Quality of automotive sand casting with different wall thickness from progressive secondary alloy

Abstract This paperwork is focused on the quality of AlSi6Cu4 casting with different wall thicknesses cast into the metal mold. Investigated are structural changes (the morphology, size, and distribution of structural components). The quantitative analysis is used to numerically evaluate the size and area fraction of structural parameters (α-phase, eutectic Si, intermetallic phases) between delivered experimental material and cast with different wall thicknesses. Additionally, the Brinell hardness is performed to obtain the mechanical property benefits of the thin-walled alloys. This research leads to the conclusion, that the AlSi6Cu4 alloy from metal mold has finer structural components, especially in small wall thicknesses, and thus has better mechanical properties (Brinell hardness). These secondary Al-castings have a high potential for use in the automotive industry, due to the thin thicknesses and thus lightweight of the construction.