Selection of Optimum Pouring Conditions for Improvement of Aluminium Alloy Castings in Ghana

Prince Yaw   Andoh; Francis  Davis; Godwin   Adablah

doi:10.4314/just.v41i2.1332

Prof. Prince Yaw Andoh Department of Mechanical Engineering, Kwame Nkrumah University of Science and Technology
Prof. Francis Davis Department of Mechanical Engineering, Kwame Nkrumah University of Science and Technology
Godwin Adablah Department of Mechanical Engineering, Kwame Nkrumah University of Science and Technology

DOI: https://doi.org/10.4314/just.v41i2.1332

Keywords: Pouring conditions, 2squuare factorial design,, hardness,, ultimate tensile strength, elongation

Abstract

It has been discovered that the pouring conditions (temperature of the molten aluminum alloy
and pouring speed) have effects on the mechanical properties of the cast aluminum alloy, either
directly or indirectly. This paper develops a model to predict the effect of pouring conditions
on the mechanical properties of the cast Aluminum alloy. In this work a 22 factorial design was
applied to investigate the effects of temperature of the molten aluminum alloy and pouring
speed on three mechanical properties, namely; the hardness, ultimate tensile strength, and
elongation. The developed models were used to select optimum pouring conditions for the
improvement of the Aluminum alloy in manufacturing companies in Ghana. The study revealed
that increasing the pouring conditions causes the hardness to decrease as well as the ultimate
tensile strength, and elongation. Also, the two – factor interaction effect of the pouring speed
and temperature of the molten aluminum alloy on hardness is significant as the interaction
effect decreases with increase in hardness but has insignificant effect on the elongation and
the ultimate tensile strength. It is established that the optimal pouring conditions to improve
the mechanical properties for the production of the Aluminum alloys are 2 cm/s for the pouring
speed and 700°C for the temperature of the molten aluminum alloy producing a hardness of
61 HB, ultimate tensile strength of 115 N/mm² and 17 % elongation.

Author Biographies

Prof. Prince Yaw Andoh, Department of Mechanical Engineering, Kwame Nkrumah University of Science and Technology

Prof. Prince Yaw Andoh is an Associate Professor at the Department of Mechanical
Engineering, Kwame Nkrumah University of Science and Technology (KNUST), Kumasi.
He has over 16 years of experience in teaching and researching in the areas of Design,
Manufacturing and Applied Mechanics. His primary research interests include modelling,
identification and control of mechanical and manufacturing systems, tribology of
manufactured surfaces, and integration of design and manufacturing.

Prof. Francis Davis, Department of Mechanical Engineering, Kwame Nkrumah University of Science and Technology

Prof. Francis Davis is an Associate Professor in Design and Manufacturing at the Department
of Mechanical Engineering, Kwame Nkrumah University of Science and Technology
(KNUST), Kumasi. His research area is design and manufacturing and his interests are:
design of experiment and modelling; design, analysis, and manufacturing of engineering
product; monitoring of machining operations using acoustic emission; maintenance and
production engineering.

Godwin Adablah, Department of Mechanical Engineering, Kwame Nkrumah University of Science and Technology

Godwin Adablah is a Master of Philosophy student in Applied Mechanics at the Department
of Mechanical Engineering, Kwame Nkrumah University of Science and Technology
(KNUST), Kumasi. His research interests include the use of numerical methods, especially,
finite element method; Computer-Aided Design and Manufacturing (CAD/CAM); design of
experiment; vibrations.