Skip to main content
SpringerLink
Log in

Properties Optimization and Strengthening Mechanism of KNO3–KCl Water-Soluble Composite Salt Core for Hollow Zinc Alloy Die Castings

International Journal of Metalcasting volume 17, pages 563–572 (2023)Cite this article

Abstract

A composite inorganic salt core with good water solubility and formability was proposed using potassium nitrate (KNO3) and potassium chloride (KCl) as base materials. The KNO3–KCl molar ratio has been optimized for the KNO3–KCl composite salt core, and then a low-cost bauxite powder acting as a reinforcing material was added to strengthen the optimized KNO3-KCl composite salt core for the application of hollow zinc alloy die castings. The results show that 70 mol% KNO3-30 mol%KCl composite salt core (CSC) possesses a good comprehensive performance, which has the maximum bending strength of 26.5 MPa and the excellent water solubility rate of 998 g/(min·m2). With increasing the bauxite powder content, the bending strength and vickers hardness of the CSC increase, but the water solubility rate of the CSC decreases gradually. When the bauxite powder content is 30 wt.%, the CSC has a bending strength of 42.99 MPa and vickers hardness of 39.2 HV, which respectively increased by 62.2% and 39.5%, and the water solubility rate is still higher than 692.9 g/(min·m2). The microanalysis reveals that the bauxite powder is stable and evenly distributed among the CSC matrix, which significantly refines the KCl primary phase, resulting in improving the properties of the CSC. Additionally, the crack deflection and branching caused by bauxite powder also enhance the properties of the CSC.

This is a preview of subscription content, access via your institution.

Access options

Buy single article

Instant access to the full article PDF.

USD 39.95

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12

References

  1. V. Reveko, F. Lampert, G. Winther, P. Moller, Change of the decorative properties of zinc-plated zinc die castings over time. Inter. Metalcast. 13, 130–136 (2019). https://doi.org/10.1007/s40962-018-0237-0

    Article  CAS  Google Scholar 

  2. A. Pola, M. Tocci, F.E. Goodwin, Review of microstructures and properties of zinc alloys. Metals 10, 253–289 (2020)

    Article  CAS  Google Scholar 

  3. M. Page, B. Weidenfeller, S. Hartmann, Influence of temperature and aging on the thermal diffusivity, thermal conductivity and heat capacity of a zinc die casting alloy. J. Alloy Compd. 786, 1060–1067 (2019)

    Article  Google Scholar 

  4. T. Xue, W.Q. Gu, Y.F. Yu, J. Wu, Research and application development in die casting zinc alloy. Special Casting & Nonferrous Alloys 36, 260–264 (2016). ((in Chinese))

    Google Scholar 

  5. M.A. Page, S. Hartmann, Experimental characterization, material modeling, identification and finite element simulation of the thermo-mechanical behavior of a zinc die-casting alloy. Int. J. Plasticity 101, 74–85 (2018)

    Article  Google Scholar 

  6. R. Huang, B. Zhang, Study on the composition and properties of salt cores for zinc alloy die casting. Inter. Metalcast. 11, 440–447 (2017). https://doi.org/10.1007/s40962-016-0086-7

    Article  Google Scholar 

  7. A. Fortini, M. Merlin, G. Raminella, A comparative analysis on organic and inorganic core binders for a gravity diecasting Al alloy component. Inter. Metalcast. (2021). https://doi.org/10.1007/s40962-021-00628-1

    Article  Google Scholar 

  8. S. Tu, F.C. Liu, G.J. Li, W.M. Jiang, X.W. Liu, Z.T. Fan, Fabrication and characterization of high-strength water-soluble composite salt core for zinc alloy die castings. Int. J. Adv. Manuf. Tech. 95, 505–512 (2018)

    Article  Google Scholar 

  9. B. Fuchs, H. Eibisch, C. Körner, Core viability simulation for salt core technology in high-pressure die casting. Inter. Metalcast. 7(3), 39–45 (2013). https://doi.org/10.1007/BF03355557

    Article  CAS  Google Scholar 

  10. M. Merchán, M.G. de Cortazar, H. Galarraga, Research on coatings and infiltration to strengthen ceramic lost cores used in high-pressure die casting processes. Inter. Metalcast. 13(3), 597–603 (2019). https://doi.org/10.1007/s40962-018-00301-0

    Article  CAS  Google Scholar 

  11. J. Beňo, E. Adámková, F. Mikšovský, Development of composite salt cores for foundry applications. Mater. Tech. 49, 619–623 (2015)

    Google Scholar 

  12. P. Jiang, F.C. Liu, Z.T. Fan, W.M. Jiang, X.W. Liu, Performance of water-soluble composite sulfate sand core for magnesium alloy castings. Arch. Civ. Mech. Eng. 16, 494–502 (2016)

    Article  Google Scholar 

  13. X.L. Gong, W.M. Jiang, F.C. Liu, Z.Y. Yang, Z.T. Fan, Effects of glass fiber size and content on microstructures and properties of KNO3-based water-soluble salt core for high pressure die casting. Inter. Metalcast. 15, 520–529 (2021). https://doi.org/10.1007/s40962-020-00480-9

    Article  CAS  Google Scholar 

  14. P. Jelínek, F. Mikšovský, J. Beňo, E. Adámková, Development of foundry cores based on inorganic salts. Mater. tech. 6, 689–693 (2013)

    Google Scholar 

  15. J. Yaokawa, D. Miura, K. Anzai, Y. Yamada, Strength of salt core composed of alkali carbonate and alkali chloride mixtures made by casting technique. Mater. Trans. 48, 1034–1041 (2007)

    Article  CAS  Google Scholar 

  16. Z. Xiao, L.T. Harper, A.R. Kennedy, N.A. Warrior, A water-soluble core material for manufacturing hollow composite sections. Compos. Struct. 182, 380–390 (2017)

    Article  Google Scholar 

  17. R.J. Donahue, M.T. Degler, Congruent melting salt alloys for use as salt cores in high pressure die casting. U.S. Patent 9878367, 2018-1-30

  18. X.Y. Liu, W.H. Liu, X.T. Wang, Composition optimization and strengthening mechanism of high-strength composite water-soluble salt core for foundry. Inter. Metalcast. (2021). https://doi.org/10.1007/s40962-021-00725-1

    Article  Google Scholar 

  19. C. Cantas, B. Baksan, Effects of composition on the physical properties of water-soluble salt cores. Inter. Metalcast. 15, 839–851 (2021). https://doi.org/10.1007/s40962-020-00511-5

    Article  CAS  Google Scholar 

  20. F.C. Liu, P. Jiang, Y. Huang, W.M. Jiang, Z.T. Fan, A water-soluble magnesium sulfate bonded sand core material for manufacturing hollow composite castings. Compos. Struct. 201, 553–560 (2018)

    Article  Google Scholar 

  21. Youji Y. Method of manufacturing expendable salt core for casting. U.S. Patent 8574476B (2013)

  22. L. Zhang, Effect of kaolin on tensile strength and humidity resistance of a water-soluble potassium carbonate sand core. Chin. Foundry 13, 15–21 (2016)

    Article  Google Scholar 

  23. W. Jiang, J. Dong, L. Lou, M. Liu, Z. Hu, Preparation and properties of a novel water soluble core material. J. Mater. Sci. Tech. 26, 270–275 (2010)

    Article  CAS  Google Scholar 

  24. X.L. Gong, X.W. Liu, Z. Chen, Z.Y. Yang, W.M. Jiang, Z.T. Fan, 3D Printing of high-strength water-soluble salt cores via layered extrusion forming. Int. J. Adv. Manuf. Tech. 118, 2993–3003 (2022)

    Article  Google Scholar 

  25. F.C. Liu, S. Tu, X.L. Gong, Z.T. Fan, Comparative study on performance and microstructure of composite water-soluble salt core material for manufacturing hollow zinc alloy castings. Mater. Chem. Phys. 252, 123257 (2020)

    Article  CAS  Google Scholar 

  26. Salt Phase Diagrams. https://www.crct.polymtl.ca/fact/phase_diagram.php?file=KCl-KNO3.Jpg&dir=FTsalt. Accessed July 6, 2020

  27. W. Yuan, S.K. Panigrahi, J. Su, R.S. Mishra, Influence of grain size and texture on Hall-Petch relationship for a magnesium alloy. Scripta Mater. 65, 994–997 (2011)

    Article  CAS  Google Scholar 

Download references

Acknowledgements

The authors would like to thank the support of the National Nature Science Foundation of China (Grant No. 51775204) and the Research Project of State Key Laboratory of Materials Processing and Die & Mould Technology (Grant No. P2021-020), and the Analytical and Testing Center, HUST.

Author information

Authors and Affiliations

  1. State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China

    Xiaolong Gong, Fuchu Liu, Xinwang Liu, Wenming Jiang & Zitian Fan

  2. School of Mechanical Engineering and Electronic Information, China University of Geosciences, Wuhan, 430074, China

    Fuchu Liu

Authors
  1. Xiaolong Gong
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Fuchu Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xinwang Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Wenming Jiang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zitian Fan
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Xiaolong Gong or Zitian Fan.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and Permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Gong, X., Liu, F., Liu, X. et al. Properties Optimization and Strengthening Mechanism of KNO3–KCl Water-Soluble Composite Salt Core for Hollow Zinc Alloy Die Castings. Inter Metalcast 17, 563–572 (2023). https://doi.org/10.1007/s40962-022-00784-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40962-022-00784-y

Keywords

search

Navigation