Determination of Porosity-A Casting Defect Occurrence in Green-Sand Casting of Al-Si5-Cu3 by the Taguchi Method

Abstract

Porosity is a significant concern in Al-Si5-Cu3, aluminum alloy casting, tending to considerably more scrap outcomes and limiting parts use in critical applications due to porosity. This defect is directly relevant to the manufacturing process thus its occurrence is closely tied to green sand-casting process parameters. Here implementing of Taguchi method offers substantial porosity reduction mapping during casting with different input parameters. A combined experiment has been carried out using Taguchi’s L27 orthogonal array (OA) to study the main effect and interaction effect of all five parameters. In a thick-walled sample casting, pouring temperature and pouring time significantly affect porosity reduction. Pouring temperature having F-Value of 8.47 and a low P-Value of 0.003, and F-Value of 5.76 and a corresponding P-Value of 0.013 of the pouring time, indicating its influential role in explaining the variation in both Average Porosity and S/N Ratio Degassing time and mould temperatures have marginal effects, while crucible volume hold minimally influences porosity. The interaction between pouring temperature, pouring time, and crucible volume in green sand casting significantly impacts the output, indicating significance influential factors for porosity occurrence, as their p-values are below 0.05 or very close to it. Assessing the anticipated enhancements in quality and the potential for cost savings based on optimal parameters forecasts a decrease in porosity and minimized losses prior to conducting experimental trials.