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mechanical properties to demonstrate the efficacy of the practice, and develop statistical data that facilitates accep- tance of the weld practice. Te AFS-AMC Phase IV (CIR), Cast E357 Aluminum Statistical Properties pro-
gram was accomplished by a consortium of casting users, metalcasting facilities, suppliers and industry support organiza- tions. Tis group assisted 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.
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
2
produced from multiple heats that met chemistry specification. All melts were grain refined, modified and processed in accordance with consensus melting and melt treatment practices estab- lished for the Cast E357 Aluminum Statistical Properties program. Te radiographic quality level in a desig- nated 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 tung- sten arc (GTA) process was accom- plished by qualified welders at each of three metalcasting facilities. When a casting is weld repaired,
the “defect” region is machined out and then filled with weld metal. For this study, known locations within a 1-in. (25.4-mm) thick cast plate were machined to represent the defec-
Procedure Tis study was designed to
determine the effect of weld repair on static and dynamic (i.e., fatigue) properties for
Fig. 1. The shape and size of the artificial defect machined into the E357 casting are similar to a surface defect by AMS standards.
42 | MODERN CASTING December 2013
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