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<p>The present study evaluates the microstructural and mechanical performance of A356 aluminum alloy castings prepared by two mold compositions: a conventional sand mold and a silica sand mold modified with 15% Silico-Manganese (Si-Mn) slag. The cast products were considered for microstructural analysis, Secondary Dendrite Arm Spacing (SDAS), porosity, surface roughness, and the mechanical behavior was assessed through hardness, tensile strength, and impact toughness. The slag-modified mold (S2) resulted in a refined microstructure, characterized by reduced SDAS (50.86&#xa0;μm vs. 64.64&#xa0;μm in conventional S1), finer grains, and more uniform eutectic silicon distribution. While a slight increase in porosity was observed in S2 (2.38%) compared to S1 (0.42%), surface roughness and hardness remained comparable. Mechanical testing revealed enhanced performance in S2 with higher UTS (193.07&#xa0;MPa), YS (61.44&#xa0;MPa), elongation (4.17%), and impact toughness (5.24&#xa0;J), reflecting improved ductility and fracture resistance. XRD analysis confirmed no phase contamination due to slag addition. These findings demonstrate that incorporating 15% Si-Mn slag into sand molds is a promising approach to enhance casting quality and support sustainable waste utilization with minimal environmental impact.</p>

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Microstructure and Mechanical Property Evaluation of A356 Alloy Casted in Conventional Silica Sand Mold and Silico-Manganese Slag Blended Silica Sand Mold

  • 期刊论文

  • 发表日期：

    2025年10月7日

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  • Trinath Talapaneni,
  • Vatsala Chaturvedi,
  • Deepak Patel,
  • Alla Keshavardhan,
  • Sumit Prasad,
  • Rahul Kumar Sahu,
  • Sejal Tandekar,
  • Kolli Venkatesh

摘要

The present study evaluates the microstructural and mechanical performance of A356 aluminum alloy castings prepared by two mold compositions: a conventional sand mold and a silica sand mold modified with 15% Silico-Manganese (Si-Mn) slag. The cast products were considered for microstructural analysis, Secondary Dendrite Arm Spacing (SDAS), porosity, surface roughness, and the mechanical behavior was assessed through hardness, tensile strength, and impact toughness. The slag-modified mold (S2) resulted in a refined microstructure, characterized by reduced SDAS (50.86 μm vs. 64.64 μm in conventional S1), finer grains, and more uniform eutectic silicon distribution. While a slight increase in porosity was observed in S2 (2.38%) compared to S1 (0.42%), surface roughness and hardness remained comparable. Mechanical testing revealed enhanced performance in S2 with higher UTS (193.07 MPa), YS (61.44 MPa), elongation (4.17%), and impact toughness (5.24 J), reflecting improved ductility and fracture resistance. XRD analysis confirmed no phase contamination due to slag addition. These findings demonstrate that incorporating 15% Si-Mn slag into sand molds is a promising approach to enhance casting quality and support sustainable waste utilization with minimal environmental impact.