Minimization of Casting Defects In Aluminum Alloy Wheels of Grade A356.2

The primary motive of this project is identification of the casting defects in Aluminium alloy wheels, to reduce the losses due to scrap and rework and also applications of techniques to reduce the defects to a minimum level. To identify the defects in the product, the process adopted in casting, inspection and testing procedures are studied. Reasons for defects in hub, spoke and rim are identified. Number of defects occurred in hub, spoke and rim are collected and techniques to minimize these are suggested. While the process of casting the wheels the major defect is found at pouring the molten metal in the Mould. To minimize this defect an alternative is suggested using the Aluminium filter cloth bags instead of G.I mesh for filtering the impurities while casting a wheel, and also another method is suggested to do "DOUBLE FILTRATION TECHNIQUE" before pouring the molten metal in to the Low Pressure Die Casting machine to reduce the defects in castings to a minimum level. Nearly 1000 wheels are observed and tested to analyze the defects and major rejection areas of aluminium castings