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<p>In this present study a novel attempt is made using a recycled sand mold with an additive made from finger millet husk, to reduce casting flaws in aluminum alloy AA 7475. This research aims to obtain perfect AA 7475 castings by optimizing the amount of additive, its size, and water to be utilized in the sand mold. It also aims to discover the most affecting process variable. A thermo-chemical technique was used to create the Si3N4 particles, which were then ground to a fine consistency using mortar. The three-layer sand/binder (bentonite), Si3N4, and water castings were based on the Taguchi L9 orthogonal array. Based on the results, it appears that the A2B3C2 experimental pattern will yield the best overall outcomes. Si3N4 enhanced the control of solidification and heat transfer. In each of the nine designs tested, the cast samples have either fine or medium grains. The optimization procedure, however, uncovered the variables with the greatest impact and improved the defect ratio and porosity. The Si3N4 weight% addition has a greater impact on the process than both size and water content, as indicated by the min and max difference level. The improved tensile strength as well as impact energy with improved hardness is observed for experimental pattern followed as 6th. With a total increase of 2.62%, the newly optimized set of process variables A2B3C1 decreased porosity by 0.379 and enhanced grey relational grade (GRG) by 0.785, as shown in the confirmation test. This results in a defect ratio reduction of 1.861. Casting products with cleaner production concerns and higher levels of accuracy may be possible with these enhanced and bioceramic replacement sand casting processes.</p>

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Optimization of Waste Finger Millet Husk Derived Silicon Nitride Addition into the Sustainable Green Sand Mould for Casting AA7475 Alloys

  • 期刊论文

  • 发表日期：

    2025年3月7日

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  • M. R. Anantha Padmanaban,
  • D. Jayabalakrishnan,
  • V. Jayaseelan,
  • S Prasath

摘要

In this present study a novel attempt is made using a recycled sand mold with an additive made from finger millet husk, to reduce casting flaws in aluminum alloy AA 7475. This research aims to obtain perfect AA 7475 castings by optimizing the amount of additive, its size, and water to be utilized in the sand mold. It also aims to discover the most affecting process variable. A thermo-chemical technique was used to create the Si3N4 particles, which were then ground to a fine consistency using mortar. The three-layer sand/binder (bentonite), Si3N4, and water castings were based on the Taguchi L9 orthogonal array. Based on the results, it appears that the A2B3C2 experimental pattern will yield the best overall outcomes. Si3N4 enhanced the control of solidification and heat transfer. In each of the nine designs tested, the cast samples have either fine or medium grains. The optimization procedure, however, uncovered the variables with the greatest impact and improved the defect ratio and porosity. The Si3N4 weight% addition has a greater impact on the process than both size and water content, as indicated by the min and max difference level. The improved tensile strength as well as impact energy with improved hardness is observed for experimental pattern followed as 6th. With a total increase of 2.62%, the newly optimized set of process variables A2B3C1 decreased porosity by 0.379 and enhanced grey relational grade (GRG) by 0.785, as shown in the confirmation test. This results in a defect ratio reduction of 1.861. Casting products with cleaner production concerns and higher levels of accuracy may be possible with these enhanced and bioceramic replacement sand casting processes.