IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 _______________________________________________________________________________________ Volume: 03 Special Issue: 11 | NCAMESHE - 2014 | Jun-2014, Available @ http://www.ijret.org 7 COMPARATIVE ANALYSIS ON MOULD FILLING OF A413 ALUMINIUM ALLOY IN SAND AND EVAPORATIVE PATTERN CASTING PROCESS USING VIRTUAL INSTRUMENTATION Tony Thomas A 1 , Parameshwaran R 2 , Kirubha C 3 , Muthukrishnan A 4 1 Assistant Professor, Department of Mechatronics Engineering, Kongu Engineering College, Erode-638052, India 2 Professor & Head, Department of Mechatronics Engineering, Kongu Engineering College, Erode-638052, India 3 UG Student, Department of Mechatronics Engineering, Kongu Engineering College, Erode-638052, India 4 UG Student, Department of Mechatronics Engineering, Kongu Engineering College, Erode-638052, India Abstract This paper deals with the comparative study on the properties of Aluminium alloy (LM6-12%Si) castings in sand casting and Evaporative pattern casting (EPC) process. Thermocouples are used to measure the temperature of the casting during solidification. Signals from the thermocouples are connected to the DAQ (Data Acquisition Card) 6024E.The software development platform used for this application is LabVIEW. The signals acquired using DAQ card is given to the LabVIEW as an input. The acquired signals from the thermocouples are processed to obtain the mould filling and solidification time for both the process. Mechanical properties and micrographs of the castings were also considered. It is revealed that the properties of the evaporative pattern castings of A413 alloy are comparable to the castings.EPC is the viable alternate for conventional casting process to make intricate Al-Si Castings with energy efficient and environmental friendly way. Keywords: Evaporative pattern casting (EPC), A413 alloy, mould filling, solidification, Data Acquisition system, microstructure, tensile strength. --------------------------------------------------------------------***---------------------------------------------------------------------- 1. INTRODUCTION The Evaporative pattern casting (EPC) process, first introduced by Flemmings in 1964[1], was modified from the full mould process originally developed by Shroyer in 1958[2]. The EPC process is distinguished from the full mould process by the use of unbounded sand as opposed to the bonded sand in the latter. This technique is referred to by several terms including Lost Form Casting (LFC), full mould process, Replicast and Policast process[3].EPC has been regarded as a cost effective ,environmental-friendly vital option to the conventional casting process for production of near-net shape castings with high quality, especially in forming components with thin-wall, complex geometry, tight tolerances and smooth as-cast surface[4].The advantages of the EPC process had not been fully realized due to lack of knowledge of the process needed to exercise proper control measures between 1950 and 1990, there was virtually no growth in the use of EPC. It is accounted for less than 1% of steel and iron castings and less than 5% of aluminum castings. The future for Evaporative pattern casting, however, is much brighter. Since 1990,there has been a significant increase in the use of the process and the outlook is strong. BY 2020,about 29% of aluminium castings and 15% of total iron castings are expected.EPC has gained prominence as a casting process over the last decade. But it requires high degree of process control compared to sand casting[6-9].In this chapter an attempt has been made to investigate the solidification behavior of A413 alloy in sand casting and EPC using Virtual Instrumaentation.A413 alloy is widely used for making intricate castings of automobile components.A413 was considered for the entire study. The chemical composition of A413 alloy is 10-13% Si, 0.6% Fe,0.04% Mn,0.03% Cu,0.05% Mg and remainder of Al.Equivalent designations of A413 are LM6(BS) 4600 (IS617-94),Al-Si 12 (ISO 3522-85),AC3A.1(Japan) and G-AlSi12 (DINI725(5)-86).A413 is a corrosion resistant aluminium casting alloy with average durability and strength, and also posses high impact strength and ductility[10]. 2. EXPERIMENTAL PROCEDURE 2.1 Evaporative Pattern Casting Rectangular shaped foam pattern of size (110mm long and 80mm wide and 20mm thickness was cut from a standard EPS (Expanded Polystyrene) Board by using a hot wire cutter. The required gating system with sprue (W20×T20×L140mm), runner (W20×T20×L60mm), and pouring basin (W40×T20×L40mm), were also cut from the same foam board. Pattern was attached to the gating system with a glue to form pattern assembly. The bottom gating system was adopted. The pattern assembly was then coated with a water-based Zircon coating by dipping method and dried. The thin dried layer of refractory coating is acting as barrier between sand and metal during mould filling. The refractory slurry consists of fine Zircon flour,bentonite and water. The pattern assembly was then placed in a steel flask and filled with unbounded dry silica sand. Silica sand of