30
seconds. The diameter of the indentation
left in the test material is measured with
low powered microscope. The average of
two reading of the diameter of impression
at right angle should be made. Surface on
which the indentations is made be smooth
and free from dirt or scale. The brinell
hardness number is calculated by dividing
the load applied by the surface area of the
Hardness Test Using Brinell
Hardness Testing Machine
 
Hardness Test Using Brinell
Hardness Testing Machine
 
OBTAINED RESULT
Applied load, P = 500 Kg
Material of Indentor : carbon steel
Diameter of Indentor , D = 10mm

TYPES OF MOULD
SAND
METAL
GRAPHITE BHN
60
58
56 3.323
DIAMETER
3.213
3.267 OF
INDENTATION (d in mm)
Hardness Test Using Brinell
Hardness Testing Machine
 
Universal Measuring
Microscope
 SURFACE ROUGHNESS
• Surface roughness is measure of the
finer surface irregularities in the
surface texture. These are results of
the manufacturing process employed
to create the surface. Surface
roughness Ra is rated as the
arithmetic average deviation are
large, the surface is rough; if they are
small the surface is smooth.
Roughness is typically considered t be
the frequency, short wavelength
component of a measured surface.
• The surface roughness of the machined
composites is measured by using
Measurement of surface
roughness using surface
profilometer.
 OBTAINED DATA
Ra is the arithmetic average of the absolute values and Ry is
the range of the collected roughness data points
SAND MOULD GRAVITY METAL MOULD
MOULD

Ra Ry Ra Ry Ra Ry

13.55 75.62 4.04 26.26 7.39 50.16

13.77 76.74 3.65 24 7.91 63.23

11.51 60.35 4.13 23.32 8.84 65.67

9.56 54.67 5.48 30.31 6.91 43.27

10.93 61.68 6.98 38.21 7.46 52.36

12.6 72.68 5.61 34.64 8.48 64.67

11.33 62.21 6.51 41.49 7.73 51.36

13.23 71.24 5.78 31.22 6.68 42.36

THANK YOU