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aluminum-silicon hypoeutectic alloys, develop mechanical proper- ties to demonstrate the efficacy of the practice, and develop statistical data that facilitates acceptance of the weld practice.


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Find the original research paper at www.metalcastingdesign.com


The AFS-AMC Phase IV


(CIR), Cast E357 Aluminum Statistical Properties program was accomplished by a consortium of casting users, metalcasting facili- ties, suppliers and industry sup- port organizations. This group as- sisted in the design of test castings by devising the gating and rigging practice, manufacturing the tool- ing and test parts, and establishing the melt, metal treatment, heat treatment and evaluation practices for the test plates.


2


Procedure


T is study was de- signed to determine the eff ect of weld repair on static and dynamic (i.e.,


fatigue) properties for conditions where the gage section of the test specimens is entirely weld metal (full weld) or consist of both weld and base metal (half weld). All castings used for this study


were produced from multiple heats that met chemistry specifi cation. All melts were grain refi ned, modifi ed and processed in accordance with consensus melting and melt treat- ment practices established for the Cast E357 Aluminum Statistical Properties program. T e radio- graphic quality level in a designated area of each casting was Grade B or better per ASTM E155, and the microstructure of the T6 heat treated castings contained Type 4 or better silicon morphology per the AFS wall chart. Weld repair using the gas tungsten arc (GTA) process was accomplished by qualifi ed welders at each of three metalcasting facilities. When a casting is weld repaired,


the “defect” region is machined out and then fi lled with weld metal. For this study, known locations within


Fig. 1. The shape and size of the artifi cial defect machined into the E357 casting are similar to a surface defect by AMS standards.


44 | METAL CASTING DESIGN & PURCHASING | Nov/Dec 2013


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