This book provides comprehensive treatment of the state of the aluminum casting industry. Built on sound physics principles, the book provides an in depth analysis of factors affecting metal quality in aluminum foundries. Providing a coherent framework for measuring metal quality throughout the casting production, the book introduces solutions to common problems and a novel technique to manage resources to consistently meet customer requirements.

Presents a new method to collect data from the foundry floor to characterize the performance of the production system Provides a complete review of techniques for improving metal quality Introduces a new process management system to meet customer requirements consistently

Autorentext

Murat Tiryakiolu grew up around a nonferrous foundry owned by his family, which has shaped his career. After receiving his PhD at the University of Missouri-Rolla, he worked at The Boeing Company in Wichita, Kansas, on aerospace castings. He received his second PhD at the School of Metallurgy and Materials at the University of Birmingham under the supervision of Prof. John Campbell. Meanwhile, he started a collaboration with Dr. James T. Staley from Alcoa. While working as a professor in Pittsburgh, he was invited to Alcoa Technical Center (ATC) as an R&D Consultant for seven straight summers, becoming the only consultant to be invited for more than one summer. At ATC, he worked primarily on the quench sensitivity of commercial wrought alloys. Over his career, he has collaborated with many researchers all over the world and conducted research on many aspects of applied statistics and aluminum alloys, especially cast alloys, while publishing over one hundred journal papers.

Dr. Tiryakiolu has been a Certified Quality Engineer (American Society for Quality). He is the recipient of the Inaugural John Campbell Medal from the Institute of Cast Metals Engineers (ICME), M. Eugene Merchant Outstanding Young Manufacturing Engineer Award from the Society of Manufacturing Engineers and Young Leader Award from TMS. He is a Fellow of ICME.

Inhalt

Current Status of the Production of Aluminum Alloy Castings.- Liquid Aluminum.- Liquid Metal Damage.- Pores: The Visible Damage.- Hidden Damage: The False Hope of Casting Soundness.- The Metric.- Tracking Damage and Melt Quality in Aluminum Casting Production.- Sources of Damage.- Damage Characteristics Curve.- The Grand Rule and The Concept of Value.- Measure the Damage.- Practices for Castings: Cost/Benefit Analysis.- Manage the Damage.