Influence of Mould Material on Metallurgical

and Mechanical Properties of A356 Alloy

PREPARED BY :
K. RAJA RAJESWARI
G. GNANESWARA RAO
T. BENARJI NAIDU
A. JIGISHA
T. HEMA CHAND
G. SRUJANA
B. VARUN SANDEEP
MOHAMMED WASIM RAJA

Under the esteemed guidance of

Prof.Babu Rao Jinugu. Mtech ,Phd

CONTENT :
 INTRODUCTION
 MOULD PREPARATION
 ALLOY PREPARATION
 CASTING
 FETTLING
 MACHINING
 TESTING - PHYSICAL PROPERTIES
HEAT TREATMENT
MECHANICAL PROPERTIES
METALLOGRAPHY (SEM)
 CONCLUSION
Aluminum Alloy :
● Aluminum alloy is a metal composed of
aluminum combined with other elements like
copper, magnesium, silicon, zinc, and
manganese, altering its mechanical and physical
properties.
● These elements are added in specific ratios to
tailor the alloy for different applications.
● Aluminum alloys are widely utilized across
various industries due to their low density,
corrosion resistance, and thermal conductivity.
● They are employed in manufacturing consumer
electronics, automobiles, aircraft, and more.
 INTRODUCTION TO ALUMINIUM A356 ALLOY

• A356 is a type of aluminum alloy specifically

designed for casting purposes.
• In the aluminum alloy designation system for casting,
alloys are grouped into series such as 1xx.x, 2xx.x,
3xx.x, and so on.
• A356 aluminium die casting alloy is renowned for its excellent casting
and machining characteristics, making it well-suited for a range of
applications including aircraft components, pump housings, impellers,
highvelocity blowers, and structural castings requiring high strength.
• A356 aluminium is often favoured for producing intricate and complex
aluminium castings due to its lightweight nature, pressure tightness,
and impressive mechanical properties. It is commonly used as an
alternative to 6061 aluminium alloy in various applications
COMPOSITION:
Elements Cu Mg Mn Si Fe Zn Ti Others Al

Composition 0.2 0.25- 0.1 6.5-7.5 0.2 0.1 0.2 0.15 Balance
0.45
(%)

PROPERTIES OF A356 ALLOY:

Density: A356 alloy typically has a density of around 2.68 g/cm³.
Melting Point: Its melting point ranges approximately between 570°C to 640°C (1060°F to
1180°F), varying with specific compositions.
Tensile Strength: A356 alloy displays favorable tensile strength, usually ranging from 190 to 310
MPa (27,500 to 45,000 psi).
Yield Strength: Its yield strength typically falls between 110 to 250 MPa (16,000 to 36,000 psi).
Elongation: A356 alloy generally exhibits an elongation at break of about 3% to 7%.
Hardness: Hardness levels for A356 alloy typically range from 70 to 150 Brinell hardness number
(BHN), subject to processing and heat treatment.
Corrosion Resistance: A356 alloy offers good resistance to corrosion, particularly in
atmospheric conditions, though it may be susceptible to specific types of corrosion in severe
environments. Machinability: A356 alloy exhibits good machinability, facilitating various
machining operations like milling, turning, and drilling.
 PROCESS FLOW CHART

Preparation of Moulds Melting of Metal in Pouring the metal into Knocking of the moulds
Crucible Furnace mould cavities after solidification

Fettling Machining Testing for Mechanical Microstructure

and Chemical Properties Observation
 MOULD PREPARATION
Types of molds used in casting of A356 Alloy :
Various types of moulds are employed in casting Al A356 Alloy. Among those we used :

• CO2 Mould

• Cast Iron Mould

• Copper Mould

Co2 Moulding :
 In this method, sodium silicate serves as the primary binder.
 However, sodium silicate exhibits binding properties or activation solely in the
presence of carbon dioxide gas. Hence, it is commonly recognized as CO2
moulding.
 Sodium silicate undergoes a reaction with carbon dioxide to produce silica gel,
which functions as the binding agent for the sand particles.
 The chemical equation representing this reaction is as follows:

Na2SiO3 (sodium silicate) + CO2 → Na2CO3 + SiO2 (silica gel)

 MOULD PREPARATION
CO2 Moulding Process :

• Prepare 2kg of moulding sand by combining 1880gm of silica sand with 120gm of sodium silicate,
constituting 6% of the total weight.
• Place the pattern on a flat surface, enclosed by the drag box. Parting sand is then sprinkled
onto the pattern's surface to prevent sand adhesion.

Co2 Moulding
 MOULD PREPARATION
• Proceed to fill the drag box with the sand mixture, manually ramming it until reaching the
top surface.
• Create vent holes and pass CO2 gas through them, inducing instant hardening of the
Mold.
• Assemble the cope box atop the drag box, positioning the sprue and riser appropriately,
and fill it with the sand mixture.
• Thoroughly ram the sand to the top surface and create vent holes using a vent rod. CO2
gas is then passed through these vent holes.
• After a brief duration, separate the cope and drag. Remove the pattern, riser, and sprue
from the Mold to form a Mold cavity.
• Utilize hand tools to cut gates, providing pathways for the flow of molten metal.The Mold is
now prepared for metal pouring.
PERMANENT MOULD:

Permanent Mould Casting makes use of a mould which is permanent i.e these moulds can
be reused many times.
These Molds are typically constructed from materials like cast iron, steel, bronze, graphite,
or other refractory materials.
They are designed in two halves to facilitate the easy removal of the casting.
 MOULD PREPARATION

Controlling the Mold temperature is a critical parameter in this process.

Initially, the Mold is heated using a torch.
Subsequently, during the casting cycle—
comprising closing, coring, opening, and ejecting
the casting—the timing is carefully managed to
ensure that the Mold maintains the appropriate
temperature throughout the metal pouring
process.

METAL MOULD
 ALUMINIUM A356 ALLOY PREPARATION

MELTING PROCEDURE OF ALUMINIUM ALLOY:

 The initial manufacturing process of A356 Alloy is melting.

 In this step, the chunks of A356 alloy which are usually a mixture of aluminum,
silicon, and magnesium are subjected to intense heat. This process transforms
them from a solid alloy into a molten state.

 The liquid metal is then maintained at the right temperature so that its viscosity
and flowability are perfect.

 Also, through the melting process, any impurities and inconsistencies are removed.
These often tend to compromise the final product’s quality and strength.

 After the melting process, the A356 alloy is prepared and maintained at the optimal
temperature ready for the next phase.
Pouring:

 The next step after melting the A356 alloy is pouring.

 The general pouring procedure for Al A356 alloy typically involves preheating the
mould, ensuring proper gating and riser design, controlling the pouring
temperature, and monitoring the fill rate to prevent defects like shrinkage or
porosity.

 Additionally, it's crucial to follow safety protocols and handle molten metal with
care to avoid accidents.
 SOLIDIFICATION OF A356 ALLOY
Cooling Rate of A356 Alloy with respect to the moulding material used for casting :
Metal Molds (e.g., steel, iron):
 Metal Molds, especially those made from materials like steel or iron, have higher thermal conductivity
 compared to sand Molds.
 This higher conductivity results in faster cooling rates, leading to quicker solidification of the A356 alloy.
 Faster solidification can help in achieving finer grain structures and may improve mechanical properties.

Copper Molds:
 Copper Molds have excellent thermal conductivity, even higher than most other metals used for
Molds.
 This high conductivity results in extremely fast cooling rates, leading to rapid solidification of the
A356 alloy.
 Quicker solidification can promote finer microstructures and potentially enhance mechanical
properties.
Sand Molds:
 Sand Molds typically have lower thermal conductivity compared to metal Molds. As a result, the
cooling rate of the molten A356 alloy in sand Molds is slower, leading to a longer solidification
 time.
 However, this slower solidification can sometimes result in better feeding and reduced risk of
defects like shrinkage.

FETTLING:

Fettling is a process of cleaning and finishing cast metal parts to remove any excess material,
surface imperfections, or unwanted features left behind after the casting process. This can
include tasks such as removing gates, risers, and excess metal, as well as grinding, sanding, or
machining to achieve the desired final dimensions and surface quality.
Fettling is an important step in the casting process as it helps ensure that the final cast parts
meet the required specifications in terms of dimensions, surface finish, and overall quality.

The fettling process may vary depending on the complexity of the cast parts, the casting method
used, and the specific requirements of the application.
MACHINING
Machining within foundries involves the utilization of machine tools to shape and refine metal castings
manufactured in the foundry. Foundries specialize in casting metal parts using processes like sand
casting, investment casting, or die casting.
However, these castings often require further refinement through machining to attain the desired final
shape, dimensions, and surface quality.

Fettling Machining
 TESTING OF PHYSICAL PROPERTIES OF A356 ALLOY:
SURFACE ROUGHNESS TEST :
A surface roughness tester is essential for assessing whether a surface meets specific
requirements. It measures parameters like roughness depth (Rz) and mean roughness
value (Ra) in micrometers (um), crucial for determining suitability for various
purposes.

To conduct a surface roughness test on Al A356 alloy, below steps to be followed :

1. Prepare the Surface
2. Choose Test Method
3. Calibrate Instrument
4. Take Measurements
5. Analyse Results
SURFACE ROUGHNESS
6. Document Findings TESTER
7. Interpret Data
8. Consider Post-Processing
 TESTING OF PHYSICAL PROPERTIES OF A356 ALLOY:

Observation:

Conclusion:

The surface roughness values of copper mold Alloy(CMA), metal mold Alloy(MMA) , sand mold
Alloy(SMA) are 2.689,5.844,4.967 respectively. This shows that using alternative moulding materials has
resulted in slightly improved surface roughness values for CMA ,MMA ,SMA. These results suggest that
alternative sand materials can serve as viable alternatives to silica sand for mold making
 TESTING OF PHYSICAL PROPERTIES OF A356 ALLOY
DENSITY TEST:
There are various methods for determining the density of a given material. The three primary
methods are
 Direct measurement,
 Indirect measurement, and
 Buoyancy Method.
Out of these three methods we conducted density test using Archimedes buoyancy Method
Buoyancy: This method, also inspired by Archimedes, involves suspending an object in a
liquid with a similar density. A common application is density columns, where a mixture of
liquids with varying densities is used. The object of interest is submerged in the column and
floats where the liquid's density matches its own. The density of a mixture of two miscible
liquids is related to the volume fraction of each liquid.
mix =AA+BB
Here, liquid A is mixed with liquid B, A and B represent the volume fractions of liquid A DENSITY TEST EQUIPMENT
and B respectively.
 TESTING OF PHYSICAL PROPERTIES OF A356 ALLOY
Observation:

Conclusion :

The density values observed are:

• Copper Mold Alloy -2.65 g/cm^3
• Cast Iron Mold Alloy-2.66 g/cm^3
• Sand Mold Alloy -2.55 g/cm^3
This test demonstrates that conducting density tests on A356 alloy, made with alternate molds of
similar composition, shows no significant change in densities.
POROSITY TEST:
A porosity test is a method used to measure the amount of void space, or pores, within a material,
typically a solid. It helps determine the material's ability to absorb fluids or gases, which is crucial in
various industries such as construction, manufacturing, and geology.
Testing the porosity of Al A356 alloy typically involves these steps:
1. Surface Preparation: Grind or polish the sample surface to remove any
irregularities or contaminants.
2. Weighing: Weigh the sample accurately before testing.
3. Density Measurement: Determine the density of the sample using
methods like Archimedes' principle or gas pycnometry.
4. Volume Calculation: Calculate the volume of the sample using its density
and weight.
5. Porosity Calculation: Subtract the calculated volume from the theoretical
volume of a solid piece of the same dimensions to find the void volume.
6. Porosity Percentage : Divide the void volume by the total volume and
multiply by 100 to obtain the porosity percentage.
7. Sample Preparation: Cut or cast a representative sample of the alloy.
8. Interpretation: Analyze the results and compare them with acceptable POROSITY TESTING
industry standards to assess the quality of the alloy. MACHINE
 TESTING OF PHYSICAL PROPERTIES OF A356 ALLOY

OBSERVATION :

CONCLUSION :
 The above graph indicates that the sand mould alloy exhibits higher porosity compared to
the copper mould alloy, while the metal mould alloy demonstrates the least amount of
porosity.
 This is because the metal mould and graphite mould do not have the precipitation pores,
while the sand mould has the precipitation pores in the entire cross section
 HEAT TREATMENT OF A356 ALLOY
Experimental procedure for age hardening of A356 alloy
 Material taken are A356 alloy casting samples which are obtained from different moulds (sand,
cooper and cast-iron mould)
 The A356 casting samples are prepared by cutting into required size and shape and nearly 12
samples are taken for heat treatment
 Now switch on the muffle furnace and adjust the set temperature to attain 520℃
 Now switch ON the muffle furnace and adjust the set temperature to solutionizing temperature i.e,
540℃ and close the furnace doors
 Wait till the muffle furnace reaches up to solutionizing temperature and it takes nearly 2 hours to
achieve that temperature
 We place the 12 samples of A356 alloy on steel mesh and load it into the muffle furnace with the
help of tongs and left them for 8 ½ hours (holding time) at 540 ℃
 Now remove the Al alloy samples (which has homogenised alpha solid solution) from the muffle
furnace and cool them rapidly to room temperature by quenching them in water
 And close the furnace door and then adjust the set temperature of the muffle furnace to 170℃ and
left for 1 hour to reach that temperature for ageing
 HEAT TREATMENT OF A356 ALLOY

 Stir the Al alloy samples while quenching them in the water to break the vapour film and cool them rapidly
 Now remove the Al alloy samples (which consist of unstable super saturated solid solution) and do artificial
ageing (which leads to precipitates (Mg2Si) nucleation and growth)

 Now place the 12 samples of A356 alloy on steel mesh and load it into the muffle furnace immediately which is at
a temperature of 170℃ and soak the samples for 8 hours
 After that time samples are removed and placed on the sand near to the furnace for air cooling
 Once the samples have equilibrated to room temperature, proceed with microstructure observation and testing.
 MECHANICAL TESTING OF A356 ALLOY
HARDNESS TEST:
 VICKERS HARDNESS TEST :
The Vickers hardness testing basic principle is to observe the ability of a material to resist permanent
deformation from a specified load. All materials have a certain level of elasticity. The Vickers hardness
test measures the maximum load applied to an object without its deformation exceeding a specified
value.
TEST PROCEDURE :
o The Vickers hardness test is commonly used to measure the hardness of
materials, particularly those with extremely hard surfaces.
o A four-sided diamond pyramid angle of 136º is used as indenter. The load,
varying from 1 to 120 kgf is usually applied for dwell time of 10-15 seconds
which produces indentation on the specimen.
o The depth of the specimen should not be less than 1.5 times the diagonal of
the impression. After removal of load opposite diagonals of square base is
measured and average diameter is considered as final as a parameter to find
area of square. Hardness number is achieved by dividing the load applied by
the area of square.
o VHN = 0.1891*F/d^2
 MECHANICAL TESTING OF A356 ALLOY

o Hardness number is achieved by dividing the load applied by the area of square indentation. The figure
9.1.a Vickers hardness tester and Figure 9.1b is graphs of the hardness of as cast Alloy and T6 Condition
alloy

OBSERVATION :

FIGURES OF HARDNESS OF SPICEMEN IN AS CAST CONDITION AND T6 CONDITION

Conclusion :
The graphs indicate a significant increase in hardness for heat-treated specimens compared
to those in their as-cast condition which are made using alternate molds .

 Hardness values in As Cast condition : CMA >> MMA>SMA

 Hardness values in T6 condition : CMA >> MMA > SMA

 The chilling effect of the metal mold produces fine grain structures which significantly
enhance physical properties.
 Elongation is 50%-100% greater and other mechanical properties are from 20%-25%
greater than sand castings of the same alloy.
 In addition, heat treatment further enhances those properties
 MECHANICAL TESTING OF A356 ALLOY
Compression Test:
A compression test is a mechanical testing method used to determine the behavior of materials under compressive
loading. In this test, a specimen of the material is subjected to a compressive force along its axis, causing it to deform.
The amount of deformation is measured and recorded, typically in relation to the applied force.
Procedure:
 Measure the dimensions of the test piece at three different points
along its height/length to determine the average cross-sectional
area.
 Ensure the ends of the specimen are planar by testing them on a
bearing plate.
 Position the specimen centrally between the two compression
plates, aligning the center of the movable head vertically above the
center of the specimen.
 Apply load to the specimen by moving the movable head. Record the Compression Testing Machine
load and corresponding deformation at regular intervals, typically with
a load interval of 500 kg. Continue applying load until the specimen
fails.
 MECHANICAL TESTING OF A356 ALLOY

OBSERVATION:
 MECHANICAL TESTING OF A356 ALLOY

Conclusion :
Analysis of the graph indicates distinct differences in compression test values among CMA,
MMA, and SMA, attributable to the inherent properties of their compositions:

 Material Composition: CMA exhibits the highest compression strength, likely due to its
copper composition. Metals generally possess superior compressive strength compared
to materials like sand, as seen in SMA.

 Sand Content (SMA): SMA displays the lowest compressive strength, consistent with
the weaker compressive properties of sand as a loose material.

 Metal Content (MMA): Falling between CMA and SMA in compressive strength, MMA
suggests a metal alloy composition possibly weakened by materials beyond pure
copper, characteristic of CMA.
 MECHANICAL TESTING OF A356 ALLOY

TENSILE TEST:
 The tensile test principle is based on applying a controlled force to a material sample, typically in the
form of a rod or wire, to measure its mechanical properties under tension. This helps determine
characteristics like ultimate tensile strength, yield strength, and elongation. The test involves
gradually increasing the force until the material fails, allowing for analysis of its behavior under
stress.
The tensile test procedure for Al A356 alloy typically involves the following steps:
1. Sample Preparation 6. Data Collection
2. Specimen Mounting 7. Failure Analysis
3. Gauge Length Measurement 8. Reporting
4. Zeroing 9. Analysis
5. Load Application 10. Quality Control
 MECHANICAL TESTING OF A356 ALLOY

OBSERVATION:

CONCLUSION :
The above graph illustrates that the tensile strength of A356 alloy made using
copper mould is much higher when compared with A356 alloy made using cast iron
mould and sand mould
TENSILE STRENGTH – CMA >> Cast Iron mould alloy > Sand mould alloy
 MICROSTRUCTURE EVALUATION
SEM ANALYSIS :
SEM micrographs of A356 alloy castings which are made in sand mould and copper , Cast iron moulds
are analysed .
 A356 aluminium alloy is a hypo eutectic alloy (Al-7.5%Si); microstructure mainly consists of soft & ductile
α-
aluminium dendrite phase containing magnesium and silicon in solution and hard & brittle eutectic phase ( α-

Al-Si in the inter dendrite region.

 The fine and refined grain structure was obtained for copper mould samples rather than cast iron and sand
MICROSTRUCTURES OF A356 ALLOY SAMPLES IN ASCAST CONDITION:
mould samples.
 MICROSTRUCTURE EVALUATION

 This may be due to the faster solidification rates in the copper moulds because of it’s high
thermal conductivity.
 Microstructure of cast iron mould castings shows in between copper mould castings and sand
mould castings.
 In general, the rate at which a casting cools affects its microstructure , quality and properties.
 The sand mould casting process cool slowly compared to metal mould castings.
 This slow cooling increases the metal’s grain size, creating a coarse microstructure, coarse
grain structure weakens the castings.
 MICROSTRUCTURE EVALUATION

HEAT TREATMENT OF A356 ALLOY :

The primary reason for applying heat treatment is to refine the eutectic phase in the A356 alloy. T6 heat
treatment has three steps, solution heat treatment, rapid quenching, and artificial ageing treatment.

MICROSTRUCTURES OF A356 ALLOY SAMPLES IN T6 CONDITION:

 MICROSTRUCTURE EVALUATION

Microstructural Evaluation after Heat Treatment :

• The A356 alloy is a hypoeutectic Al–Si alloy that can be heat treatable. This figure shows the
microstructures of the A356 alloy before and after T6 heat treatment, respectively.
Microstructural Evaluation after Heat Treatment :

• The eutectic Si particles are refined and have fewer sharp edges than the as-cast alloy before heat
treatment. The eutectic Si particles are broken up and spheroidised during the coarsening stage in
solution treatment

• The flaky morphology of Si particles in the T6 heat- treated as-cast samples was transformed to
spherical-shaped with a considerable amount lamellar shaped particles remaining after the T6 heat
treatment process .

• In T6 condition of A356 alloy, if we need best results we should use copper mould so we can get
precipitates which are uniformly arranged with best aspect ratio so it can give best mechanical
properties in T6 condition when compared with alloy made using Sand mould and cast iron
mould.
 Conclusion
This is to conclude that there is a change observed in the properties of A356 alloy which is casted by
using alternate molds after T6 heat treatment.

 when we compared the properties of A356 alloy casting which are produced by
alternate molds, excellent properties are achieved by castings which are produced by
copper mold (CMA) when it compared with the other molds (SMA, MMA).
 The castings are heat treated under T6 condition. The as-cast and heat treated
samples are subjected to various mechanical tests like hardness, tensile and
compression, porosity and density, surface roughness.
 The as-cast and heat treated samples are also characterised using optical micrographs
and SEM micrographs.
 The crystal lattices of Mg2Si precipitates show coherence with that of the α-aluminium
matrix. Consequently, severe strain fields are created around these crystals which
impede the motion of dislocations and thereby causing increased hardness of castings
obtained from CO2 and metal moulds
 The better casting is obtained from copper mould along with heat treated condition.
This may be attributed due to better conductivity of copper and precipitation
hardening from T6 condition.
Properties of CMA>MMA>SMA
REFERENCES :
1)Mechanical metallurgy – by G.E. Dieter
2)Introduction to physical metallurgy - Sydney H. Avener
3)Heat Treatment Principles and Techniques - by T.V. RajanSarma,
Ashok Sharma.
4)Foundry technology - O.P.Khanna
5) T. V. Rajan, C.V.Sharma, Ashok Sharma - Heat treatment
THANK YOU