Experimental Study and Optimization of Process Parameters for Producing Semi-Solid A392 Alloy Using Vibration-Assisted Cooling Slope Process Integrated with Mould Vibration.

The present study investigates the impact of integrating mould vibration with the vibration-assisted cooling slope (VCS) process on the microstructural and mechanical properties of A392 alloy and the optimization of process parameters. The optimization is done by considering process parameters such as slope length (300 mm, 400 mm, 500 mm, 600 mm and 700 mm), pouring temperature (680 °C, 690 °C, 700 °C, 710 °C and 720 °C), slope vibration (0 Hz, 15 Hz, 30 Hz, 45 Hz and 60 Hz), mould vibration (0 Hz, 15 Hz, 30 Hz, 45 Hz and 60 Hz) and slope angle (15°, 30°, 45°, 55° and 60°), using the multi-objective method (Taguchi-based grey relational analysis). The output responses (mechanical and microstructural properties) were converted into single objective responses as grey relational grades, and the obtained grades were analysed using Taguchi and ANOVA (analysis of variance). The results revealed that the integration of mould vibration with the vibration-assisted cooling slope process (VCS) improved the microstructure homogeneity and mechanical properties of the A392 alloy. It was observed that the optimum parameters for the VCS-integrated mould vibration process were a slope length of 600 mm, pouring temperature of 700 °C, slope vibration of 45 Hz, mould vibration of 30 Hz and slope angle of 45°. The confirmation test was done with optimum values. The optimization of process parameters resulted in the further enhancement of the properties. The results are very close to the predicted value with a difference of 9%. The findings of this study could provide valuable insights for optimizing the vibration-assisted cooling slope process (VCS) integrated with mould vibration for A392 alloy and similar materials. [ABSTRACT FROM AUTHOR]