Minimization of Casting Defects in Aluminium Alloy Oil Tank Casting through Quality Control and Design

ABSTRACT Casting process contains complex interactions with various parameters and operations related to molding, melting, degassing, metal composition, hardening, cooling and machining. In Gravity die casting process the metals enters the mold under gravity. Gravity die casting method is used for manufacturing of aluminium alloy oil tank. Aluminium alloy replaced many metal to maintain quality of performance. Aim of the project is to reduce minimize the defect in aluminium alloy (LM6) oil tank casting and improving the productivity of organization using statistical process control approach. Casting defects analysis is done by Cause and Effect diagram or Ishikawa diagram and Pareto chart. Rejection of castings is due to blow holes, pin holes, porosity and shrinkage finally casting defect is reduced by improving degasification step and by checking the temperature of molten metal and mold and new design proposal is given. KEYWORDS - Ishikawa diagram, Pareto chart,Degasification, LM6 Aluminum alloy