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1. at present, the most widely used high strength alloys are of the aluminum silicon magnesiuim type. strengthening is accomplished by the controlled precipitation of the magnesium silicate compound. the degree of strengthening is related to the amount of precipitation. this, in turn, is determined by the magnesium content of the alloy because the silicon is well in excess of the amount required to react with the magnesium.

2. to achieve optimum properties in aluminum castings, basic theoretical considerations must be translated into commercial practice. controls are required over various factors including microstructure, alloy chemistry, gas content, mode of fluid flow, and feeding. these points are discussed in terms of specific castings whose case histories illutrate the operation of the relevant factors under commercial conditions.

3. as indicated, metal may be poured into a metal die within which the cavity has been machined. although no pattern is used the die, like an expendable mold. must have a joint line, in this case to enable the casting to be extracted. the die cavity, to aid extraction of the casting. castings produced in dies may not be quite as precise as those produced by the lost-wax process, but they are noted for a high degree of precision and consistency.

4. in the traditional sand casting precess, sand is mixed with day and water to produce a moldable mixture. the moistened clay provides the bonding agent which binds the sand grains together when the molding sand is compacted arround a pattern to produce a mold. in order that the pattern may be removed from the mold, to provide the cavity into which the metal will be poured, the mold must be made in at least two parts. these mold parts can be separated for removal of the pattern and joined again to receive the metal.

5. the preceding observations lead us to a discussion of the forms and causes of porosity in die castings. as you who are foundry men know, the absolutely perfect casting has probably industry has come a long way, it has a long way to go toward consistently making die castings with few or no internal and external imperfections. imperfections and defects should be differentiated as the terms are used here; a defect is an imperfection that makes a casting unsuitable for its intended role. thus an imperfection may or may not be a defect.

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