Analysis of optimized green sand on mechanical properties of LM6 aluminum alloy based grey analysis method

Casting is a manufacturing process used to mass-produce metal materials with complex shapes. Casting process configuration is essential for creating quality and efficiency. It is unavoidable that a wide range of imperfections takes place in the casting process, such as porosity and incomplete filling. Sand quality extraordinarily influences casting quality and ought to have the accompanying attributes: strength, permeability, thermal stability, collapsibility, reusability. This study aims to optimize the composition of green sand in a sand casting system using Grey Relation Analysis based Taguchi method by examining the impact of mechanical properties and microstructure conduct on LM6 casting products. The effect of the composition of green sand on tensile strength, hardness, and microstructure of specimen aluminum alloy LM6 was investigated for continuous improvement in casting quality. Analysis of Grey Relational Analysis identified that bentonite is the primary interaction effect in all the experiments. The optimal green sand composition settings are silica sand-85%, bentonite-7%, water-5%, and coal dust-4% based on Grey Relation Grade ranking.