The quality of cast aluminum alloy products is directly related to the amount of dissolved hydrogen in the molten alloy. Current measurement techniques are unreliable, time-consuming, and labor-intensive. An aluminum alloy with 7.77 wt% silicon and 3.48 wt% copper, which readily absorbs hydrogen in the liquid state, is widely used in the automotive, aerospace, and, more recently, 3D printing industries for metal parts. Experimental results show that the porosity level in the hardened samples is directly related to the initial hydrogen content of the liquid alloy. The key result of this work is the derived exponential function for estimating the maximum solubility of hydrogen in liquid aluminum alloy under industrial conditions. The calculated value of the maximum solubility of hydrogen is 0.236 ml H2/100 g alloy for the alloy that was kept at 790 o C at atmospheric pressure, while the value of the maximum porosity is 2.26 %. This mathematical correlation, based on experimental data, enables real-time corrective measures during casting, resulting in high-quality products with reduced porosity. The results of this study are intended for manufacturers of metal parts, especially in the context of Industry 4.0, where advanced mathematical modeling and smart manufacturing techniques are key to improving production efficiency and product quality.
Mitrašinović et al. (Thu,) studied this question.