Experimental and optimization of die casting parameters on Al-Si alloy with snail shell reinforcing agent

Abstract

Abstract The demand for aluminum in various fields continuously grows, including in the automotive industry. In this industry, aluminum is used as the material for the spare part. Therefore, aluminum with high mechanical properties and low casting defects is required. One of the available alternatives for producing excellent aluminum is through aluminum casting, including die casting. Die casting offers low cost in mass manufacturing of complex shaped components with acceptable casting results. Further, the selection of die-casting parameters and the addition of reinforcing elements can also improve the mechanical properties of aluminum. In this study, we strengthened the Al-Si matrix using High Pressure Die Casting process with particles from snail shell powder (calcium carbonate). Further, this study also explores the mechanical properties and microstructure of the product produced through experiment and optimization. The optimization was adopted to identify the optimum parameter. For the optimization, we used the Taguchi method. Our analysis results suggested that the reinforcing agent from the snail shell powder has the CaO and Ca(OH)2 phases, with a crystallite size of 106.59 nm. The morphology of the shell powder reinforcing agent showed the presence of agglomeration and interconnected structures, such as skeletons, with average particle size of 0.4 micro. The functional group of the shell powder reinforcing agent showed the OH band during the water absorption by CaO, along with asymmetric C–O with vibration from the carbonate group and Ca–O bound. The most excellent hardness level was identified from T8, with 86.33 HRB and die casting parameters of 0.15% reinforce agents, 750 °C temperature injection, and 50 MPa pressure. Meanwhile, the best tensile strength was found from the T9 sample, with 109,95 MPa and die casting parameters of 0.15% reinforce agents, 800 °C temperature injection, and 60 MPa pressure. Microstructure on the used piston die casting sample with snail shell powder reinforcing agent showed the presence of Al, Si, dendrite, and Al4Ca phases. The multiple response analysis on the three factors indicated that the reinforcing agent presented the most significant effects toward the tensile strength and hardness, followed by pressure and temperature injection. Meanwhile, the Taguchi method and ANOVA results showed the optimal parameter die casting was obtained from a combination of 0.15 wt% reinforce agent, 800 °C injection temperature, and 50 MPa pressure. A multiple linear regression mathematical model for tensile strength and hardness was developed from the observed data. In regression model, the value of R2 of tensile strength 74.02% and R2 of the hardness is 95,18% Thus, the developed model can be effectively used to predict the tensile strength and hardness