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Abstract The aim of this investigation is the study of the effect of both the molding conditions, silicon content (2% - 5% ), magnesium content (2% - 6% ) and the dimensions of the mold on the mechanical and tribological behavior of aluminum alloys. The solidification behavior, grain size and x-ray diffraction of the alloys have been taken into consideration to discuss the mechanical and the mechanical and tribological I properties. Literature review has been carried out for the researches that investigate the effect of the alloying elements on the metallurgical, mechanical and tribological behavior of aluminum alloys. This was followed by the distribution for chemical analysis of the material under consideration, the test specimens, the measuring equipments and the cross-pin testing machine. The obtained results are drawn graphically and discussed. The conclusions drawn from this work can be summarized as follows: I. The increase of silicon content increases the solidification time and temperature of beginning of solidification and decrease the temperature range of complete solidification, while the increase of magnesium content decreases the solidification time, temperature of beginning of solidification and the temperature of complete solidification. 2. The increase of mold diameter increases the solidification time, and the elongation percent, while it decreases ultimate tensile strength and hardness. 3. The relative higher solidification rate and under cooling temperature have been achieved by using copper shell mold which provides a significant improvement for the metallurgical properties. 4. An increase of silicon content tends to an increase of both the ultimate tensile strength and the hardness with decrease of the elongation percent. However, an increase of both the ultimate tensile strength, the hardness and the elongation percent is observed by the increase of the magnesium content. 5. Copper shell mold provides aluminum alloys relative higher ultimate tensile strength and hardness and lower elongation percent compared to sand and cast iron molds. Also, it provides the aluminum alloys relative higher wear resistance and minimal coefficient of friction compared to sand and cast iron molds. 6. Aluminum-Silicon-Magnesium alloy with 3.67 % Si and 4.9 % Mg shows the best wear resistance due to the precipitation of the AL4Si phase. 7. The increase of mold dimensions decreases the wear resistance and increase the coefficient of friction. |