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Alusil as a hypereutectic aluminium-silicon alloy (EN AC-AlSi17Cu4Mg / EN AC-48100 or A390) contains approximately 78% aluminium and 17% silicon. [1] [2] This alloy was theoretically conceived in 1927 by Schweizer & Fehrenbach, [3] of Badener Metall-Waren-Fabrik, [4] but practically created only by Lancia [5] in the same year, for its car engines.
A billet is a length of metal that has a round or square cross-section, with an area less than 36 in 2 (230 cm 2). Billets are created directly via continuous casting or extrusion or indirectly via hot rolling an ingot or bloom. [1] [2] [4] Billets are further processed via profile rolling and drawing. Final products include bar stock and wire. [3]
Aluminum or copper strip casting: Commercial twin-belt continuous strip casting machines are capable of producing as-cast dimensions from 10–35 mm thick, and up to 2035 mm wide. After being directly fed into a hot rolling mill, the as-cast strip is typically rolled down to 1–3 mm thickness strip.
Many internal combustion engines use cast iron and steel extensively for their strength and low cost. Aluminum offers lighter weight at the expense of strength, hardness and often cost. However, with care it can be substituted for many of the components and is widely used. Aluminum crank cases, cylinder blocks, heads and pistons are commonplace.
Bar stock, also (colloquially) known as blank, slug or billet, [1] is a common form of raw purified metal, used by industry to manufacture metal parts and products. Bar stock is available in a variety of extrusion shapes and lengths. The most common shapes are round (circular cross-section), rectangular, square and hexagonal.
Aluminum-silicon phase diagram. Aluminum forms a eutectic with silicon, which is at 577 °C, with a Si content of 12.5% [7] or 12.6%. [8] Up to 1.65% Si can be dissolved in aluminum at this temperature. However, the solubility decreases rapidly with temperature. At 500 °C it is still 0.8% Si, at 400 °C 0.3% Si and at 250 °C only 0.05% Si.
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Using vermicular graphite cast iron (GGV), a casting material with great strength, enables weight reductions by about 30% compared to conventional casting materials such as GG 25. Weight reduction, to this extent, requires engineering for the engine block, taking into account the particular needs of the material.
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