Evaluating the effects of as-casted and aged overcasting of Al-Al joints
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This research aims to evaluate Al-Al joints fabricated by overcasting liquid 2024 Al alloy onto Zn-electroplated 2024 Al alloy solid inserts followed by solidification under pressure. The effects of three most influencing process parameters including squeeze pressure, die temperature and melt temperature on the mechanical properties of as-casted and aged overcast joints were investigated. Response surface methodology with central composite design was employed for experimental design and development of empirical models. The observed responses in this research include ultimate tensile strength and hardness. Adequacy and validity of the developed models were verified through ANOVA and confirmation experiments, respectively. For both as-casted and aged overcasting conditions, the results revealed melt temperature as the most significant process parameter affecting ultimate tensile strength and hardness followed by die temperature and squeeze pressure. The comparative analysis of the two conditions suggested aged overcasting as the better alternative which resulted in 5.7~9.8 and 3.6~12.4% improvement in ultimate tensile strength and hardness, respectively.
KeywordsWrought Al alloy Overcasting Squeeze casting Aging Mechanical properties Response surface methodology
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