AFS Aluminum Div. Permanent Mold Practices Committee (2-E); Robinson, S T

Abstract: Maintaining tight process controls and learning from previous experience can mean the difference between a foundry that squeaks by and one that sees a healthy margin. A panel presentation on quality and scrap reduction at the AFS 5th international conference on Permanent Mold Casing of Aluminum provided several case studies on improving quality while reducing cost. The following case studies were presented: (1) 5% shrinkage scrap associated with a 1.7 lb cast piston, (2) flywheel housing porosity in a 356.1 alloy, (3) control arm shrinkage porosity and blistering in a B356 alloy automotive control arm, (4) misrun and shrink in a 356-alloy breather casing and (5) cylinder head porosity. In each case, the problem is thoroughly discussed and the solution is presented.

Keywords: Cost concerns, Foundry, Permanent mold casting, Quality, Automotive, Misrun, Shrinkage.