Title: Automobile Parts Casting - Methods and Materials Used: A Review

Core Objective of the Research: This review paper aims to comprehensively analyze the various casting methods and materials used in the automotive industry for manufacturing different parts. It examines the suitability of each method and material based on the specific requirements of the components, considering factors such as cost-effectiveness, mechanical properties, and environmental impact. The review intends to highlight the trade-offs associated with each approach to guide engineers in making optimal material and process selections.

Main Methodology: The authors conducted a literature review, collecting and analyzing data from existing publications on automotive casting processes. The review focused on five primary casting methods: green sand casting, centrifugal casting, lost-foam casting, die casting, and squeeze casting. The paper further discusses the materials employed in these processes, including various types of cast iron (grey cast iron and compacted graphite iron), aluminum alloys (Al-Si alloys), magnesium alloys, and metal matrix composites (MMCs).

Key Results: The paper detailed the characteristics of each casting method, highlighting their advantages and disadvantages. Specific applications for each method were described. For example:

Green Sand Casting: Cost-effective, flexible design, but low dimensional accuracy and poor surface finish.
Centrifugal Casting: High metallurgical cleanliness, homogenous microstructure, limited length-to-diameter ratio.
Lost-Foam Casting: Good dimensional accuracy and surface finish, suitable for complex shapes, but more expensive.
Die Casting: High production rate, excellent surface finish and dimensional accuracy, but high initial investment cost.
Squeeze Casting: Superior mechanical properties, porosity reduction, near-net shape, but complex process.

The paper also discussed material selection criteria for different automotive components based on their specific requirements. For instance, Al-Si alloys were highlighted for their high thermal conductivity and strength-to-weight ratio, especially in engine components. The use of MMCs for enhanced properties like stiffness and wear resistance was also explored.

Researcher Information:

Affiliation: Vellore Institute of Technology
Authors: Madhav Goenka, Chico Nihal, Rahul Ramanathan, Pratyaksh Gupta, Aman Parashar, Joel J
Main Research Area: Mechanical Engineering, Materials Science, Manufacturing Processes

Research Background and Objective:

Industrial Background: The automotive industry's continuous drive towards lighter, stronger, and safer vehicles. This necessitates advancements in manufacturing techniques to meet the stringent quality and safety standards (e.g., NCAP).
Specific Technical Challenges: Finding cost-effective and efficient manufacturing processes to produce high-quality automotive parts with complex geometries and demanding performance characteristics.
Research Goal: To provide a comprehensive review of automotive casting methods and materials, offering guidance to engineers in selecting the most suitable options for various components.

Main Objectives and Research Content of the Paper:

Main Objectives and Research Content: A thorough examination of automotive casting processes (green sand, centrifugal, lost-foam, die, and squeeze casting) and the materials used (cast iron, aluminum alloys, magnesium alloys, MMCs). The analysis included a comparison of the advantages and disadvantages of each method and material in terms of cost, mechanical properties, dimensional accuracy, and surface finish.
Problems Addressed: The challenges of producing high-quality, lightweight, and cost-effective automotive components with complex geometries. The need for efficient and environmentally friendly manufacturing processes.
Step-by-Step Approach to Problem Solving: The paper systematically reviews each casting method, detailing the process, advantages, disadvantages, and suitable materials. It then discusses material selection for various components, focusing on factors like strength, weight, cost, and manufacturability.
Key Figures:

Fig. 2. Flow chart of manufacturing of MMC pistons using squeeze casting.

Fig. 3. The process of squeeze casting. (a) Initial poring of molten metal; (b) Plunger moving;
(c) Plunger moving to reach the gate of molten metal; (d) Plunger moving to completely filling of die cavity.

Results and Achievements:

Quantitative Results: While the paper doesn't present extensive quantitative data, it provides comparative analyses of the properties of different materials (e.g., strength-to-weight ratio) and processes (e.g., production rate, surface finish).
Qualitative Results: The review provides a comprehensive qualitative analysis of the strengths and weaknesses of various casting methods and materials, establishing a basis for informed decision-making in the automotive industry.
Technical Achievements: The paper compiles and synthesizes existing research on automotive casting, providing a valuable resource for engineers and researchers.

References:

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Copyright and References:

Automobile Parts Casting – Methods and Materials Used: A Review (Summary)