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Analysis of annealing on the micro‑porosity and ductility of squeeze‑casted Al7050 alloy for the structural applications

Mufti Nadeem Ahmad, Islam Moiz ul, Ali Muhammad Asad, Raza Muhammad Huzaifa, Ahmed Naveed

Archives of Civil and Mechanical Engineering

2022

Vol. 22, no. 3

art. no. e107

Squeeze casting has emerged as an attractive alternative for the casting of aluminum alloys to boost the mechanical and microstructural attributes. However, the alloys practiced in structural applications where ductility is considered a key characteristic, additional heat treatment processes are opted after casting. Considering the industrial applications of Al7050, the current study focused on manufacturing defect-free casting for structural applications. For this purpose, three key process variables including squeeze pressure (SP), melt temperature (MT) and die temperature (DT) have been preferred to improve the percentage elongation, ultimate tensile strength and hardness with minimal casting defects. Annealing treatment is preferred to further advance the ductile behavior of the squeeze-casted Al7050 alloy. Among different process variables, SP has a significant contribution in raising the mechanical properties followed by MT and DT. Taguchi-based Grey relational analysis (GRA) has been used to attain the optimal level of input parameters (SP = 135 MPa, MT, 740 °C and DT = 240 °C) for the superior microstructural and mechanical attributes simultaneously. Microstructural investigations revealed that application of high SP and DT with reasonable MT significantly improved the grain structure and minimized the typical casting defects including micro-voids, porosity and shrinkage cavities. Annealing treatment has been observed productive for improving ductility and reducing the casting defects specifically micro-porosity.

Analysis of the effect of wire electric dischage machining process parameters on the formation of high speed steel form tool

Ishfaq Kashif, Mufti Nadeem Ahmad, Jawad Muhammad, Sajid Muhammad, Jahanzaib Mirza

Advances in Science and Technology. Research Journal

2018

Vol. 12, no 1

89--98

The use of form tools is growing in industry, owing to their inherent advantage of improving productivity. However, the accurate formation of form tool profile is a really tedious task. In this research work, wire electric discharge machining (WEDM) process has been used for the generation of a form tool. Pulse on-time, pulse off-time, servo voltage, wire tension, flushing pressure have been considered as input parameters, whereas tool geometry (clearance angle, included angle), surface roughness and material removal rate are the selected responses. Response surface methodology (RSM) (Box Bhenken experimental design) technique has been used for design of experiments. Analysis of Variance (ANOVA) has shown that pulse on-time and pulse off-time are the two influential control factors for material removal rate (MRR), surface roughness (Ra), clearance angle and included angle. Contour plot analysis has been performed to find out the optimal ranges of the most influential control factors for each response characteristics.