CASTING TECHNOLOGYpsasir.upm.edu.my/id/eprint/57971/1/Shamsuddin sulaiman.pdfCASTING TECHNOLOGY SUSTAINABLE METAL FORMING PROCESS Profesor Dr.Shamsuddin Sulaiman B.Eng (UPM), MSc (Wales),PhD

CASTING TECHNOLOGYSUSTAINABLE METALFORMING PROCESS

CASTING TECHNOLOGYSUSTAINABLE METALFORMING PROCESS

Profesor Dr. Shamsuddin SulaimanB.Eng (UPM), MSc (Wales), PhD (Wales)

21 AUGUST 2015

Auditorium JuruteraFakulti Kejuruteraan

Universiti Putra Malaysia

UIrWERIITlI"tmtAMAL.Av.aA

"hi! i • "" ""

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Contents

Abstract

Introduction 3Advances in Materials 5Mathematical Model 7

Flow Analysis 7

Thermal Analysis 8

Simulation Model 11

Experimental Works 24Advanced Technology Application 32Conclusions 35References 36Biography 41

Acknowledgements 43List of Inaugural Lectures 45

ABSTRACTMetal casting is a process where molten metal is poured by gravityor injected with pressure into a mould cavity to produce the desiredproduct. Most cast products are in finished goods form, whichrequire minimal level of machining and surface finishing to achievethe desired tolerance and surface quality. Many industrial parts andcomponents are produced by the method of casting, including engineblocks, crankshafts, automotive components, railroad equipment,plumbing fixtures, power tools, very large components for hydraulicturbines and so on. In terms of the theoretical application, twopertinent parameters, i.e. flow and thermal aspects, are explained indetail. The advancement from conventional to advanced materialshas pushed casting technology into a competitive environmentbased on product requirements. Further, Computer Aided Designand Computer Aided Manufacturing (CAD/CAM) together withmachine technology have also been introduced to the foundryor casting industry. This lecture will cover the development ofAdvanced Manufacturing Technology (AMT) applied in metalcasting processes. Selected works on casting processes andtechnology for conventional and advanced materials are reviewed,and studies on metal matrix composites for engineering products arediscussed. Other than process simulation technology, advances inmould and die design technology are also being applied in castingproduct development. With these technologies, the casting processwill be maintained and sustained as an important and relevantcomponent of the metal forming process.

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INTRODUCTIONCasting is one of the oldest known processes used to producemetallic components. The first metal casting was done usingstone and metal moulds during the 4000 -3000 B.C. period. TheMesopotamians were the first to cast bronze using forged moulds.Since then, various casting processes have been developed. Incasting, the liquid material is poured into a cavity (die or mould)corresponding to the desired geometry. The shape adopted by theliquid material is stabilized, usually by solidification, and it canthen be removed from the cavity as a solid component (Bruce etaI., 1998).

Casting processes are important and extensively usedmanufacturing methods because they can be used to produce veryintricate parts in nearly all types of metals at high production rates,can produce very large parts, with average to good tolerances,acceptable surface roughness and good material properties.The casting process reduces the need for expensive machiningtechniques which are often needed with other metal workingtechniques, thus reducing the overall cost of the products (Clegg,1991). The competitiveness of the casting process is based primarilyon the fact that casting allows the elimination of substantial amountsof expensive machining often required in alternative productionmethods.

In casting, the liquid material is poured into a cavity (die ormould) corresponding to the desired geometry. The shape adoptedby the liquid material is stabilized, usually by solidification, and itcan be removed from the cavity as a solid component. In principle,no limits exist with regards to the size or geometry of the parts thatcan be produced by casting. The limitations are set primarily bythe material's properties, the melting temperatures, the propertiesof the mould material (mechanical, chemical and thermal) and the

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Casting Technology: Sustainable Metal Forming Process

material's production characteristics, such as, whether it is to beused only once or many times (Bruce et ai., 1998). Therefore,in terms of applications, various types and shapes of componentscould be produced. Figure 1 shows cast parts in typical automobileapplications. Figure 2 shows different automotive cast partsproduced with various types of metals. As the process generallyinvolves the material being melted down and poured into a castmould, it can virtually be applied to any type of material that isprocessed in the same way. Thus non-metallic materials suchas plastics and composites can also be made by casting,process(Kalpakjianand Schmid, 2010).

Figure 1 Cast parts in a typical automobile(Kalpakjian and Schmid, 2012)

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All ComposileExterior Panels

AluminumSpace-Frame

lead-Acid Banery PackCast MagnesiumSeal Frame &- SleeringWheel Insert

Fiberglass,""einlDrCed Ur1!thaneInstrument Panel

low Aolling-Reslstance Tires

Squeeze-CastAluminum Wheels General Motors

Running lamps

~~~~~~~ntrol System Hydralll,lc~~;~e~~:~PIiCSlighting Front DIsc Brakes

Figure 2 Some components of automotive parts (Groover, 2007)

In order to produce castings that are free from defects and meetrequirements such as strength, dimensional accuracy and surfacefinish, factors that need to be controlled are the flow of the moltenmetal into the mould cavity and heat transfer during solidificationand cooling of the metal in the mould. These parameters mayinfluence the type of mould material and solidification of the metalfrom its molten state (Kalpakjian and Schmid, 2010).

ADVANCES IN MATERIALSConventionally, the materials that are used for casting can be dividedinto two main categories, i.e non-ferrous alloys and ferrous alloys.A large and diverse group of alloys can be utilized in non-ferrousalloy castings. The most commonly used alloys are aluminium-based alloys. Other non-ferrous alloys which are often used areMagnesium, Copper, Zinc, Tin and Lead alloys. Ferrous alloys can

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be categorized into the three groups, Cast Irons, Cast Steels andCast Stainless steels, with numerous applications (Kalpakjian andSchmid, 2010).

One of the most commonly used aluminium alloy in theautomotive industry is the aluminium silicon alloy. Aluminium-Silicon designation with LM numbers is used in the United Kingdomwhile the American National Standards Institute (ANSI) designationsystem is used in the United State of America. Aluminium AI-Si(LM6) is equivalent to Aluminium association alloy: 356.0 [3]. AI-Sialloys are versatile materials which account for 85% to 90% of thetotal aluminium components used in the automotive industry. AI-Sialloys are categorized based on the silicon content in weight percent:hypoeutectic «12% Si), eutectic (12-1 3% Si) and hypereutectic(14-25% Si). The addition of the silicon element in aluminiumalloys will increase cast-ability by increasing mould filling abilityand solidification of casting with absence of hot tearing or hotcracking issues [4]. AI-Si (LM6) alloys exhibit excellent resistanceto corrosion under both atmospheric and marine conditions. It alsohas high fluidity which allows thinner and intricate sections to becast as compared to any of other types of casting alloys (Apelian,2009).

The advancement of materials has resulted in the introductionof composite materials and applications. For metal, Metal MatrixComposites (MMC) are considered as potential material candidatesfor a wide variety of structural applications in the transportation,automobile and sport goods manufacturing industries due to theirsuperior range of mechanical properties(Hasyim et aI., 2002).MMCs combine the metallic properties of matrix alloys (ductilityand toughness) with the ceramic properties of reinforcements (highstrength and high modulus), leading to greater strength in shear andcompression and higher service-temperature capabilities (Clegg,1991).

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MATHEMATICAL MODELTheoretically, mould filling (fluid flow) and solidification (thermal)are two of the most important parameters in the casting process.Studies in these areas help to predict molten metal temperaturesduring the filling, the solidification patterns and to improve thequality and accuracy of the final products

FLOW ANALYSIS

Study of fluid flow is a very critical part of the design of the castingsystem. The two principles of Bernoulli's theorem and the law ofmass continuity should thus be investigated.

a) BernouHi's TheoremThis theory investigates the conservation of energy, pressure,velocity and the elevation of the fluid at any location in thespecimen, as expressed in Eq. (1) (Kalpakjian and Schmid, 2010):

h +p/pg + v/2g = constant (1)

In this equation h is the elevation above the reference level, p is thepressure at this level, p is the density of the fluid, g is the gravityconstant and v is the velocity of the fluid at that leveL

b) Mass Continuity

This law mentions that in the system with impermeable walls therate of incompressible liquid flow is constant as is shown by Eq,(2) (Kalpakjian and Schmid, 2010):

(2)

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In Eq. (2) Q is volume rate offlow; A is the cross sectional area of theliquid stream and v is the velocity of the liquid at that cross section.

c) Solidification TimeSolidification time of the specimens depends on the volume ofcasting and its surface area as is clearly shown in Eq. (3) (Kalpakjianand Schmid, 2010).

Solidification time = C (Volume / Surface areal (3)

In this equation C is the constant, which relates to mould andmetal properties, and n is taken as being between 1.5 to 2.

THERlVIAL ANALYSISFor all transient casting heat transfer analysis, there is heat transferby conduction and a temporal depletion of energy from the moltenmetal which causes its solidification. This physics must be expressedin mathematical form for the process.

The heat flow through the single homogeneous link (Figure 3)is given by:

dTq= -leA-

d"\:(4)

which can be converted into a matrix form as

kA [ 1 1 ] {I;} {QI}L -1 -1 T2 = Q1 (5)

Where there are different materials joined at an interface (Figure5), the matrix equation becomes

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(6)

and with heat loss to a cooling surface it is expressed as (Figure 4),

k A2

L

Figure 3 Single homogenous link

h,

Figure 4 Heat loss to cooling surface

Figure 5 Different materials joined at an interface

(7)

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In a transient analysis, energy is removed from the system byconduction, and this transient energy loss per unit volume can be

expressed as:

o dTE=pC-

dt(8)

or where phase change takes place over a finite temperature interval

it is then expressed as:

E- dH dT- p dT dt

(9)

In discretized form, at time step 'j' equation (9) can be expressed

as

• dH [1:J+1 -1:11E=p- I I

dT M(10)

This can be combined with the conduction matrices (Equations5, 6 or 7) to give an appropriate transient algorithm, which maybe explicit, implicit or explicit-implicit (Crank-Nicolson). Forexample, for an implicit formulation and a homogeneous conduction

link the equation is:

dH [1 0] kA [1pV- --MdT OIL -1

-1]{Tr}= vdH{T/}1 TJ+l p dT TJ2 2 (11 )

Similar equations may be derived by incorporating Equations6 and 7 for the appropriate heat removal path, where in the die ormould the enthalpy gradient (dH/dT) is replaced by the materialspecific heat. Thus for an implicit formulation, the general form ofthe matrix equation can be written as:

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(12)

Using this basis, the heat capacity matrix (Sulaiman and Gethin,1996) needs to be recalculated at each time step to account forphase change and where nonlinear thermal conductivity {k(T)} ispresent, the equation set needs to be solved iteratively within eachstep, with an update of the thermal conductivity at each iteration.

SIMULATION MODELComputer simulation is widely used to predict mould filling,solidification characteristics and to detect defects. This is veryeconomical and saves a lot of time. Software such as MagmaSoft,EdStefan and AnyCasting are commonly used for casting simulation.For this study, mould filling and solidification times were estimatedusing AnyCasting and MAGMASoft softwares.

In this simulation and experimental work, mould fillingand solidification time for both sand and permanent moulds areestimated. Further, the results include values of tensile test, hardnesstest and micro-structures obtained from the SEM test.

Results for the Sand Mould (AnyCasting)

The image of the center of the cylinder cavity produced bysimulation model for a sand mould was captured and is presentedin Figure 6. It shows the sequence of the solidification time for theLM6 alloy matrix without TiC as particulates. The legend shows thetime and the colored regions represent the solidified casting parts.The model shows the pattern of the solidified casting which is ofoval shape. The solidification time of the casting is clearly evidentfrom the color regions. For the blue region solidification occurredwithin 78.08 to 161.92 seconds (Suraya, et aI., 2011).

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Figure 6 The sequence of solidification time

As can be seen in Figure 7, 2.81 seconds were needed for'25%filling with no solidification seen. The temperature distribution wasbetween 627°C to 650°C. The mould filling visualizations for theLM6 alloy matrix, without TiC as particulates, are shown in Figures8 to 10, respectively. Figure 8 shows molten metal fill 55% of thesand mould. The duration taken to fill the cavity was 6.19 secondsand the molten metal temperature was between 611°C to 642°C.The solidification percentage for the 55% mould filling was O.Figure 9 shows the filling time for 75% cavity fill as 8.44 secondswith no solidification shown. 11.19 seconds were needed for themolten metal to completely fill the mould cavity, as shown in Figure10. The temperature distribution was maintained at around 627°Cto 650°C. The results, show that temperature distribution duringmould filling was between 619°C to 650°C and no solidified areacould be seen throughout this process.

III 12

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Temperature is642.39"C to 650.00oC (whiteregion).

Figure 7 25% cavity fill

Temperature isbetween 611.97°C to619.5SoC (red region)

Temperature is between634.79°C to 642.39

Temperature is between627.18°C to 634.79°C

(brown region).





As carl be seen in Figure 7, 2.81 seconds were needed for 25%filling with no solidification seen. The temperature distribution wasbetween 627°C to 650°C. The mould filling visualizations for theLM6 alloy matrix, without TiC as particulates, are shown in Figures8 to 10, respectively. Figure 8 shows molten metal fill 55% of thesand mould. The duration taken to fill the cavity was 6.19 secondsand the molten metal temperature was between 611°C to 642°C.The solidification percentage for the 55% mould filling was o.Figure 9 shows the filling time for 75% cavity fill as 8.44 secondswith no solidification shown. 11.19 seconds were needed for themolten metal to completely fill the mould cavity, as shown in Figure10. The temperature distribution was maintained at around 627°Cto 650°C. The results, show that temperature distribution duringmould filling was between 619°C to 650°C and no solidified areacould be seen throughout this process.

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Temperature is64Z.39°C to 650.00oC (whiteregion) ..

to(yellow region).


Temperature isbetween 611.97°C to619.5SoC (red region)

Temperature is between634.79°C to 642.39(yellow region)

Temperature is between634.79°C



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Casting Technology: Sustainable Metal Fanning Process


Results for the Permanent Mould (AnyCasting)

Figure 11 is an image of the center of the cylinder cavity fromthe simulation model using a permanent copper metallic mould.The figure shows the sequence of solidification times and thevisualizations of molten metal percentage fill in the cylinder cavityand solidification of the composites cavity. The legend shows thetime and the colored regions show the parts of casting solidifying.The model shows the pattern of the solidified casting which issimilar to a half oval shape. The patterns of solidification using thepermanent copper mould are different from those observed withthe sand mould whereby with the sand mould the pattern appearsto be oval whereas a conical shape is observed for the permanentmould. The solidification time for the casting is clearly seen inthe colored region. For the blue region, 1.45 to 5.01 seconds wereneeded for solidification. It is seen that the solidification was notmore than 7.7%. The other images for the LM6 alloy matrix withTiC as particulates are shown in Figures 12 to 15, respectively.The figures illustrate the sequence of solidification times andvisualization of the percentage of molten metal fill of the cylindercavity and the solidification of the composite ..

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TIle shape of the solidification


Figure 12 25% solidification Figure 13 55% solidification

Figure 14 75% solidification Figure 15 95% solidification

The visualization of the mould filling for the LM6 alloy matrixwithout TiC as particulates is shown in Figure 16. It is observed that2.8 seconds were needed for 25% filling with 4.20% solidificationoccuring. The temperature distribution was between 573.91°C to

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650°C. The other images for the LM6 alloy matrix with 5-20 wt%of TiC as particulates are shown in Figures 17 to 19. The legendshows the temperature and the colored regions show the percentageof mould filling. Figure 17 shows 55% fill of molten metal into thesand mould. The duration to fill the cavity was 6.1 seconds and themolten metal temperature was between 573.91 °C to 604.35°C. Thesolidification percentage of this 55% mould filling was 10.44%.Figure 18 shows that a duration of 8.4 seconds was needed formolten metal to fill 75% of the cavity and 14.73% solidification canbe seen throughout this figure. A duration of 11.2 seconds were, .needed to completely fill the mould cavity with the molten metal asshown in Figure 19. The temperature distribution was maintainedat around 574°C to 650°C and 23.39% solidified area was seenthroughout this process.

Temperature is betweenS81.52°C to 589.13°C (dad;

blue region).

Temperature is573.91oC to 581.52°C (blueregion).


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Temperature is between581.52°C to 589.I3°C(dad; blue region)

"

ITemperature is between589.13°C to 596.74°C(purple region) I The 55% cavity fill

The grey region showsthe solidified part.




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Mould filling (MAGMAs oft)

The MAGMAsoft simulation was used to track mould filling andsolidification processes at the same time. The visualization of themould filling process can be seen in Figures 20 to 26. The flow frontwas tracked by VOF (volume of fluid) method by MAGMAsoft. Itwas found that for every successive one second, 10% of the totalvolume (encompasses pouring basin, sprue and runner system,gatings, casting and feeder) was filled up. Due to the design ofthe stepped runner system, the molten metal entered the mouldthrough all gates at the same time, as shown in Figure 21. Themelt rose almost uniformly in the cavity of the mould till it wascompletely filled. This is a good filling method because it ensuresthat the temperature distribution in the mould is equal throughoutjust after filling and thust he solidification rate would be fairlyconsistent throughout the casting. Equal rate of solidification willresult in uniform shrinkage of the casting and minimize defectssuch as shrinkage cavities as a result of non-uniform cooling rates.The color contours also indicate that during mould filling, coolinghad actually started especially at the end of the runner. It can beseen that the down sprue and feeder were filled up simultaneouslysince their dimensions and shapes are very similar. The down spruewas the entrance for the molten metal, whereby it was not filledup or completely wet during filling of the mould cavity. To ensurethat there is no risk of air entrapment carried into the casting andcausing porosity, it may be best if the down sprue dimensions areredesigned, so that complete wetting of its wall occurs during initialmould filling. Generally, the mould filling is successful as a resultof the proper design of the stepped runner system.

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Figure 20 0.5 sec. 10% filled up Figure 21 1.0 sec. 20% filled up

- ._-- .......


J'- .---. - ...


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Figure 26 5.0 sec. 100% filled up Figure 27 Mould filling time

Visualization of variations in filling time for the entire sandmould can be seen in Figures 22 to 27. It can be seen that in contrastthe stepped runner and gatings were filled up within the first second.

Solidification (MAGMASoft)

For the cast material AlSi 1OMg, solidification starts whenthe temperature drops below 595°C, and is fully completed attemperatures below 555°C. Solidification is a result of heat transferfrom the internal casting to the external environment. The heattransfer from the interior of the casting is through the followingroutes(Sulaiman and Tham, 1997):1. Internal liquid convection above liquidus temperature during

mould filling

11. The solidified metal conduction after complete solidificationis achieved throughout the bulk of the casting

111. The heat conduction at the metal-mould interface

IV. Heat conduction within the green sand mould

v. Convection and radiation from mould surface to thesurroundings

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The temperature contours of the casting for different percentagesof solidification are shown in Figures 28 to 30. Figure 31 showsthe time required to reach solidus from the initial temperature of700°C (Sulaiman and Lim, 2004).

Figure 28 Temperature contourat 10% solidification



Figure 31 Liquidus to solidus time

As seen in Figure 31, it is apparent that directional solidificationis achieved in the runner system. The tip of the runner, which hasthe lowest thickness, resulted in faster solidification than in otherplaces. After about 60 seconds, the molten metal in the runner tiphad completely solidified. Solidification time is proportional to the

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volume to surface area ratio (modulus of casting) (Sulaiman andHamouda, 2004), therefore the faster solidification rate at the runnertip is expected. The solidification front propagates towards the spruebase from the runner tip. It can be calculated that the mould cavityhas a modulus of 10.56 (432000/40920) while the runner tip hasa modulus of 2.67 (18900/7080). According to Chvorinov's rule(Grieve,2012),

t = solidification time ;c is a cons tan t for a given meta/ and mould.

The mould cavity, which is at the center of the sand mould, hadcomparatively the longest solidification time. This is understandablebecause according to Fourier's law of conduction, thermal resistanceincreases with the thickness across which heat is to be conducted.

From the casting to the external environment, the heat transferequation is (Hagen, 1991):

Q = UA sroverall

A is the interfacial area between two media and U is the overallheat-transfer coefficient (or conductance), which has the unit of W/m2.K.

u =1

For the casting, hi is the interfacial heat transfer coefficient betweenmould and cast, h; is the heat transfer coefficient between the mould

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and the surroundings. ~x is the thickness of the mould wall and kis the thermal conductivity of the mould material. The green sandlayer in the cavity is thicker than in the runner, therefore a higherAx will reduce U or increase thermal resistance R, which is thereciprocal of U.

The sand casting model took about 400 seconds to solidify atthe center of the cast. A hot spot is noticed at the center of the cast,which has comparatively the longest cooling time to solidus. Hotspots may be deprived of liquid metal because liquid metal canbe absorbed into places which solidified earlier, and thus result indefective shrinkage and cavities. Shrinkage at hot spots is also thecause oflocalized contraction stresses, which will prevail as residualstress at room temperature. Stresses can lead to three specificphenomena in castings, namely the appearance of cracks, warpingof the casting shape and the presence of locked-up stresses whichmay show up during subsequent use of the casting (Roosz et al.,1993). For this particular simulation model, it is suggested to shiftthe feeder to the top of the location of the hot spot so that freshliquid metal can be supplied to this region to counteract volumetriccontraction.

Outcomes from the Simulation (Castingl\iodification)

The simulation and experimental results make it evident that somemodification of the casting components should be carried out.This includes the gating and runner system of the whole castingcomponents. Some typical modifications are shown in Figures 32and 33.

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Figure 32 Before simulation Figure 33 After simulation

EXPERIMENTAL WORKSThe equipment required for this experiment covers 3 categories:a) thermocouple for temperature measurement; b) equipmentfor melting and pouring metal; and c) computer hardware andsoftware for execution of the instruction program and real-timedata collection. Be:

Figure 34 Components used in Temperature Measurement

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As illustrated in Figure 34, the sand mould was connected tothermocouple wires placed at the various predetermined pointsin the sand mould. Datataker was used to compile the qualitativeinformation in numerical format. This numerical data will then besent to the computer for display and recording (Sulaiman and Tham,1997).

In the experiment, the host computer continuously retrieved datafrom the datataker at specified time intervals until a stop commandwas issued from the computer. Thermocouple wires were used tomeasure the temperature of the mould at various points because ofits sensitivity to temperature changes.

The input parameters for the simulation were based onexperimental observations. The input parameters are shown in Table1.

Table 1 Tensile strength and modulus young without and with 5 to20% weight percentages of titanium carbide particulates

Sand casting Permanent metallicWeight mould

percentage Tensile Modulus Tensile Modulus(%wt.) Strength, (J Young,E Strength, (J Young,E(Mpa) (Mpa) (Mpa) (Mpa)

0 82.29 8023.32 121.81 8762.045 107.52 9493.18 140.34 8393.3910 103.94 9022.05 139.33 8409.7815 84.50 10485.62 132.55 7760.7920 82.71 8382.71 123.83 13278.85

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Experiment ResultsThese results include the values from the tensile test, hardnesstest and microstructures obtained from the SEM test. For everyreinforced particulate, explanations based on the results arediscussed. Further, a comparison approach is used to identify theprocessed particulate composite castings which are superior in allaspects of properties and microstructural features (Sulaiman andTham, 1997).

Mould and Casting TemperatureTemperature measurement was a very important step in this researchstudy where the temperature history of the casting was acquiredby using K-type thermocouples inserted into each section of themould and connected to a data-logger called DATATAKER 605.The data-logger was connected to a computer running the Deloggerprogram to capture the thermal data into an Excel file. The coolingcurves data of the solidification process, for each section of differentthicknesses, were obtained by DATATAKER.

From Figure 35 and Figure 36, it can be seen that the coolingrates were different for the two different moulds. The thermocouplesreadings were used to find the temperature profiles as a functionof time corresponding to the liquidus front passing by eachthermocouple. The average data were taken to plot the coolingcurves. The temperature profile of the composite using the sandmould showed slow freezing rates as compared to the temperatureprofile of the composite using the permanent metallic moulds(copper). These results can be explained by the influence of severalfactors.

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800.-.,o0'- 600 --0%Cl)...El -5%

'" 400 -[0%1;;0- -[5%E~ 200 -20<}~

0-~~OM~~N~®-~~O~~~N~~-~~~N~M~~~~~~$~~~~~~~

Time (second)

Figure 35 Cooling curve for sand casting mould

800G'~ 600 -0%Cl) -5%...::s -[0%~ 400... -[5%Cl)

0- -20%E 200~

0 o~o~o~o~o~o~o~o~o--NN,....,,....,':t':t~~\D\Cr--r--ooTime (second)

Figure 36 Cooling curve for copper permanent metaIlic mouJds

Tensile TestThe objective of this experiment was to investigate the behavior ofthe specimen in two types of moulds under a tensile test. Throughperformance of the tensile test the properties determined weretensile strength and young's modulus. This experiment which wasused to determine the material's properties is used in a wide rangeof industries. Average tensile strength versus weight percentagesof Tie is shown in Figure 37 (Lim et aI., 2005).

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The graph shows that the tensile strength values graduallydecreased with increasing 10 to 20%wt. particle reinforcement.The decrease in strength of both types of cast composites isattributable to lower resistance and more sites for crack initiationdue to increased TiC reinforcement, hence lowering the load-bearingcapacity of the reinforcement (Vijayaram et al., 2006). The presenceof higher quantity TiC particulates content lead to the particlesno longer being isolated by the ductile LM6 alloy matrix and thismakes it more prone to tensile failure. As a result, the cracks are notarrested by the ductile matrix and would propagate easily betweenthe titanium carbide particulates (Fatchurrohman, et al., 2012;Sayuti, et al., 2011).

~ 1506~ 100c:e':;; 50..2:r,c:~ 0

.sand mold

Graph Tensile Strength Vs. Weight Percentages

.pemlennntmetallic mold

o 5 10 15 20 25Weight percentages (%wt)

Figure 37 Average tensile strength versus weight percentages of Tie.

Hardness Test

Ten readings were taken for each weight percentage and the meanhardness value used to plot the graph as shown in Figure 38. Fromthe graph it clearly seen that the hardness value increased graduallyfrom 0 to 10% wt. and after 10% wt. the hardness value startedto decrease. The maximum hardness value obtained was 85.82 for10 percentage. The effect of the TiC particulate is apparent from

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the improvement in hardness. Similar enhancement in hardness isobserved in aluminium-II.8% silicon alloy with TiC as particulatesusing the permanent metallic mould. The trend of the hardnessresults is partly attributable to the constrained metallic matrixmaterial as well as the replacement of some of the LM6 alloy matrixwith the harder TiC particles (Suraya et al., 2011).

Hardness versus weight percentages of TiC88 ~-------------------------------

86 -I--::i>"'..::::::.------.Ik--.::::::...~------

Figure 38 Hardness versus weight percentages ofLM6 alloy matrix.

SEM - Images of the Fracture Surface in Both theSand and Permanent MouldsA scanning electron microscope (SEM) was used to obtain highlymagnified images of the fracture surface to help determine thefailure mode. In order to assess the nature of failure and thebonding of the TiC particles with the matrix, fractured surfacesof tensile specimens were examined under a SEM machine. Themicrostructures shown in Figure 39 illustrate aluminium 11.8%Si alloy without particulates and with 5, 10, 15, 20 %wt (Sayutiet al., 2011).

The features show the sharp straight lines of high-hardnessmaterials after they fail. The crystallographic planes are cleaved, intheory, to the weakest direction, leaving the material with knifelike

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edges. However, the embrittled zone was observed to be larger atthe fracture surface ofthe specimen having higher TiC content.

(a) (b) (c) (d) (e)

Figure 39 Tensile fracture surface of LM6 aluminium alloyssolidified in a sand mould with a) O%wt, b) 5%wt, c) IO%wt, d) 15%wt

and e) 20%wt TiC.

From the fractographs (Figure 40) of the copper permanentmetallic moulds, the fracture surface of composites indicate aductile dimple structure. It shows micro-void coalescence, whichbasically looks like clay that has been ripped apart. The voids wereformed mainly at the particle-matrix interface. However, growth ofthe voids was limited by the competing and synergistic influencesof the brittleness of the reinforcing TiC particles and cyclic ductilityof the matrix material (Suraya et aI., 2011).

The factor that influenced this failure is the load transferbetween the soft LM6 alloy matrix and the hard brittle TiC particlesreinforcement. The presence of the hard, brittle TiC particulatescaused the pre-existing high dislocation density in the LM6 alloymatrix. Residual stresses generated in the LM6 alloy matrix anddislocations arose from the mismatch in the thermal expansioncoefficient between the soft matrix and the hard reinforcement TiCparticulates (Fridlyander, 1995).

During cyclic deformation it seems possible that the mismatchthat exists between the brittle reinforcing particles and the

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Shamsuddin Sulaiman

ductile matrix favors concentration of stress near the particle-matrix interface, causing the matrix in the immediate vicinity topermanently fail or the particles to separate from the matrix.

(a) (b) (c) (d) (e)

Figure 40 Tensile fracture surface of LM6 aluminium alloys solidifiedin a copper mould with a) O%wt, b) 5%wt, c) lO%wt, d) 15%wt and e)

20%wtTiC.

Comparison of Results

For this research, cylindrical moulds were used and the patternflows of the mould filling were not very complex. This type ofexperimental study is suitable to find a new composition of newmaterials. By using the data, AnyCasting can simulate the behaviorof other complex moulds to predict the flow of the molten metalmeeting in the cavity, to predict molten metal temperatures duringfilling and the solidification patterns which can be used to enhanceand improve the quality and accuracy of the final products. Tables2 and 3 show the comparison of the simulation and experimentalresults for both the sand and permanent moulds (Taufik et aI., 2011).

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Table 2 Comparison of simulation experimental study results for thepermanent mould

Solidification Time (seconds)(wt%)

Experimental Simulation

0 971.50 1285.50

5 770.00 947.54

ID 575.50 665.54

15 377.00 430.74

20 260.00 233.23

Table 3 The comparison of simulation and and experimental studyresults for the sand mould

(wt%)Solidification Time (seconds)

Experimental Simulation

0 32.19 37.22

5 29.10 28.35

10 27.9 27.23

15 14.9 13.78

20 12.1 11.76

ADVANCED TECHNOLOGY APPLICATIONWith the increased need for quality manufacturing along with thefactors of short lead times and short product lives, as well as theincreasing consumer awareness regarding the quality of products,it is becoming increasingly important for manufactures to initiatesteps to fulfill all of these requirements. View this against thefact that developments in microelectronics in the recent past havemade higher computational ability available at low costs. It is thu

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imperative that manufacturing takes advantage of the availabilityof these low cost yet more powerful computers. Hence, the useof Computer Aided Engineering, particularly for mechanicalindustries, should now be a realizable goal (Rao, 2004).

CAD / CAM (computer-aided design and computer-aidedmanufacturing) is a term that refers to computer systems that areused to both design and manufacture products. While CAD is theuse of computer technology for the process of design and designdocumentation, CAD / CAM systems are used both for designinga product and for controlling manufacturing processes. Thegeometries in the CAD drawings are used by the CAM portion ofthe program to control the machine that creates the exact shapesthat were drawn. The total components can be assumed to consistof a number of inter-linked domains, as shown in Figure 41.

COmputer GraphicsCAD standardsFinite Element Modeling(FEM)

Finite Element Analysis(FEA)Design ToolsMechanicalFeature and SolidModeling

Machining. AssemblyMaterial handling.StorageProduction ControlFlexible ManufacturingSystemsQuality ControlLoading, Scheduling.Balancing

Process PlanningProductionPlanningCNC PartProgramingRobotProgramingCMMPrograming

Figure 41 The influence of computers used in the ManufacturingEnvironment (Rao, 2004)

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Computer Aided Design (CAD) and Computer AidedEngineering (CAE)

Computer Aided design (CAD) involves the use of computersto create design drawings and product models. Computer aideddesign is usually associated with interactive computer graphics,known as a CAD system. There are several powerful commerciallyavailable programs to aid designers in geometry description andengineering analysis, such as CATIA, AutoCAD, SolidWorks,ProEngineering, Solid Edges and VectorWorks. The software canhelp identify potential problems, such as excessive loads, deflectionsor interface at mating surfaces (Kalpakjian and Schmid, 2010).Figure 42 shows the outcomes of product design using CAD andengineering software.

Figure 42 Design of products in engineering software

Finite Element Modeling (FEM) and Finite Element Analysis(FEA) are widely used as part of CAE. Conventional analyticalmethods for solving stresses and strain become very complex andalmost impossible when the part geometry is intricate. In suchcases Finite Element Modeling (FEM) becomes a very convenientmeans to carry out the analysis. The Finite Element Analysis(FEA) is a very powerful analysis tool, which can be applied to arange of engineering problems, such as, stress analysis, dynamic

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Shamsuddin Sulaiman

analysis, deformation studies, fluid flow analysis and heat flowanalysis. Various related sophisticated software packages are nowavailable, such as, ABAQUS, ANSYS, NASTRAN, LS-DYNA,MARQ, ALGOR and DEFORM (Rao, 2004). Figure 43 showsthe outcomes of FEA of a product.

~12O ~----------

i100 H-------_...~~~ eo~ 60, 40j 20... 0

CLottllgtWne l'i.e",_en hloo"odoo .Slmulauon h1oo"odoo.e",_ort h100".,;>00 .sIm<Jotion h100 'oC2OO.e",enmenl h100 'lC3oo .sIm<Jotion h100 'IC3OO

Figure 43 Finite element analysis of a product.

CONCLUSIONSThis study focused on the casting process application as one ofthe important metal forming processes. In terms of theoreticalapplication, two pertinent parameters i.e. flow and thermal aspectswere explained in detail, for example, the filling and solidificationcharacteristics of titanium carbide particulate reinforced LM6 alloymatrix composite castings made in sand and permanent metallicmould made of copper. The results of the experimental work havebeen compared with the results of computer simulations. Theobjective of the simulation was to predict the pattern of filling andthe solidification behaviors of the aluminium 11.8% silicon alloyswith titanium carbide as a particulate in sand and permanent metalliccasting moulds. Simulation of temperature versus time helped in thevisualization of the temperature contours and the distribution insidethe solidifying composites. The solidification rate is influenced

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by the thermal properties of the mixture of LM6 alloys matrixwith particles and it is dependent on the solid weight percentages.The presence of the TiC particles in the LM6 alloy matrix causedshortening of the solidification rates because of the diminishinglatent heat released during solidification. During the experimentalwork values of tensile test, hardness test and microstructures wereobtained from SEM test and the cooling curves data were obtainedusing datataker.

Other than simulation process technology, advances in designof mould and die technology are also being applied in castingproduct development. With these advanced technologies, thecasting process will be maintained and sustained as an importantand relevant component of the metal forming processes.

REFERENCESAmerican Society for Testing and Material (1999), Manual Book ofASTM

Standards, USA.

Apelian, D. (2009), Aluminum Cast Alloys: Enabling Tools for ImprovedPerformance, North American Die Casting Association:Wheeling,IIlinois.

Brady, G .S., Clauser, H.R. and Vaccari, lA. (2002), Materials Hand Book,Fifteenth Edition, Me Graw-Hill Handbook.

Bruce, R.G., Tomovic, M.M., Neely, lE. and Kibbe, R.R. (1998), ModernMaterials and Manufacturing Processes, 2nd Edition, Prentice HaIl1998.

Clegg, A.1. (1991), Precision Casting Processes, Pergamon press.

Fatchurrohman, N., Sulaiman, S., Ariffin, M.K.A., Baharuddin, B.T.H.T.and Faieza, A.A. 2012. Solidification characteristic of titanium carbideparticulate reinforced aluminium aIloy matrix composites, Journal ofEngineering Science and Technology 7(2), 248.

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Fridlyander,l N. (1995), Metal Matrix Composite, Chapman & Hall.

Grieve, D. (2014), Metals Selection and Specifications Aluminium andits Alloys, http://www.tech.plym.ac.uk/sme/desnotes/matalu.html.Accessed 18th January 2014.

Groover, M.P. (2007). Fundamentals of Modem Manufacturing, 3rd Edition,John Wiley & Sons (Asia) Pte Ltd.

Hagen, K.D. (1999), Heat Transfer with Applications, Prentice HallInternational Inc.

Hasyim, 1,Looney, L. and Hashmi, M.S.l (2002) Particle distribution incast metal matrix composites-Part I, Journal of Materials Processingand Technology. 123,251-257.

Jacobs, lA. and KilduffT.F. (1994), Engineering Materials Technology,Structures, Processing, Properties & Selection, Prentice Hall.

Kaczmar, i.w, Pietrzak, K. and Wlosinski, W (2000), The production andapplication of metal matrix composite materials, Journal of 'MaterialsProcessing and Technology. 106, 58-63.

Kalpakjian, S., and Schmid, S. (2012), Manufacturing Engineeringand Technology, 6rd Edition, New York, Addison-Wesley PublishingCompany.

Lim, Y.P., Sulaiman, S., Hamouda A.M.S. and M.M.H.M.Ahmad,M.M.H.M. (2005), Grain refinement of LM6 AI-Si alloy sand castingsto enhance mechanical properties, Int. Journal of Materials ProcessingTechnology, 162-163, 435-441.

Mona Kiaee, Shamsuddin Sulaiman and Tang Sai Hong. (2014).Investigation on microstructure and Mechanical Properties of SqueezeCast AI-Si Alloys by Numerical Simulation, Advanced MaterialsResearch Vol. 1043,31-35.

Rao, P.N. (2004), CAD/CAM principle and applications, 2nd Edition,Iowa USA.

Rizkalla, H.L. and Abdulwahed, A. (1996), Some mechanical properties ofmetal-nonmetal Al-Si0

2particulate composites, Journal of Materials

Processing and Technology. 56, 398-403.

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http://www.tech.plym.ac.uk/sme/desnotes/matalu.html.


Roosz, A. and Exner, Piwonka, H.E., Voller, V. and Katgerman, L. (1993),Modeling of casting, welding and advanced solidification processesVI, TMS, Warrendale, PA, USA.

Sulaiman, S. and Gethin, D.T. (1996). A Network Technique for Analysisof the Thermal Transient Casting Process, Pertanika J. Sci. & Technol.4(2): 251-261.

Sulaiman, S. and Gethin, D.T. (1996), An experimental investigation into themetal filling system of pressure diecasting process, Journal of Institutionof Engineers Malaysia (IEM) March. pp.9-13.

Sulaiman, S. and Tham, C. K. (1997), Flow analysis along runner andgating system of casting process, Int. Journal of Materials ProcessingTechnology, 63, 690-695.

Sulaiman, S. and Lim, Y.P. (2004), Validation of MAGMAs oft simulationof sand casting process, Journal of IEM, 65(1/2), 29-38.

Sulaiman, S. and Hamouda, A.M.S. (2001), Modelling of the thermalhistory of sand casting process, Int. Journal of Material ProcessingTechnology, I 13( 1), 245-250.

Suraya, S" Sulaiman, S., Ariffin, M.K.A., and Sayuti, M. (2011), Computersimulation and experiemental investigation of solidification castingprocess, Key Engineering Materials, 471-472, 601-605.

Suraya Sulaiman, Shams uddin Sulaiman, Nur Najmiah Jaafar and NorImrah Yusoff. (2014). Studies on tensile properties of TitaniumCarbide (TiC) particulate composite, Applied Mechanics andMaterials 529, 151-156.

Sahroni, T.R. and Sulaiman, S. (2014). Casting quality model for castedaluminium silicon carbide based on non-linear thermal expansion, Int.J. Materials and Product Technology, 48( 112/3/4), , pp217-233.

Suraya Sulaiman, Shamsuddin Sulaiman, Munira Ali and Fazilah Abdul Aziz.(2014). Effect of TiC particulate on the microstructure and mechanicalproperties of Aluminium-Based Metal Matrix Composite, AppliedMechanics and Materials, 529, 145-150.

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Sayuti, M., Sulaiman S., Baharudin, B. T. H. T., and Arifin, M.K.A.(2014). The influence of mechanical mold vibration on temperaturedistribution and physical properties of Al-II.8% Si Matrix composites,Materials Science Forum, 773-774, 195-202.

Sayuti, M., Sulaiman, S., Ariffin, M.K.A., Baharuddin, B.T.H.T., Vijayaram,T.R. and Suraya, S. (2011), Influence of Mechanical VibrationMoulding Process on the Tensile Properties of Tie Reinforced LM6Alloy Composite Castings, Applied Mechanics and Materials, 66-68.1207-1212.

Taufik, R.S., Sulaiman, S., Baharudin, B.T.H.T., Ariffin M.K.A., and Arep,H. (20 II), Design and Simulation on Investment Casting Mould forMetal Matrix Composite Material, Applied Mechanics and Materials66-68,1676-1681.

Vijayaram, T.R., Sulaiman, S., HamoudaA.M.S. and Ahmad, M.M.H.M.(2006), Fabrication of fiber reinforced metal matrix composites bysqueeze casting technology, Int. Journal of Materials ProcessingTechnology, 178. 34-38.

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BIOGRAPHYProfessor Shamsuddin was born on 4 January 1963, in KampongParit Hj Adnan, Pontian, Johor. He obtained his B.Eng degree inAgricultural Engineering from Universiti Pertanian Malaysia (nowcalled Universiti Putra Malaysia) in 1986. He then joined UPMas a Tutor in the Department of Mechanical and ManufacturingEngineering. Subsequently, he continued his studies and obtainedhis MSc in Mechanical Engineering (specialising in Product Designand Economic Manufacture) from the University of Swansea,Wales, United Kingdom, in 1989, and finally his Ph.D in 1992, in thearea of metal casting process, from the same university. ProfessorShamsuddin has been a Professor in the Department of Mechanicaland Manufacturing Engineering since September 2007. Currentlyhe is the research coordinator and programme coordinator for theMaster of Manufacturing System Engineering (MSE) programmeat the Department of Mechanical and Manufacturing Engineering.He has also held other posts, including Deputy Dean of School ofGraduate Studies (ApriI2008-March 20 II), Senate Member (July2011- June 2014), Deputy Dean of Faculty of Engineering (Sept2003-Aug 2006), Deputy Director of University Agricultural Park(TPU) (Feb 2001-Nov 2011), Head of Department of Mechanicaland Manufacturing Engineering (Jan 1995-Aug 1998) andLecturer and Associate Professor, Department of Mechanical andManufacturing Engineering (Feb 1992-Aug 1998).

Professor Shamsuddin has taught more than 5 subjectsat Postgraduate, Bachelor and Diploma levels. He has beencontributing continuously to the development of various engineeringprogrammes, curricula and syllabi during his 20 years of serviceas tutor, lecturer, associate professor and professor, at the Facultyof Engineering. He was one of the key persons in developing the

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Master of Engineering programme, in the area of ManufacturingSystem Engineering and Engineering Management, at thedepartment.

Professor Shams uddin has been the leader in acquiring andcompleting several major research projects with total funding ofmore than RM3 million from the Ministry of Science, Technologyand Innovation (MOSTI). Consequently, hundreds of his workshave been recognized and published extensively in renownedjournals and conference proceedings. He has also been invited tobe a speaker and panelist at various international conferences. Intandem with his expertise, he has also supervised and co-supervised38 MS students, 62 MEng students and 27 PhD students. He isalso an external examiner for students from other higher learninginstitutions, both local and international, for their MS/PhD degrees.

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ACKNO\VLEDGEMENTSProfessor Shamsuddin would like to thank his late father HajiSulaiman Haji Abdullah, late mother Hajjah Mariam Sadiran,his wife, Pn Salmah Sahudin, his sons Ashraf and Arief and hisdaughter, Aisyah, for their understanding and prayers.

He also thanks all individuals involved in the research,preparation and writing of this book.

He also wishes to express his gratitude for the financial supportfrom MOST! through the Science Fund, Ministry of HigherEducation through FRGS and Universiti Putra Malaysia through theResearch University Grant Scheme (RUGS) and short term Grant.The support from other staff and students at the Department ofMechanical and Manufacturing Engineering, UPM is also highlyappreciated. The contribution of all UPM students and staff, ingeneral, is similarly highly appreciated.

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Shamsuddin Sulaiman

LIST OF INAUGURAL LECTURES

1. Prof. Dr. Sulaiman M. Yassin 9. Prof. Ir. Dr. Mohd. Zohadie Bardaie

The Challenge to Communication Engineering TechnologicalResearch in Extension Developments Propelling Agriculture

22 July 1989 into the 21st Century28 May 1994

2. Prof. Ir. Abang Abdullah Abang AliIndigenous Materials and Technology 10. Prof. Dr. Shamsuddin Jusop

Jor Low Cost Housing Rock. Mineral and Soil30 August 1990 18 June 1994

3. Prof. Dr. Abdul Rahman Abdul Razak II. Prof. Dr. Abdul Salam Abdullah

Plant Parasitic Nematodes, Lesser Natural Toxicants Affecting Animal

Known Pests oj Agricultural Crops Health and Production30 January 1993 29 June 1994

4. Prof. Dr. Mohamed Suleiman 12. Prof. Dr. Mohd. Yusof Hussein

Numerical Solution of Ordinary Pest Control: A Challenge in Applied

Differential Equations: A Historical EcologyPerspective 9 July 1994II December 1993

13. Prof. Dr. Kapt. Mohd. Ibrahim Haji

5. Prof. Dr. Mohd. AriffHussein Mohamed

Changing Roles oj Agricultural Managing Challenges in Fisheries

Economics Development through Science and

5 March 1994 Technology23 July 1994

6. Prof. Dr. Mohd. Ismail AhmadMarketing Management: Prospects 14. Prof. Dr. Hj. Amat Juhari Moain

and Challenges Jar Agriculture Sejarah Keagungan Bahasa Melayu

6April1994 6 August 1994

7. Prof. Dr. Mohamed Mahyuddin Mohd. 15. Prof. Dr. Law Ah Theem

Dahan Oil Pollution in the Malaysian Seas

The Changing Demand for Livestock 24 September 1994

Products20April1994 16. Prof. Dr. Md. Nordin Hj. Lajis

Fine Chemicals from Biological

8. Prof. Dr. Ruth Kiew Resources: The Wealthfrom Nature

Plant Taxonomy, Biodiversity and 21 January 1995

ConservationII May 1994 17. Prof. Dr. Sheikh Omar Abdul Rahman

Health, Disease and Death inCreatures Great and Small25 February 1995

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18. Prof. Dr. Mohamed Shariff MohamedDinFish Health: An Odyssey through theAsia - Pacific Region25 March 1995

19. Prof. Dr. Tengku Azmi Tengku IbrahimChromosome Distribution andProduction Performance of WaterBuffaloes6 May 1995

20. Prof. Dr. Abdul Hamid MahmoodBahasa Melayu sebagai Bahasa Ilmu-Cabaran dan HarapanID June 1995

21. Prof. Dr. Rahim Md. SailExtension Education forIndustrialising Malaysia: Trends.Priorities and Emerging Issues22 July 1995

22. Prof. Dr. Nik Muhammad Nik Abd.MajidThe Diminishing Tropical Rain Forest:Causes. Symptoms and Cure19 August 1995

23. Prof. Dr. Ang Kok JeeThe Evolution of an EnvironmentallyFriendly Hatchery Technology forUdang Galah, the King of FreshwaterPrawns and a Glimpse into the Futureof Aquaculture in the 21st Century14 October 1995

24. Prof. Dr. Sharifuddin Haji AbdulHamidManagement of Highly Weathered AcidSoils for Sustainable Crop Production28 October 1995

25. Prof. Dr. Yu Swee YeanFish Processing and Preservation:Recent Advances and FutureDirections9 December 1995

11146

26. Prof. Dr. Rosli MohamadPesticide Usage: Concern and Options10 February 1996

27. Prof. Dr. Mohamed Ismail AbdulKarimMicrobial Fermentation andUtilization of AgriculturalBioresources and mlstes in Malaysia2 March 1996

28. Prof. Dr. Wan Sulaiman Wan HarunSoil Physics: From Glass Beads toPrecision Agriculture16 March 1996

29. Prof. Dr. Abdul Aziz Abdul RahmanSustained Growth and SustainableDevelopment: Is there a Trade-Off I orMalaysia13 April1996

30. Prof. Dr. Chew Tek AnnSharecropping in PerfectlyCompetitive Markets: A Contradictionin Terms27 April 1996

31. Prof. Dr. Mohd. Yusuf SulaimanBack to the Future with the Sun18 May 1996

32. Prof. Dr. Abu Bakar SallehEnzyme Technology: The Basis forBiotechnological Development8 June 1996

33. Prof. Dr. Kamel Ariffin Mohd. AtanThe Fascinating Numbers29 June 1996

34. Prof. Dr. Ho Yin WanFungi: Friends or Foes27 July 1996

35. Prof. Dr. Tan Soon GuanGenetic Diversity of Some SoutheastAsian Animals: Of Buffaloes andGoats and Fishes Too10August 1996


36. Prof. Dr. Nazaruddin Mohd. JaliWill Rural Sociology Remain Relevantin the 21st Century?21 September 1996

37. Prof. Dr. Abdul Rani BahamanLeptospirosis-A Model/orEpidemiology, Diagnosis and Control0/ Infectious Diseases16 November 1996

38. Prof. Dr. Marziah MahmoodPlant Biotechnology - Strategies/orCommercialization21 December 1996

39. Prof. Dr. Ishak Hj. OmarMarket Relationships in the MalaysianFish Trade: Theory and Application22 March 1997

40. Prof. Dr. Suhaila MohamadFood and Its Healing Power12 April 1997

41. Prof. Dr. Malay Raj MukerjeeA Distributed CollaborativeEnvironment/or Distance LearningApplications17 June 1998

42. Prof. Dr. Wong Kai ChooAdvancing the Fruit Industry inMalaysia: A Need to Shift ResearchEmphasis15 May 1999

43. Prof. Dr. Aini IderisAvian Respiratory andImmunosuppressive Diseases- A FatalAttraction10July 1999

44. Prof. Dr. Sariah MeonBiological Control ofPlant Pathogens:Harnessing the Richness 0/MicrobialDiversity14 August 1999

45. Prof. Dr. Azizah HashimThe Endomycorrhiza: A FutileInvestment?23 October 1999

46. Prof. Dr. Noraini Abdul SamadMolecular Plant Virology: The WayForward2 February 2000

47. Prof. Dr. MuhamadAwangDo We Have Enough Clean Air toBreathe?7 April2000

48. Prof. Dr. Lee Chnoong KhengGreen Environment, Clean Power24 June 2000

49. Prof. Dr. Mohd. Ghazali MohayidinManaging Change in the AgricultureSector: The Need/or InnovativeEducational Initiatives12 January 2002

50. Prof. Dr. Fatimah Mohd. ArshadAnalisis Pemasaran Pertaniandi Malaysia: Keperluan AgendaPembaharuan26 January 2002

51. Prof. Dr. Nik Mustapha R. AbdullahFisheries Co-Management: AnInstitutional Innovation TowardsSustainable Fisheries Industry28 February 2002

52. Prof. Dr. Gulam Rusul Rahmat AliFood Safety: Perspectives andChallenges23 March 2002

53. Prof. Dr. Zaharah A. RahmanNutrient Management Strategies/orSustainable Crop Production in AcidSoils: The Role 0/ Research UsingIsotopes13 April 2002

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54. Prof. Dr. Maisom AbdullahProductivity Driven Growth: Problems& Possibilities27 April 2002

55. Prof. Dr. Wan Omar AbdullahImmunodiagnosis and Vaccination forBrugian Filariasis: Direct Rewardsfrom Research Investments6 June 2002

56. Prof. Dr. Syed Tajuddin Syed HassanAgro-ento Bioinformation: Towardsthe Edge of Reality22 June 2002

57. Prof. Dr. Dahlan IsmailSustainability of Tropical Animal-Agricultural Production Systems:Integration of Dynamic ComplexSystems27 June 2002

58. Prof. Dr. Ahmad lubaidiBaharumshahThe Economics of Exchange Rates inthe East Asian Countries26 October 2002

59. Prof. Dr. Shaik Md. Noor Alam S.M.HussainContractual Justice in Asean: AComparative View of Coercion31 October 2002

60. Prof. Dr. Wan Md. lin Wan YunusChemical Modification of Polymers:Current and Future Routes forSynthesizing New PolymericCompounds9 November 2002

61. Prof. Dr. Annuar Md. NassirIs the KLSE Efficient? Efficient MarketHypothesis vs Behavioural Finance23 November 2002

11148

62. Prof. Ir. Dr. Radin Umar Radin SohadiRoad Safety Interventions in Malaysia:How Effective Are They?21 February 2003

63. Prof. Dr. Shamsher MohamadThe New Shares Market: RegulatoryIntervention, Forecast Errors andChallenges26 April 2003

64. Prof. Dr. Han Chun KwongBlueprint for Transformation orBusiness as Usual? A StructurationalPerspective of the Knowledge-BasedEconomy in Malaysia31 May 2003

65. Prof. Dr. Mawardi RahmaniChemical Diversity of MalaysianFlora: Potential Source of RichTherapeutic Chemicals26 July 2003

66. Prof. Dr. Fatimah Md. YusoffAn Ecological Approach: A ViableOption for Aquaculture Industry inMalaysia9 August 2003

67. Prof. Dr. Mohamed Ali RajionThe Essential Fatty Acids-Revisited23 August 2003

68. Prof. Dr. Azhar Md. lainPsychotheraphyfor Rural Malays -Does it Work?13 September 2003

69. Prof. Dr. Mohd. Zarnri SaadRespiratory Tract Infection:Establishment and Control27 September 2003

70. Prof. Dr. Jinap SelamatCocoa-Wonders for Chocolate Lovers14 February 2004

Shamsuddin Sulaiman

71. Prof. Dr. Abdul Halim ShaariHigh Temperature Superconductivity:Puzzle & Promises13 March 2004

72. Prof. Dr. Yaakob Che ManOils and Fats Analysis - RecentAdvances and Future Prospects27 March 2004

73. Prof. Dr. Kaida KhalidMicrowave Aquametry: A GrowingTechnology24 April 2004

74. Prof. Dr. Hasanah Mohd. GhazaliTapping the Power oj Enzymes-Greening the Food IndustryII May 2004

75. Prof. Dr. YusoflbrahimThe Spider Mite Saga: Quest forBiorational Management Strategies22 May 2004

76. Prof. Datin Dr. Sharifah Md. NorThe Education oj At-Risk Children:The Challenges Ahead26 June 2004

77. Prof. Dr. Ir. Wan Ishak Wan IsmailAgricultural Robot: A New TechnologyDevelopment Jar Agro-Based Industry14August 2004

78. Prof. Dr. Ahmad Said SajapInsect Diseases: Resources forBiopesticide Development28 August 2004

79. Prof. Dr. Arninah AhmadThe Interface of Work and FamilyRoles: A Quest for Balanced LivesII March 2005

80. Prof. Dr. Abdul Razak AlimonChallenges in Feeding Livestock:From ffllstes to Feed23 April 2005

81. Prof. Dr. Haji Azimi Hj. HamzahHelping Malaysian Youth MoveForward: Unleashing the PrimeEnablers29 April 2005

82. Prof. Dr. Rasedee AbdullahIn Search oj An Early Indicator ojKidney Disease27 May 2005

83. Prof. Dr. Zulkifli Hj. ShamsuddinSmart Partnership: Plant-Rhizobacteria Associations17 June 2005

84. Prof. Dr. Mohd KhanifYusopFrom the Soil to the TableI July 2005

85. Prof. Dr. Annuar KassimMaterials Science and Technology:Past, Present and the Future8 July 2005

86. Prof. Dr. Othman MohamedEnhancing Career DevelopmentCounselling and the Beauty oj CareerGames12 August 2005

87. Prof. Ir. Dr. Mohd Amin Mohd SoomEngineering Agricultural WaterManagement Towards PrecisionFraming26 August 2005

88. Prof. Dr. Mohd Arif SyedBioremediation-A Hope Yetfor theEnvironment?9 September 2005

89. Prof. Dr. Abdul Hamid Abdul RashidThe Wonder oj Our NeuromotorSystem and the TechnologicalChallenges They Pose23 December 2005

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90. Prof. Dr. Norhani AbdullahRumen Microbes and Some of TheirBiotechnological Applications27 January 2006

91. Prof. Dr. Abdul Aziz SahareeHaemorrhagic Septicaemia in Cattleand Buffaloes: Are We Ready forFreedom?24 February 2006

92. Prof. Dr. Kamariah Abu BakarActivating Teachers' Knowledge andLifelong Journey in Their ProfessionalDevelopment3 March 2006

93. Prof. Dr. Borhanuddin Mohd. AliInternet Unwired24 March 2006

94. Prof. Dr. Sundararajan ThilagarDevelopment and Innovation in theFracture Management of Animals31 March 2006

95. Prof. Dr. Zainal Aznam Md. JelanStrategic Feedingfor a SustainableRuminant Farming19 May 2006

96. Prof. Dr. Mahiran BasriGreen Organic Chemistry: Enzyme atWork14 July 2006

97. Prof. Dr. Malik Hj. Abu HassanTowards Large Scale UnconstrainedOptimization20 April 2007

98. Prof. Dr. Khalid Abdul RahimTrade and Sustainable Development:Lessons from Malaysia s Experience22 June 2007

11150

99. Prof. Dr. Mad Nasir ShamsudinEconometric ModellingforAgricultural Policy Analysis andForecasting: Between Theory andReality13 July 2007

100. Prof. Dr. Zainal Abidin MohamedManaging Change - The Fadsand The Realities: A Look atProcess Reengineering. KnowledgeManagement and Blue OceanStrategy9 November 2007

101. Prof. Ir. Dr. Mohamed DaudExpert Systems for Environme~talImpacts and Ecotourism Assessments23 November 2007

102. Prof. Dr. Saleha Abdul AzizPathogens and Residues; How Safeis Our Meat?30 November 2007

103. Prof. Dr. Jayum A. JawanHubungan Sesama Manusia7 December 2007

104. Prof. Dr. Zakariah Abdul RashidPlanningfor Equal IncomeDistribution in Malaysia: A GeneralEquilibrium Approach28 December 2007

105. Prof. Datin Paduka Dr. KhatijahYusoffNewcastle Disease virus: A Journeyfrom Poultry to Cancer11 January 2008

106. Prof. Dr. Dzulkefly Kuang AbdullahPalm Oil: Still the Best Choice1 February 2008

107. Prof. Dr. Elias SaionProbing the Microscopic Worlds byLonizing Radiation22 February 2008

Shamsuddin Sulaiman

108. Prof. Dr. Mohd Ali HassanWaste-to-Wealth ThroughBiotechnology: For Profit. Peopleand Planet28 March 2008

109. Prof. Dr. Mohd MaarofH. A. MoksinMetrology at Nanoscale: ThermalWave Probe Made It SimpleII April 2008

110. Prof. Dr. Dzolkhifli OmarThe Future oj Pesticides Technologyin Agriculture: Maximum Target Killwith Minimum Collateral Damage25 April 2008

III. Prof. Dr. Mohd. Yazid Abd. ManapProbiotics: Your Friendly GutBacteria9 May 2008

112. Prof. Dr. Hamami SahriSustainable Supply of Wood andFibre: Does Malaysia have Enough?23 May 2008

113. Prof. Dato' Dr. Makhdzir MardanConnecting the Bee Dots20 June 2008

114. Prof. Dr. Maimunah IsmailGender & Career: Realities andChallenges25 July 2008

115. Prof. Dr. Nor Aripin ShamaanBiochemistry oj Xenobiotics:Towards a Healthy Lifestyle and SafeEnvironmentI August 2008

116. Prof. Dr. Mohd Yunus AbdullahPenjagaan Kesihatan Primer diMalaysia: Cabaran Prospek danImplikasi dalam Latihan danPenyelidikan Perubatan sertaSains Kesihatan di Universiti PutraMalaysia8 August 2008

117. Prof. Dr. Musa Abu HassanMemanfaatkan Teknologi Maklumat& Komunikasi ICT untuk Semua15 August 2008

118. Prof. Dr. Md. Salleh Hj. HassanRole of Media in Development:Strategies. Issues & Challenges22 August 2008

119. Prof. Dr. Jariah MasudGender in Everyday Life10 October 2008

120 Prof. Dr. Mohd Shahwahid HajiOthmanMainstreaming Environment:Incorporating Economic Valuationand Market-Based Instruments inDecision Making24 October 2008

121. Prof. Dr. Son RaduBig Questions Small Worlds:Following Diverse Vistas31 October 2008

122. Prof. Dr. Russly Abdul RahmanResponding to Changing Lifestyles:Engineering the Convenience Foods28 November 2008

123. Prof. Dr. Mustafa Kamal MohdShariffAesthetics in the Environment anExploration of Environmental:Perception Through LandscapePreJerence9 January 2009

124. Prof. Dr. Abu Daud SilongLeadership Theories. Research& Practices: Farming FutureLeadership Thinking16 January 2009

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125. Prof. Dr. Azni Idris 135. Prof. Dr. W. Mahmood Mat YunusWaste Management. What is the Photothermal and Photoacoustic:Choice: Land Disposal or Biofuel? From Basic Research to Industrial23 January 2009 Applications

10 July 2009126. Prof. Dr. Jamilah Bakar

Freshwater Fish: The Overlooked 136. Prof. Dr. Taufiq Yap Yun HinAlternative Catalysis for a Sustainable World30 January 2009 7 August 2009

127. Prof. Dr. Mohd. Zobir Hussein 137 Prof. Dr. Raja Noor Zaliha RajaThe Chemistry of Nanomaterial and Abd. RahmanNanobiomaterial Microbial Enzymes: From Earth to6 February 2009 Space

9 October 2009128. Prof. Ir. Dr. Lee Teang Shui

Engineering Agricultural: Water 138 Prof. Ir. Dr. Barkawi SahariResources Materials. Energy and CNGDI20 February 2009 Vehicle Engineering

6 November 2009129. Prof. Dr. Ghizan Saleh

Crop Breeding: Exploiting Genes for 139. Prof. Dr. Zulkifli IdrusFood and Feed Poultry Welfare in Modern6 March 2009 Agriculture: Opportunity or Threat?

13 November 2009130. Prof. Dr. Muzafar Shah Habibullah

Money Demand 140. Prof. Dr. Mohamed Hanafi Musa27 March 2009 Managing Phosphorus: Under Acid

Soils Environment131. Prof. Dr. Karen Anne Crouse 8 January 20 I0

In Search of Small Active Molecules3 April2009 141. Prof. Dr. Abdul Manan Mat Jais

Haman Channa striatus a Drug132. Prof. Dr. Turiman Suandi Discovery in an Agro-Industry

Volunteerism: Expanding the SettingFrontiers of Youth Development 12 March 201017 April 2009

142. Prof. Dr. Bujang bin Kim Huat133. Prof. Dr. Arbakariya Ariff Problematic Soils: In Search for

Industrializing Biotechnology: Roles Solutionof Fermentation and Bioprocess 19 March 2010Technology8 May 2009 143. Prof. Dr. Samsinar Md Sidin

Family Purchase Decision Making:134. Prof. Ir. Dr. Desa Ahmad Current Issues & Future Challenges

Mechanics of Tillage Implements 16April201012 June 2009

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144. Prof. Dr. Mohd Adzir MahdiLightspeed: Catch Me If YOllCan4 June 2010

145. Prof. Dr. Raha Hj. Abdul RahimDesigner Genes: Fashioning MissionPurposed Microbes18 June 2010

146. Prof. Dr. Hj. Hamidon Hj. BasriA Stroke 0/ Hope. A New Beginning2 July 2010

147. Prof. Dr. Hj. Kamaruzaman JusoffGoing Hyperspectral: The "Unseen"Captured?16 July 2010

148. Prof. Dr. Mohd Sapuan SalitConcurrent Engineering/orComposites30 July 2010

149. Prof. Dr. Shattri MansorGoogle the Earth: What's Next?IS October 20 I0

I SO. Prof. Dr. Mohd Basyaruddin AbdulRahmanHaute Couture: Molecules &Biocatalysts29 October 2010

151. Prof. Dr. Mohd. Hair BejoPoultry Vaccines: An Innovation forFood Safety and Security12 November 2010

152. Prof. Dr. Umi Kalsom YusufFern 0/Malaysian Rain Forest3 December 2010

153. Prof. Dr. Ab. Rahim BakarPreparing Malaysian Youthsfor TheWorld a/Work: Roles of Technicaland Vocational Education andTraining (rVEr)14 January 20 II

154. Prof. Dr. Seow Heng FongAre there "Magic Bullets "forCancer Therapy?II February 20 II

ISS. Prof. Dr. Mohd Azmi Mohd LilaBiopharmaceuticals: Protection.Cure and the Real Winner18 February 20 II

156. Prof. Dr. Siti Shapor SirajGenetic Manipulation in FarmedFish: Enhancing AquacultureProduction25 March 2011

157. Prof. Dr. Ahmad IsmailCoastal Biodiversity and Pollution:A Continuous Conflict22 April 20 II

158. Prof. Ir. Dr. Norman MariunEnergy Crisis 2050? GlobalScenario and HiIY Forward forMalaysia10 June 2011

159. Prof. Dr. Mohd Razi IsmailManaging Plant Under Stress: AChallenge/or Food Security15 July 2011

160. Prof. Dr. Patimah IsmailDoes Genetic Polymorph isms AffectHealth?23 September 2011

161. Prof. Dr. Sidek Ab. AzizfVtmders a/Glass: Synthesis.Elasticity and Application7 October 2011

162. Prof. Dr. Azizah OsmanFruits: Nutritious. Colourful. YetFragile Gifis a/Nature14 October 20 II

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163. Prof. Dr. Mohd. Fauzi Ramlan 172. Prof. Dr. Norlijah OthmanClimate Change: Crop Performance Lower Respiratory Infections inand Potential Children: New Pathogens. OldII November 2011 Pathogens and The WilY Forward

19 April 2013164. Prof. Dr. Adem Kilicman

Mathematical Modeling with 173. Prof. Dr. Jayakaran MukundanGeneralized Function Steroid-like Prescriptions English25 November 2011 Language Teaching Can Ill-afford

26 April 2013165. Prof. Dr. Fauziah Othman

My Small World: In Biomedical 174. Prof. Dr. Azmi ZakariaResearch Photothermals Affect Our Lives23 December 20 II 7 June 2013

166. Prof. Dr. Japar Sidik Bujang 175. Prof. Dr. Rahinah IbrahimThe Marine Angiosperms. Seagrass Design Informatics23 March 2012 21 June 2013

167. Prof. Dr. Zailina Hashim 176. Prof. Dr. Gwendoline Ee ChengAir Quality and Children's Natural Products from MalaysianEnvironmental Health: Is Our RainforestsFuture Generation at Risk? I November 201330 March 2012

177. Prof. Dr. Noor Akma Ibrahim168. Prof. Dr. ZainaI Abidin Mohamed The Many Facets of Statistical

Where is the Beef? Vantage Point Modelingform the Livestock Supply Chain 22 November 201327 April20I2

178. Prof. Dr. Paridah Md. Tahir169. Prof. Dr. Jothi Malar Panandam Bonding with Natural Fibres

Genetic Characterisation of Animal 6 December 2013Genetic Resources for SustaninableUtilisation and Development 179. Prof. Dr. Abd. Wahid Haron30 November 2012 Livestock Breeding: The Past. The

Present and The Future170. Prof. Dr. Fatimah Abu Bakar 9 December 2013

The Good The Bad & Ugly of FoodSafety: From Molecules to Microbes 180. Prof. Dr. Aziz Arshad7 December 2012 Exploring Biodiversity & Fisheries

Biology: A Fundamental Knowledge171. Prof. Dr. Abdul Jalil Nordin for Sustainabale Fish Production

My Colourful Sketches from Scratch: 24 January 20 I4Molecular Imaging5 April2013 181. Prof. Dr. Mohd Mansor Ismail

Competitiveness of BeekeepingIndustry in Malaysia21 March 2014

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182. Prof. Dato' Dr. Tai Shzee YewFood and Wealthfrom the Seas:Health Check for the MarineFisheries of Malaysia25 April2014

183. Prof. Datin Dr. Rosenani Abu BakarWaste to Health: Organic WilsteManagementfor Sustainable SoilManagement and Crop Production9 May 2014

184. Prof. Dr. Abdul Rahman OmarPoultry Viruses: From Threat toTherapy23 May 2014

185. Prof. Dr. Mohamad Pauzi ZakariaTracing the Untraceable:Fingerprinting Pollutants throughEnvironmental Forensics13 June 2014

186. Prof. Dr. -Ing, Ir. RenuganthVaratharajooSpace System Trade-offs: TowardsSpacecraft Synergisms15 August 2014

187. Prof. Dr. Latiffah A. LatiffTranformasi Kesihatan ffanita keArah Kesejahteraan Komuniti7 November 2014

188. Prof. Dr. Tan Chin PingFat and Oils for a Healthier Future:Makro. Micro and Nanoscales21 November 2014

189. Prof. Dr. Suraini Abd. AzizLignocellulosic Biofuel: A WayForward28 November 2014

190. Prof. Dr. Robiah YunusBiobased Lubricants: Harnessingthe Richness of AgricultureResources30 January 2015

190. Prof. Dr. Khozirah ShaariDiscovering Future Cures fromPhytochemistry to Metabolomics13 February 2015

191. Prof. Dr. Tengku Aizan Tengku AbdulHamidPopulation Ageing in Malaysia: AMosaic of Issues. Challenges andProspects13 March 2015

192. Prof. Datin Dr. Faridah HanumIbrahimForest Biodiversity: Importance ofSpecies Composition Studies27 March 2015

192. Prof. Dr. Mohd Salleh KamarudinFeeding & Nutritional Requirementsof Young FishIOApril2015

193. Prof. Dato' Dr. Mohammad ShatarSabranMoney Boy: Masalah Sosial EraGenerasi Y8 Mei 2015

194. Prof. Dr. Aida Suraya Md. YunusDeveloping Students' MathematicalThinking: How Far Have We Come?5June2015

195. Prof. Dr. Amin IsmailMalaysian Cocoa or Chocolates: AStory of Antioxidants and More ...14 August 2015

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Documents

CASTING TECHNOLOGYpsasir.upm.edu.my/id/eprint/57971/1/Shamsuddin sulaiman.pdfCASTING TECHNOLOGY SUSTAINABLE METAL FORMING PROCESS Profesor Dr.Shamsuddin Sulaiman B.Eng (UPM), MSc (Wales),PhD