Manufacturing Specimen

This week a recycled aluminum test body was fabricated through the casting process in green sand. The test specimen shall be subjected to a metallographic and tensile test. The manufacturing process began in the preparation of the mold of the test body. To perform this activity, it was necessary to mix sand, clay and water to produce the green sand. This blend was obtained using the weight ratio 100, 20 and 4, respectively. It was obtained by the team a metal test piece, so that it was used as a mold. The mold was placed in the center of the sandbox (Figure 1), called a "molding box", which serves to give mechanical support to the confection of the mold and to support the weight of liquid metal during casting. After the lower molding box was filled and the surface was level, this surface was sprinkled with white sand, to facilitate the process of separating the boxes.

Figure 1

Source: Own

The top impression box was then prepared. One box was inserted into the other and soon green sand was added, making sure that it was well compacted (Figure 2).

Fugure 2

Source: Own

Subsequently, the model was carefully removed to prevent the sand from collapsing (Figure 3). Soon after the casting channels were realized: leakage channel and massalote. With the aid of a small spoon rope a leakage channel has been constructed, which will later feed the mold with the liquid metal.

Figure 3

Source: Own

After this procedure, the two boxes were resealed allowing the beginning of the aluminum casting process. In the video below, the execution of the team activity is shown under the guidance of the advisor, Prof Guilherme Souza.

After solidification of the aluminum, the mold was destroyed, obtaining a part that was not yet desired (Figure 4), since it was still necessary to remove the pour channel and the distribution channel. After the removal of the channels, the piece shown in Figure 5 was obtained.

Figure 4

Source: Own

Figure 5

Source: Own