Experimental Study and Squeeze Casting Process Optimization for High Quality AC2A Aluminium Alloy Castings

This study focuses on the attempt for the production of AC2A aluminium alloy castings through direct squeeze casting process. Samples were prepared for each experimental condition based on L'16 orthogonal array of Taguchi method. Initially, the effect of casting parameters on tensile yield strength was investigated. Taguchi method and genetic algorithm were employed for process optimization in order to produce high quality castings. The effect of squeeze pressure on macrostructure and microstructure was also investigated for various casting conditions. The castings obtained for optimum squeeze casting condition exhibited better grain refinement in microstructure and around 65 % improvement in tensile yield strength than gravity die casting condition. Squeeze pressure was noted to be an important process parameter for producing defect-free, sound, high quality castings. The experimental results show that squeeze casting is noted to be practicable for processing this alloy by applying and holding high level compression directly on the melt up to the time of complete solidification.