EFFECTS OF APPLIED PRESSURE AND DIE TEMPERATURE ON THE

ELECTRICAL CONDUCTIVITY OF SQUEEZE CAST ALUMINIUM RODS

J.O. Aweda and M.B. Adeyemi
Department of Mechanical Engineering,
University of Ilorin, P.M.B. 1515, Ilorin, Nigeria
Abstract
The effects of applied pressure and die pre-heat temperature on the electrical
conductivity of squeeze cast aluminium rods were experimentally investigated and
presented. The results show that applied pressure and die temperature have significant
and positive effects on the electrical properties of squeeze cast aluminium rods up to
certain levels. With increase in applied pressure, there is a steady increase in the
electrical conductivity up to a pressure level of 105MPa, which gives a maximum
value of electrical conductivity. Increasing the values of the applied pressure further
leads to a decrease in the electrical conductivity up to a pressure of 150MPa. Beyond
this pressure, increase in applied pressure has no significant effect on the values of
electrical conductivities. With die pre-heating, electrical conductivity increases with
increase in die temperature, reaching a maximum value at die temperature of 1500C.
Further increase in the die temperature beyond 1500C leads to a fall in the electrical
conductivity.

Keywords: electrical conductivity, electrical resistivity, squeeze casting, applied pressure, die
temperature.
Alloying and metal working processes
1.0 Introduction such as squeeze casting of aluminium
Aluminium has very wide and varied metal improve the mechanical strength
fields of applications (space, aircraft, [1,2,3].
vehicle, electricity, building, Until recently, copper was the
packaging, electronic, kitchen utensils dominant conductor material for
etc) due mainly to its light weight, electric power transmission and
corrosion resistance, good mechanical distribution because of its good
and electrical properties. Aluminium is electrical properties. Today aluminium
a light metal and can be given great is now taking the place of copper
strength by alloying, mechanical and because of its lightweight and
heat treatment thereby improving the relatively low cost [4]. The density of
mechanical properties [1,2]. aluminium is about 30% that of copper
Aluminium metal resists corrosion, [3,4,5]. In overhead line construction,
conducts heat and electricity and the lighter weight of aluminium makes
reflects light and radiant energy. it more acceptable for use than copper,

1
because heavy conductors lead to
heavy and expensive pole structures
[5,6]. In handling and transportation,
aluminium conductors are much easier
compared to heavy copper conductors
and cables. The electrical conductivity
of aluminium is 2.12 times that of an
equal mass of copper [4,5,6]. Due to its
diversities of applications, this research
work addresses the effects of casting
parameters of aluminium on
electrical properties. In this work, the
effects of squeeze cast parameters such
as applied pressure and die temperature
on the electrical properties
solidifying aluminium metal were
investigated.
2.0 EXPERIMENTAL METHODS
2.1 Squeeze casting rig
The rig used for the production of
squeeze cast aluminium rods for
electrical conductivity determination
was a split-type steel mould rig. It has
an external diameter of 85mm, internal
diameter of 20mm and 140mm in
height. It consisted of a movable
punch, a split cylindrical steel mould
and a lower support die (see Figure 1).
The punch was used to apply
predetermined loads on the solidifying
molten aluminium metal in the steel
mould. In the cylindrical steel mould
were drilled three 12mm diameters
holes to accommodate three heater
rods (220V-100W) to heat the steel
container/die. A bimetallic thermostat
was used for the control mould.
2.2 Preparation of aluminium cast
specimens
Aluminium electric overhead cables of
percentage composition of 99.5% of
aluminium and traces of other elements
its were cut into smaller sizes and melted
in an electric heating furnace of
maximum operating temperature of
11000C, set at temperature of 7500C.
of The molten aluminium metal was
soaked in the furnace for between 15
to 20 minutes at 7500C to allow the
melt to achieve uniform temperature of
7500C. The melt average temperature
of 7200C as indicated by the Chromel-
Alumel thermocouple inserted in the
aluminium melt, was used throughout
the experiment as the pouring
temperature. The inner surface of the
die/container core was lubricated
initially with used engine oil before
melt pouring to allow for easy removal
of the cast specimen after
solidification. A metered quantity of
molten aluminium metal was poured
carefully within 3-5 seconds so as to
avoid turbulence into the steel mould
cavity at a temperature of about 7200C
to attain a height of about 90±5mm.
2
The punch was released to close the
mould cavity without applying any
load on the aluminium melt and the
mould at room temperature. The punch
position was maintained without
pressure application, until total
solidification was achieved.
Cast specimens were produced with
the punch used to apply varying
pressures on the molten metal by a
Vega Compression Machine, model
UTM 3C, serial No 1061 with a
capacity of 89,000 N. The compression
loads were applied on the solidifying
molten aluminium metal at a delay
time of about 5 seconds, after pouring
molten aluminium metal and retained
on the solidifying molten metal for a
retention period of about 60 seconds.
Aluminium cast specimens were
produced with mould pre-heating
temperatures of 50, 80, 150, 250 and
310 0C without pressure application on
the solidifying aluminium metal. The
die heating process was carried out
through three electric heater rods of
100Watts each, that were connected to
a.c supply and the set temperatures for
tool heating were maintained uniform
by using bimetallic thermostat.
3
2.3 Electrical conductivity
determination
The specimens produced were 100mm
long and 20mm in diameter. The
specimens obtained were machined on
the lathe to give them good surface
finish both at their ends and cylindrical
surfaces for proper contact during
electrical testing. The cylindrical
surfaces of the specimens after turning
on the lathe machine were reduced to
diameters of between 18.75±0.25mm
and 90±5mm long.
The electrical circuit diagram shown in
Figure 2, was used for the
measurement of voltage across the
specimens [7, 8, 9]. The circuit
consisted mainly of a variable resistor,
ammeter, voltmeter and energy source
supply from the mains. The step-down
transformer steps down the high
alternating voltage from 240V to 12
volts, which was used as energy source
for the circuit. The rheostat regulated
the resistance across the circuit and
was used to vary the current passing
through the circuit of between 0.2 to
0.8A. The two flat copper metals (one
at each ends of the specimen) acted as
conductors [8, 9] and were used
because copper possesses higher
conductivity than that of aluminium
metal and will allow minimal voltage
loss across the entire circuit. The cast
specimen was placed in between the V
R= (4)
two flat copper metals to maintain a I
good contact at both ends. The rectifier
where, A -cross-sectional area of
was used to regulate and stabilise the
the specimen
circuit resonance. The regulator
C -electrical conductivity,
controlled the current across the circuit
ρ -electrical resistivity,
and maintained it at a constant value
V -voltage,
throughout the period of measurement.
I -current,
The ammeter read the current in the
L -length of specimen,
circuit in ampere (A) and the voltmeter
R -resistance of specimen.
reading was taken across the specimen
The resistance of the cast specimens
to calculate the electrical
was also taken directly, using a high
conductivities and resistivities of the
sensitive digital ohmmeter used to
cast aluminium metal rods.
measure resistance in ohms. The
Each specimen was placed in between
electrical resistivities of the cast
the two flat copper metals and
specimens were calculated using
potential difference (voltage) across it
equation 3.
was read in millivolt by the digital
voltmeter and the corresponding
3.0 Results and discussions
reading of the current was taken.
Figure 3 shows the variation of
Repeated readings were taken for each
electrical conductivity and resistivity
selected current and average values of
of aluminium rod with applied squeeze
voltage and current were used for the
casting pressure. As the values of
determination of electrical conductivity
applied pressure increases, there is an
and resistivity, using equations (1) and
increase in the electrical conductivity
(2) respectively.
of aluminium up to an applied pressure
IL
C= (1) level of 105MPa with a corresponding
VA
electrical conductivity of
VA
ρ= (2) +7 -1
6.77x10 (Ωm) . Above this pressure,
IL
the electrical conductivity decreases
A
ρ=R (3) and become relatively constant with
L
increase in applied pressure. The
where,
decrease in electrical conductivity

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above applied pressure of 120MPa is pre-heat temperature for good
due to greater obstacles required to electrical conductivity should not
overcome the more closely packed exceed 1500C as die pre-heat
grains resulting from greater, non- temperature above this value reduces
uniform deformation occurring with the electrical conductivity of
increase in applied pressure. Also aluminium metal.
shown in Figure 3 is the variation of Figure 5 shows the effects of
electrical resistivity with applied electrical resistivity on the die pre-heat
pressure, which is the reciprocal of temperature as determined by
electrical conductivity. voltmeter/ammeter and ohmmeter
Figure 4 is the graph showing methods, which is the reciprocal of the
the effects of electrical conductivity on electrical conductivity given in Figure
the die pre-heat temperature. There is 4.
also close agreement in the values as
obtained from the two methods. The 4.0 Conclusion
values of electrical conductivity In the present work, applied pressures
increases fairly slowly at die and die temperatures are found to have
temperatures maintained between room significant effects on the electrical
temperature and temperature of 800C. properties of squeeze cast aluminium
Above this temperature, electrical rods. Electrical conductivity increases
conductivity rises with tool heating with increase in applied pressure up to
temperature to a peak value of an applied pressure level of 105MPa.
2.884x10+8 (Ωm)-1 at die temperature Above this pressure, the electrical
of 1500C and dropping from this value conductivity decreases. With die
to a lower value of 0.832x10+8 (Ωm)-1 temperature, electrical conductivity
at maximum tool temperature of reaches a maximum value of
0 +8 -1
310 C. The reduction in electrical 3.204x10 (Ωm) at die temperature
conductivity at elevated pre-heat of 1500C and falls again when die
temperature is possibly due to high temperature exceeds 1500C. Optimum
thermal conditions [1], which reduce value of electrical conductivity occurs
die chilling effect on the molten at an applied pressure of 105MPa and
aluminium metal that leads to lower die temperature of 1500C and therefore
thermal gradient during the process of this pressure and temperature values
metal solidification. This indicates that are recommended for squeeze casting

5
of aluminium rods for optimum 3. Aniyi, J.A. (1994), “Effects
electrical performance. of Die and Stress-relief
5.0 Acknowledgement Temperatures on Squeeze
The authors wish to acknowledge the Cast Commercially Pure
assistance rendered by the authority of Aluminium Alloy”, Ph.D
the Institute of Technology, Kwara Thesis, Mrchanical
State Polytechnic, Ilorin, Nigeria for Engineering Department,
making their laboratory available for University of Ilorin,
use. Nigeria.
4. Guile, A.E. and Paterson,
References W., (1978), Electrical
1. Aniyi, J.A. , Bello- Power Systems, Pergamon
Ochende, F.L. and M.B. Press, Oxford, Vol.1 2nd ed
Adeyemi, (1996), “Effects 5. William D. Callister, Jr.
of Pressure, Die and Stress (1997), Materials Science
Relief Temperatures on the and Engineering: An
Residual Stresses and Introduction, 4th Edition,
Mechanical Properties of John Wiley and Sons Inc.,
Squeeze-Cast Aluminium New York.
Rods”, Journal of Materials 6. Olafsson, P. Sandstrom, R.,
Engineering and and Karlsson, A., (1977),
Performance, Vol. 5(3), “Comparison of
pp399-404. Experimental, Calculated
2. Abifarin M.S. and and Observed Values of
Adeyemi, M.B., (2003), Electrical and Thermal
“Influence of Process Conductivity of Aluminium
Variables on the Alloys”, Journal of
Mechanical Properties and Materials Science, 32,
Microstructures of Squeeze pp4383-4390.
Cast Aluminium Alloy”, 7. Joseph, J. Carr, (1979),
Nigerian J. of How to Design and Build
Technological Electrical Instrumentation,
Development, Vol3(1), TAB Books, USA.
pp1-7.

6
8. Belove, Charles and
Drossman, Melvyn M,
(1976), Systems and
Circuits for Electrical
Engineering Technology,
McGraw-Hill Book
Company, New York.
9. Spence, Robert and Soin,
Randeep Singh (1988),
Tolerance Design of
Electronic Circuits,
Addison-Wesley Publishing
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10. Higgins, Raymon A.,
(1965), Engineering
Metallurgy Part I: Applied
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 1

Ø20
140

Ø85

[mm]

Figure 1. Schematic diagram of electrical rig.

1-punch, 2-cylindrical split steel mould, 3-die support

8
 Variable resistor

Ammeter
I Battery
Specimen

Voltmeter

Fig. 2 Electric circuit used to measure voltage and

current across the specimen

0.8 3.0

0.7
2.5
Electrical resistivity,
Electrical conductivity,

0.6
x10+8(ohms.m) -1

2.0 x10-7(ohms.m)
0.5

0.4 1.5

0.3
1.0
Electrical co nductivity
0.2
Electrical resistivity
0.5
0.1

0 0.0
0 20 40 60 80 100 120 140 160 180 200
Applied pressure, MPa
Figure 3 Effect of applied pressure on the the electrical resistivity and
conductivity of alum inium m etal

9
 Co nductivity with die heating(vo ltmeter/ammeter metho d)
Co nductivity with die heating (o hmmeter metho d)
3.5

3.0
Electrical conductivity,
x10+8(ohms.m) -1

2.5

2.0

1.5

1.0

0.5

0.0
0 50 100 150 200 250 300 350
0
Die tem perature, C
Figure 4 Effect of electrical conductivity of alum inium on die pre-heat
tem perature by voltm eter/am m eter and ohm m eter m ethods (P=95.49MPa
(P=95.49MPa)

3.0

2.5
Electrical resistivity,

Resistivity with die heating (vo ltmeter/ammeter metho d)

x10-8 (ohms.m)

2.0 Resistivity with die heating (o hmmeter metho d)

1.5

1.0

0.5

0.0
0 50 100 150 200 250 300 350
Die tem perature, 0C
Figure 5 Effect of electrical resistivity of alum inium on die pre-heat
tem perature by voltm eter/am m eter and ohm m eter m ethods (P=95.49MPa)

10