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Relevant bibliographies by topics / Aluminium casting; Quality

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Academic literature on the topic 'Aluminium casting; Quality'

Author: Grafiati

Published: 4 June 2021

Last updated: 2 February 2022

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Journal articles on the topic "Aluminium casting; Quality"

1

Gaspar, Stefan, and Ján Pasko. "Analysis of Fracture Process and Common Defects in Casting Alloys EN43100 Manufactured by Die Casting Technology." Advanced Materials Research 1077 (December 2014): 39–43. http://dx.doi.org/10.4028/www.scientific.net/amr.1077.39.

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Recent research in the process of die casting production of aluminium alloys which are nowadays deeply implemented in the rapidly developing automobile, shipping and airline industry aims to increase the manufacture and quality properties of the casting in order to obtain its high mechanical properties at acceptable economic costs. In terms of ensuring the quality indicators in the production of aluminium castings it is necessary to pay close attention to internal structural quality of the castings characterized by type and extent of foundry defects (cavities, Al2O3 particles, internal cold laps). The presenting contribution deals with the analysis of the fracture process, the microorganism disturbance of test samples, the impact of casting speed on the occurrence and extent of the castings porosity and reasons for the internal foundry defects of casting alloys EN 43100 manufactured by die casting technology.

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Arulra, M., P. K. Palani, and L. Venkatesh. "Optimization of Process Parameters in Stir Casting of Hybrid Metal Matrix (LM25/SiC/B4C) Composite Using Taguchi Method." JOURNAL OF ADVANCES IN CHEMISTRY 13, no. 11 (March 29, 2017): 6038–42. http://dx.doi.org/10.24297/jac.v13i11.5774.

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Aluminium based composites exhibit many attractive material properties such as increased stiffness, wear resistance, specific strength and vibration damping and decreased co-efficient of thermal expansion compared with the conventional aluminium alloys. Aluminium Matrix Composites consist of non-metallic reinforcement which offers advantageous properties over base material. Reinforcements like SiC, B4C and Al2O3 are normally preferred to improve the mechanical properties. Here Aluminum LM25 is selected as matrix material while Silicon carbide and Boron carbide are selected as reinforcement material. The fabrication of aluminium matrix was done by stir casting method. In the present study an attempt has been made to investigate the effect of three major stir casting parameters (stir speed, stir duration and preheated temperature of reinforcement material) on stir casting of Aluminium LM25 - SiC - B4C composite. Experiments were conducted based on Taguchi methodology. Taguchi quality design concepts of L9 orthogonal array has been used to determine S/N ratio and through S/N ratio a set of optimum stir casting parameters were obtained. The experimental results confirmed the validity of Taguchi method for enhancing tensile strength of castings.

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Arulraj, M., P. K. Palani, and L. Venkatesh. "Optimization of Process Parameters in Stir Casting of Hybrid Metal Matrix (LM25/SiC/B4C) Composite Using Taguchi Method." JOURNAL OF ADVANCES IN CHEMISTRY 13, no. 9 (February 22, 2017): 6475–79. http://dx.doi.org/10.24297/jac.v13i9.5777.

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Aluminium based composites exhibit many attractive material properties such as increased stiffness, wear resistance, specific strength and vibration damping and decreased co-efficient of thermal expansion compared with the conventional aluminium alloys. Aluminium Matrix Composites consist of non-metallic reinforcement which offers advantageous properties over base material. Reinforcements like SiC, B4C and Al2O3 are normally preferred to improve the mechanical properties. Here Aluminum LM25 is selected as matrix material while Silicon carbide and Boron carbide are selected as reinforcement material. The fabrication of aluminium matrix was done by stir casting method. In the present study an attempt has been made to investigate the effect of three major stir casting parameters (stir speed, stir duration and preheated temperature of reinforcement material) on stir casting of Aluminium LM25 - SiC - B4C composite. Experiments were conducted based on Taguchi methodology. Taguchi quality design concepts of L9 orthogonal array has been used to determine S/N ratio and through S/N ratio a set of optimum stir casting parameters were obtained. The experimental results confirmed the validity of Taguchi method for enhancing tensile strength of castings.

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Korchmit, Anton Viktorovich, Nikita V. Martyushev, and Yuriy Yu Drozdov. "Casting Quality Enhancement of Bushings Made of Foundry Aluminium Bronzes." Key Engineering Materials 685 (February 2016): 459–62. http://dx.doi.org/10.4028/www.scientific.net/kem.685.459.

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The paper is devoted to the establishment of the technology of castings manufacture out of multicomponent aluminium bronzes for oil and gas producing equipment. Aluminium bronze containing iron has been chosen as a material for casting manufacture. Founding into sand mixtures has been chosen as a manufacturing method. It has been shown that this type of founding allows obtaining the castings with minimal subsequent treatment and high quality surface. The use of the coke furnace at metal melting allows obtaining the castings with high performance characteristics due to gas protection of the melt.

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Ardeleanu, Laurenţiu, Constantin Bratu, and Ioan Mărginean. "Effects of Vibration and Salts Treatments on Aluminium Alloy Properties Used in Mould Manufacture." Advanced Materials Research 1128 (October 2015): 58–63. http://dx.doi.org/10.4028/www.scientific.net/amr.1128.58.

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Metallic mould properties are influenced by the technological process used on casting. The mechanical properties of aluminium castings can be affected by dissolved gases, heterogeneous impurities or shrinkage remaining in casting after solidification. Dissolved gases and oxide inclusions in aluminium all have a deleterious effect on casting quality. The treatment of molten aluminium using vibrations and salts was found to be highly efficient in refining the microstructure of the alloy. The main objective of the paper is to understand the effects of vibrations and salts treatment on the final microstructure and changes that take place and influences aluminium alloy properties used in mould manufacture. The microstructural changes have a great significance in improving the properties of aluminium alloy castings. Understanding this effects and the modification mechanism can undoubtedly be of great significance for improving casting quality. Fluxes based on a KCl-NaCl mixture may be used to cover and protect the metal from oxidation. Most fluxes are based on a mixture of KCl and NaCl, which forms at low-temperature (665 °C) eutectic.

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Asokan, Manivannan, Sasikumar Rathinasabapathy, Shaik Dawood Abdul Khadar, and Mohammed Sadique Khan. "Novel Combined Feeding Approach to Produce Quality Al6061 Composites for Heat Sinks." High Temperature Materials and Processes 38, no. 2019 (February 25, 2019): 647–50. http://dx.doi.org/10.1515/htmp-2019-0009.

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AbstractThis elementary work aims to address agglomeration and non-uniform dispersion of reinforcement particles in stir casting using Al6061 alloy (AA 6061) as a matrix and Aluminium oxide (Al2O3) as reinforcement particles. A novel combined feeding method of Encapsulate feeding technique & Two Step Stir Casting was developed & attempted to produce good quality composites by varying weight fractions of Aluminium Oxide (0 to 5 wt.%). The wetting agent Mg (2 wt.%) added in all castings to ensure better binding between ceramics and matrix. The SEM photomicrograph ensures homogenous dispersion of reinforcement particles by combined feeding method. The thermal properties of produced good quality composites are enhanced with increase in Aluminium Oxide (Al2O3) from 0 to 5 wt.%.

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Hussainy, Syed Ferhathullah, Mohd Viquar Mohiuddin, P. Laxminarayana, S. Sundarrajan, and A. Krishnaiah. "Analysis of Shrinkage Characteristics of Aluminium Silicon Alloy." Journal for Manufacturing Science and Production 16, no. 3 (September 1, 2016): 163–71. http://dx.doi.org/10.1515/jmsp-2016-0002.

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AbstractAnalysis of shrinkage characteristics of Aluminium-Silicon alloy was studied theoretically and experimentally. The Aluminium alloys considered in the study are A413 (LM6), A360 (LM9) and A380 (LM24). Extensive literature survey has suggested that cavity filling and solidification process are two most critical aspects to produce high quality casting components. A statistical model of parameters and response to understand the influence of parameters on shrinkage and casting yield studies has been presented. Experiments were conducted in foundry in industrial environment to produce commercially treated aluminium alloy castings in sand mould. Alloy was found to be most significant factor influencing shrinkage. The yield of casting was improved using insulating and exothermic sleeves. Solidification time of exothermic riser was 10 % more than insulated riser. Thus, in order to produce radiographic quality casting a theoretical and experimental method is presented so that number of trials in foundry is reduced which leads to increased reliability and productivity. Study also shows that by using sleeves considerable metal is saved, energy saving during melting, improved quality, reduced cost and increased capacity of plant can be achieved.

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Kotus, M., E. Jankajová, and M. Petrík. "Quality control of aluminium melt in production process." Research in Agricultural Engineering 61, Special Issue (June 2, 2016): S43—S47. http://dx.doi.org/10.17221/28/2015-rae.

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The quality of aluminium alloy in the production process on the chemical composition basis was evaluated. The quality of casting alloy depends on the chemical composition of melt and on the technological process of production process. The basic elements such as Si, Cu, Fe, Mg and Al in melting were evaluated. The obtained data were compared with the guide data referred to in the standard for aluminium alloy.

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Yuksel, C., O. Tamer, E. Erzi, U. Aybarc, E. Cubuklusu, O. Topcuoglu, M. Cigdem, and D. Dispinar. "Quality Evaluation of Remelted A356 Scraps." Archives of Foundry Engineering 16, no. 3 (September 1, 2016): 151–56. http://dx.doi.org/10.1515/afe-2016-0069.

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AbstractA356 is one of the widely used aluminium casting alloy that has been used in both sand and die casting processes. Large amounts of scrap metal can be generated from the runner systems and feeders. In addition, chips are generated in the machined parts. The surface area with regard to weight of chips is so high that it makes these scraps difficult to melt. Although there are several techniques evolved to remedy this problem, yet the problem lies in the quality of the recycled raw material. Since recycling of these scrap is quite important due to the advantages like energy saving and cost reduction in the final product, in this work, the recycling efficiency and casting quality were investigated. Three types of charges were prepared for casting: %100 primary ingot, %100 scrap aluminium and fifty-fifty scrap aluminium and primary ingot mixture were used. Melt quality was determined by calculating bifilm index by using reduced pressure test. Tensile test samples were produced by casting both from sand and die moulds. Relationship between bifilm index and tensile strength were determined as an indication of correlation of melt quality. It was found that untreated chips decrease the casting quality significantly. Therefore, prior to charging the chips into the furnace for melting, a series of cleaning processes has to be used in order to achieve good quality products.

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Wang, Xiang Jie, Gang Sun, Li Juan Wang, Peng Wei Li, and Jian Zhong Cui. "A New Approach of Casting Aluminium Alloy Bar by Applying Low Frequency Electromagnetic Field." Materials Science Forum 794-796 (June 2014): 167–71. http://dx.doi.org/10.4028/www.scientific.net/msf.794-796.167.

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Aluminum is the richest metallic element in the earth, the ingots cast by DC casting process are usually extruded into aluminum bars. When the final products do not require high strength, this process appears to be low efficiency and high cost. We try to design a new technology to cast aluminum bar by horizontal direct chill (HDC) casting process directly. An electromagnetic field is applied during the horizontal continuous casting of 6061 aluminium bar with a diameter of 30mm. The experimental results show the asymmetry of the sump can be overcome by electromagnetic field. Ingot with good upper and lower surface quality is obtained. The structure of ingot is refined and the angle between growth direction and horizontal direction becomes small with increasing casting speed.

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Dissertations / Theses on the topic "Aluminium casting; Quality"

1

Cao, Xinjin. "Heat treatment of liquid metal : precipitation and sedimentation processing of liquid Al-11.5Si-0.4Mg alloy." Thesis, University of Birmingham, 2001. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.369168.

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Jaradeh, Majed. "The Effect of Processing Parameters and Alloy Composition on the Microstructure Formation and Quality of DC Cast Aluminium Alloys." Doctoral thesis, KTH, Materialvetenskap, 2006. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-4205.

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The objective of this research is to increase the understanding of the solidification behaviour of some industrially important wrought aluminium alloys. The investigation methods range from direct investigations of as-cast ingots to laboratory-scale techniques in which ingot casting is simulated. The methods span from directional solidification at different cooling rates to more fundamental and controlled techniques such as DTA and DSC. The microstructure characteristics of the castings have been investigated by optical and Scanning Electron microscopy. Hardness tests were used to evaluate the mechanical properties. The effects of adding alloying elements to 3XXX and 6XXX aluminium alloys have been studied with special focus on the effects of Zn, Cu, Si and Ti. These elements influence the strength and corrosion properties, which are important for the performance of final components of these alloys. Solidification studies of 0-5wt% Zn additions to 3003 alloys showed that the most important effect on the microstructure was noticed at 2.5 wt% Zn, where the structure was fine, and the hardness had a maximum. Si addition to a level of about 2% gave a finer structure, having a relatively large fraction of eutectic structure, however, it also gave a long solidification interval. The addition of small amounts of Cu, 0.35 and 1.0 wt%, showed a beneficial effect on the hardness. Differences have been observed in the ingot surface microstructures of 6xxx billets with different Mg and Si ratios. Excess Si compositions showed a coarser grain structure and more precipitations with possible negative implications for surface defect formation during DC casting. The comparison of alloys of different Ti content showed that the addition of titanium to a level of about 0.15 wt% gave a coarser grain structure than alloys with a normal Ti content for grain refinement, i.e. < 0.02 wt%, although a better corrosion resistance can be obtained at higher Ti contents. The larger grain size results in crack sensitivity during DC casting. A macroscopic etching technique was developed, based on a NaOH solution, and used in inclusion assessment along DC cast billets. Good quantitative data with respect to the size and spatial distribution of inclusions were obtained. The results from studied billets reveal a decreasing number of inclusions going from bottom to top, and the presence of a ring-shaped distribution of a large number of small defects in the beginning of the casting. The present study shows how composition modifications, i.e. additions of certain amounts of alloying elements to the 3xxx and 6xxx Al alloys, significantly change the microstructures of the materials, its castability, and consequently its mechanical properties
QC 20100901

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Dewhirst, Brian A. "Optimization of the heat treatment of semi solid processed A356 aluminum alloy." Link to electronic thesis, 2005. http://www.wpi.edu/Pubs/ETD/Available/etd-111705-111503/.

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Thesis (M.S.)--Worcester Polytechnic Institute.
Keywords: microstructure; casting; Fluid Bed; Quality Index; Aluminum; A356; heat treatment; SSM; Semi Solid Metal Includes bibliographical references. (p.105-106)

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LEE, SANG-HUNG, and 李尚紘. "Combining Taguchi and DMAIC approaches to improve aluminum die-casting quality." Thesis, 2013. http://ndltd.ncl.edu.tw/handle/87452695735679575096.

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碩士
國立勤益科技大學
工業工程與管理系
101
The research will combine Taguchi and DMAIC approach, applies to Aluminum Casting so as to establish best parameters module, process improvement and reduce defects. First of all, Casting is the key target as set in order to increase profit and capability for competition as the company is looking for; secondly, we will apply Taguchi Method and combine 5 steps DMAIC of 6Sigma to improve casting process for product of Power Tools Industry than old fashion Try and Error so as to generate cost reduction, improve quality of product and capability for competition in the end. The result of experiment comes up Cpk value dramatically up to 1.89 was 0.11; porosity defect down to 4% was 34%; in terms of cost improvement, the cost saving from quality aspect, the cost saving was $231,000 before implementing the process ，and the cost saving was $1,155,000 after implementing the process. In other words, the best parameters identified through this study do improve the quality of aluminum die casting product.

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Li, Cheng-Lung, and 李正隆. "The Quality Change Of Molten Aluminum Alloy After Flowing Through The Ceramic Foam Filter In Gravity Casting." Thesis, 2013. http://ndltd.ncl.edu.tw/handle/35553263310024679491.

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碩士
國立聯合大學
材料科學工程學系碩士班
101
Ceramic foam filter is normally applied in the design of runner system in aluminum gravity casting. The purpose of using this filter is to reduce the velocity of liquid aluminum under the so-called critical gating velocity (e.g., 0.5 m/s for aluminum alloys). After liquid aluminum flows through the foam filter, its static pressure energy is recovered from kinetic energy. The foam filter then can be used for stabilizing the aluminum flow during the filling of mold cavity. The so-called bi-film defect, deriving from the surface turbulence and the entrapment of oxide films during filling process, can thus be avoided. The purpose of this study was to understand the change of profile and melt quality of liquid aluminum after flowing through the foam filter in various runner system designs. Three types of bottom gating runner systems were designed. For observing the flow going through the ceramic foam filter, water analogy method, dyed water filling test in a transparent PMMA material mold, was applied. This flowing profile had been used for the validating the result of computational modeling. In the casting experiment, the aluminum casting sample in the outlet region of the foam filter was sectioned. These specimens then did re-re-melt reduced pressure test (re-melt RPT). The bulk density of the specimens was measured by Archimedes method. By comparing the density differences between the original degassed liquid aluminum and the casting specimens, the contamination of hydrogen of the liquid aluminum after flowing through the filter was measured. "Area normalized" Bifilm index map was proposed to quantify the content of bifilm defects within the casting samples.

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Books on the topic "Aluminium casting; Quality"

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International Symposium on Quality and Process Control in the Reduction and Casting of Aluminum and Other Light Metals (1987 Winnipeg, Man.). Proceedings of the International Symposium on Quality and Process Control in the Reduction and Casting of Alumninum and Other Light Metals, Winnipeg, Canada, August 23-26, 1987. New York: Pergamon Press, 1987.

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Saha, Pradip K. Aluminum Extrusion Technology. ASM International, 2000. http://dx.doi.org/10.31399/asm.tb.aet.9781627083362.

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Aluminum Extrusion Technology covers the theory and practice of extrusion and its application in the production of aluminum alloy parts. The first few chapters discuss the mechanics and thermodynamics of direct and indirect extrusion processes and the effect of key variables such as strain and strain rate, friction, pressure, flow stress, and temperature. Subsequent chapters explain how to implement and maintain industrial-scale aluminum extrusion processes. The chapters cover extrusion presses and equipment, tooling and die design, billet casting, and process control. They also provide information on the extrusion characteristics of soft, medium, and hard alloys and discuss the use of statistical process and quality control. For information on the print version, ISBN 978-0-87170-644-7, follow this link.

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Proceedings of the International Symposium on Quality and Process Control in the Reduction and Casting of Aluminum and Other Light Metals. Pergamon Press, 1987.

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Proceedings of the International Symposium on Quality and Process Control in the Reduction and Casting of Aluminum and Other Light Metals, Winnipeg, Canada, August 23–26, 1987. Elsevier, 1987. http://dx.doi.org/10.1016/c2009-0-00793-4.

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Book chapters on the topic "Aluminium casting; Quality"

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Austen, P. R., E. J. Swain, and C. M. Keeley. "Experience with Automation and the Introduction of Casting and Degassing Technology for Improved Productivity, Product Quality and Safety at Comalco Bell Bay's VDC4 Facility." In Aluminium Cast House Technology, 259–69. Hoboken, NJ, USA: John Wiley & Sons, Inc., 2013. http://dx.doi.org/10.1002/9781118787304.ch23.

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Zheng, Chang Qing, Ehab Samuel, and Florentin Laplume. "Optimization of the Process Parameters and Tooling Improvement for the Rheocasting of High Quality Aluminum Components Using the SEED Process." In Shape Casting, 273–80. Hoboken, NJ, USA: John Wiley & Sons, Inc., 2011. http://dx.doi.org/10.1002/9781118062050.ch33.

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Kim, Shae K. "Effect of Product Quality on Life Cycle Assessment in Aluminum Die Casting Process." In Materials Science Forum, 259–62. Stafa: Trans Tech Publications Ltd., 2007. http://dx.doi.org/10.4028/0-87849-431-6.259.

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Achard, Jean-Louis, Fabio Taina, Pierre Le Brun, and Pierre-Yves Menet. "An Innovative Ultrasonic Technology for the Continuous Quality Monitoring of Liquid Aluminum on Casting Lines." In The Minerals, Metals & Materials Series, 871–78. Cham: Springer International Publishing, 2018. http://dx.doi.org/10.1007/978-3-319-72284-9_113.

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El-Bealy, M. O. "Influence of Direct Chill Casting Process Variables on Surface Quality of Aluminum Alloy Sheet Ingots." In Light Metals 2012, 1107–12. Cham: Springer International Publishing, 2012. http://dx.doi.org/10.1007/978-3-319-48179-1_190.

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O. El-Bealy, M. "Influence of Direct Chill Casting Process Variables on Surface Quality of Aluminum Alloy Sheet Ingots." In Light Metals 2012, 1107–12. Hoboken, NJ, USA: John Wiley & Sons, Inc., 2012. http://dx.doi.org/10.1002/9781118359259.ch190.

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CLOSSET, B. "QUALITY IMPROVEMENT BY STRONTIUM MODIFICATION OF LOW PRESSURE ALUMINIUM CASTINGS." In Proceedings of the International Symposium on Reduction and Casting of Aluminum, 243–54. Elsevier, 1988. http://dx.doi.org/10.1016/b978-0-08-036093-5.50032-7.

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Stolt, Roland, and Anders E. W. Jarfors. "Manufacturing of High Pressure Die Casting Die Inserts Using SLM." In Advances in Transdisciplinary Engineering. IOS Press, 2020. http://dx.doi.org/10.3233/atde200206.

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Dies for high pressure die casting are normally manufactured by machining of slabs of tool steel to the required dimensions. This manufacturing requires several steps such as rough machining, heat-treatment, EDM (electro discharge machining) and polishing. With the AM (additive manufacturing) method SLM (Selective Laser Melting) it has become possible to print the dies fully or in part. Several advantages are expected, such as a better thermal distribution in the die in service and thereby extended die life and better component quality. This is due to the possibility of making the cooling channels conformal. There are also expectations of reduced time and cost in the manufacturing process due to fewer manufacturing steps and better material utilisation. Hopes are to print a net shape or near net shape that can be used directly as a die component. In this paper it is investigated to what extent this can be fulfilled by printing two die inserts to be used for casting fatigue test samples of aluminium. They were printed on a 3D Systems ProX DMP 300 in maraging steel powder. The result is that it is possible to obtain a sufficiently smooth surface die surface. However, the current design with an SLM insert fitted in a machined die makes extensive post printing manufacturing necessary.

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Campbell, John. "Castings: Ten Rules for Good Castings." In Encyclopedia of Aluminum and Its Alloys. Boca Raton: CRC Press, 2019. http://dx.doi.org/10.1201/9781351045636-140000285.

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The Ten Rules are a checklist of the conditions necessary for the production of successful castings, particularly dealing with the metal quality, with a view to achieving a casting with minimal, preferably zero, faults. The first five Rules specify the conditions to avoid entrainment defects, particularly bifilms and bubbles. The remaining Rules deal with the provision of feeding, avoidance of convection, chemical segregation, and residual stress, and the provision of pickup locations for machining.

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Tiryakioğlu, Murat, and Nelson Netto. "Friction Stir Processing: Effect on Microstructure and Mechanical Properties in Cast Aluminum Alloys." In Encyclopedia of Aluminum and Its Alloys. Boca Raton: CRC Press, 2019. http://dx.doi.org/10.1201/9781351045636-140000347.

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Microstructural and mechanical data from the literature of friction stir processed (FSPed) cast aluminum alloys were reanalyzed. Results indicated that friction stir processing (FSP) produced more homogeneous microstructures, with finer eutectic Si particles, grains, and intermetallics. However, a relationship between microstructural measures and process parameters could not be established. Regardless of the resultant microstructure, structural casting defects, i.e., pores and oxide films, were reduced in size or completely eliminated after FSP. Consequently, ductility and fatigue life were drastically improved by FSP. Quality index analysis showed that some FSPed specimens have a higher structural quality than aerospace and premium quality castings, and can be used to determine the intrinsic properties of cast aluminum alloys.

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Conference papers on the topic "Aluminium casting; Quality"

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Gellrich, Sebastian, Thomas Beganovic, Alexander Mattheus, Christoph Herrmann, and Sebastian Thiede. "Feature Selection Based on Visual Analytics for Quality Prediction in Aluminium Die Casting." In 2019 IEEE 17th International Conference on Industrial Informatics (INDIN). IEEE, 2019. http://dx.doi.org/10.1109/indin41052.2019.8972093.

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Lyon, P., J. F. King, and G. A. Fowler. "Developments in Magnesium Based Materials and Processes." In ASME 1991 International Gas Turbine and Aeroengine Congress and Exposition. American Society of Mechanical Engineers, 1991. http://dx.doi.org/10.1115/91-gt-015.

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Recent developments in Magnesium alloys, processing techniques and corrosion protection schemes are reviewed. The casting alloy WE43 is detailed, data being presented which shows that it compares favourably with Aluminium based casting alloys on a strength to weight basis. In addition its intrinsic corrosion characteristics are shown to be similar to those of Aluminium base alloys. A counter - gravity casting process, specifically designed to make higher quality, thin-walled Magnesium alloy components is described together with property data indicating the improvements obtained. Also discussed are the ongoing developments in Metal Matrix Composites and Rapid Solidification technologies, showing the benefits offered by these processing routes. Finally current corrosion protection schemes are reviewed and their overall cost effectiveness discussed.

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King, Philip, Daniel Martinez, and Guha P. Manogharan. "Novel Sprue Designs to Reduce Casting Defects in Nickel-Aluminum Bronze: A Computational Study." In ASME 2020 15th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2020. http://dx.doi.org/10.1115/msec2020-8486.

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Abstract As 3D Sand-Printing technology becomes more widely available to the casting market, the search for opportunities to take advantage of its freedom of design is critical for its rapid adoption by the casting community. This original research investigates casting design principles towards defect-free alloy Nickel-Aluminum Bronze (NAB). This is an alloy of interest for marine applications due to its corrosion resistance, mechanical strength and good castability. Numerical modeling of flow within a casting is examined, and rigging redesigns are proposed to improve casting quality by controlling flow behavior. It has been demonstrated that turbulence and filling velocity are determining factors that seriously impact casting performance due to the generation of casting defects. Among these are bifilm formations, gas and sand entrapment and cold shut. This work examines the effectiveness of mathematically designed rigging components in controlling mold filling and compares the results to a conventional casting rig. Design solutions are proposed using 3DSP that can be directly applied to casting operations of Nickel-Aluminum Bronze. The results from this study demonstrate the effectiveness of mathematically designed sprues to reduce filling velocity of Nickel-Aluminum Bronze. The procedure followed here can be extended to marine casting production environments. Findings from this study can be seamlessly transferred to castings of any geometry, alloy and pouring conditions.

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Cook, Daniel P., Sachin S. Deshmukh, and David P. Carey. "Modeling Permanent Mold Casting of Aluminum." In ASME 2007 International Mechanical Engineering Congress and Exposition. ASMEDC, 2007. http://dx.doi.org/10.1115/imece2007-42409.

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Modeling the complex, coupled fluid flow, heat transfer and solidification phenomena taking place in metal casting is a challenging task. The quality of any metal casting depends on many parameters such as the type of mould, rate of filling, and rate of solidification. Optimization of these operational parameters is very important in reducing casting defects such as oxide inclusions and porosity. This paper addresses the first steps in validating a computational fluid dynamics (CFD) model of permanent mold casting of aluminum. A mathematical model of the casting system has been developed using the commercial CFD package StarCD. A physical model of the system has been used to validate the mold filling phenomena in the process. Comparison of the results from these models will be presented.

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Jekic, Nikolina, Belgin Mutlu, Manuela Schreyer, Steffen Neubert, and Tobias Schreck. "Visual Data Analysis of Production Quality Data for Aluminum Casting." In Hawaii International Conference on System Sciences. Hawaii International Conference on System Sciences, 2021. http://dx.doi.org/10.24251/hicss.2021.179.

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Gyarmati, Gábor, György Fegyverneki, Tamás Mende, and Monika Tokár. "The Effect of Melt Treatments on the Melt Quality of Aluminum Casting Alloys." In MultiScience - XXXIII. microCAD International Multidisciplinary Scientific Conference. University of Miskolc, 2019. http://dx.doi.org/10.26649/musci.2019.074.

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Chinnakurli Suryanarayana, Ramesh, Saleem Khan, Praveennath G. Koppad, and Zulfiqar Khan. "Tribological Behaviour of Hot Extruded Al6061-Si3N4 Composite." In ASME 2013 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2013. http://dx.doi.org/10.1115/imece2013-64459.

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Silicon nitride (Si3N4) possesses excellent hot hardness, wear resistance coupled with good corrosion resistance. Further, it possesses high anti friction properties making it an ideal reinforcement in developing high quality light weight, metal matrix composites for tribological applications. Silicon nitride has been successfully dispersed in aluminum alloy matrices. Their tribological properties with the beneficial effect of silicon nitride in enhancing the wear resistance of metal matrix composite have been reported by several researchers. Most of the researchers have focused on development of silicon nitride reinforced aluminum composite by powder metallurgy and casting route. However, meager information is available as regards the secondary processing of these composites in particular hot extrusion. Several researchers have reported an improved tribological behaviour in composites after extrusion. Hot extrusion of light weight metal matrix composites is very challenging. In the light of the above, this paper discusses the tribological behaviour of hot extruded Al6061 aluminum composites, which were initially developed by stir casting technique. Nickel coated silicon nitride particles were dispersed in Al6061 alloy using stir casting process. The cast composites were extruded at an extrusion ratio of 1:10 adopting a temperature of 550°C. The hot extruded composite (6Wt% Si3N4) and the matrix alloy were subjected to metallographic studies, microhardness and friction and wear tests using a pin on disc machine. Friction and wear test were carried out at loads ranging from 10 to 60 N at a sliding velocity of 0.314m/s. The worn surfaces and wear debris analysis have been carried out to understand the mechanism of wear in the developed hot extruded composites. The developed hot extruded composites exhibited lower coefficient of friction and wear rates when compared with matrix alloy.

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Mun, Jiwon, Matthew Busse, Jaehyung Ju, and James Thurman. "Multilevel Metal Flow-Fill Analysis of Centrifugal Casting for Indirect Additive Manufacturing of Lattice Structures." In ASME 2015 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2015. http://dx.doi.org/10.1115/imece2015-52270.

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The centrifugal casting is a classical manufacturing method and it has been widely studied. However, when it comes to manufacture thin walled lattice materials with complex three-dimensional meso-structures, a multiscale flow-fill analysis may be needed for macro-filling at the sprue system and micro-filling at lattice structures. On the micro-filing analysis for a thin walled lattice structure, the surface tension of molten metal appears to be an important factor. On the other hand, flow inertia may affect the flow-filling process more than the surface tension of molten metal does. Our hypothesis is that there exist a range of ratios of cell wall thickness to length that are primarily affected by surface tension or density. From comparison with two different molten metals — aluminum and copper alloys, we can estimate the characteristic of flow, which will be of benefit when designing lattice structures and selecting materials for the manufacturing process. The objective of this study is to test the hypothesis by constructing an analytical model on flow filling of molten metals (aluminum alloy and copper alloy) associated with manufacturing lattice structures. The Naiver-Stokes equation with surface tension is considered for modeling of the flow of molten metal along the micro-channel of lattice structures and is numerically implemented with MATLAB. Temperature dependent properties of the liquid metals; e.g., density, viscosity, and conductivity, are considered for building the analytical model. Numerical simulations with a commercial code, ANSYS are conducted using a user defined function. Experimental validation is followed to manufacture a cubic truss lattice structure with a varying wall thickness; 0.5–1mm. Two molten metals — aluminum alloy and copper alloy are used for filling the mold at the centrifugal casting system. The mold is prepared by removing sacrificial lattice patterns made by a polyjet 3D printer. The preliminary result shows that the final lattice structures with an aluminum alloy through the 3D printing of sacrificial pattern followed by centrifugal casting have relatively good flow filling property at thin wall thickness (∼0.5mm) due to low surface tension of aluminum alloy. On the other hand, the high surface tension of a copper alloy prevents flow-fill to micro-channel mold cavity, resulting in early solidification. The indirect additive manufacturing based casting shows an excellent surface quality, which can be used for manufacturing cellular structures. A coupled flow and heat transfer of molten metal successfully simulate flow-fill and solidification and is compared with the experiment. Faster filling-time and faster solidification for the temperature-dependent material properties were shown.

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Liu, X. J., S. H. Bhavnani, and R. A. Overfelt. "Numerical Modeling of EPS Foam Decomposition in the Lost Foam Casting Process." In ASME 2005 International Mechanical Engineering Congress and Exposition. ASMEDC, 2005. http://dx.doi.org/10.1115/imece2005-81471.

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The importance of smooth mold filling in the lost foam casting process has been recognized for a long time. The more uniform the filling process, the better the quality of the casting products that are produced. Successful computer simulations can help reduce the number of trials and cut down the lead time in the design of new casting products by better understanding the complex mechanisms and interplay of different process parameters in the mold filling process. In this study, a computational fluid dynamics (CFD) model has been developed to simulate the fluid flow of molten aluminum and the heat transfer involved at the interfacial gap between the metal and the expanded polystyrene (EPS) foam pattern. The commercial code FLOW-3D was used because it can track the front of the molten metal by a Volume of Fluid (VOF) method and allow complicated parts to be modeled by the Fractional Area/Volume Ratios (FAVOR) method. The code was modified to include the effects of varying interfacial heat transfer coefficient based on gaseous gap pressure which is related to foam degradation and coating permeability. The modification was validated against experimental studies and the comparison showed better agreement than the basic model. Process parameters such as initial metal temperature, foam pattern property, and gating system were investigated. The defect prediction model was also used to study the dependence of defect formation on the process variables.

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Hasan, Mainul. "Numerical Study of a Direct Chill Slab Caster Fitted With a Porous Filter for Aluminum Alloy AA-2024." In ASME 2014 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2014. http://dx.doi.org/10.1115/imece2014-36748.

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The present study is undertaken to model an industrial-sized vertical Direct Chill (DC) slab caster fitted with a porous filter near the melt entry region. The modeled alloy is a high strength aluminum alloy AA-2024 which is extensively used by the aerospace industry. The model has incorporated the 3-D turbulent aspect of the melt flow and heat transfer in the liquid sump and the mushy region solidification aspect of this long solidification range (136° C) alloy. The verified 3-D turbulent CFD in-house code is used to study the effects of various parameters of this casting process in order to gain some fundamental understanding of the melt flow and solidification behavior of the process. The studied caster consists of a popular ‘hot-top’ mold fitted with a porous filter above which molten aluminum alloy is delivered with a constant flow-rate across the entire hot-top. Because of two-fold symmetry, a quarter of the domain of the caster is modeled to save computational costs and time. A staggered control volume based finite-difference scheme is used to solve the non-dimensional modeled equations and the associated boundary conditions. The turbulent aspect of the flow in the porous filter is modeled using the latest suggested version of the Brinkman-Forcheimer extended form of Darcy equation for a porous media. The turbulent melt flow and solidification heat transfer in the clear fluid region are modeled using a low Reynolds number version of the k–ε eddy viscosity model. Computed results for the steady-state phase of the casting process are presented for four casting speeds, varying from 100 to 220 mm/min, for three metal-mold contact regions, varying from 20 to 50 mm and for three metal-mold convective heat transfer boundary conditions, varying from 1.0 to 4.0 kW/m2K and all for a fixed inlet melt superheat of 64° C. The permeability of the filter is also varied to ascertain its influence on the predicted results. Computed results of the velocity and temperature profiles, the sump depth and mushy region at the centre of the caster as well as the solidification shell thickness at the exit of the mold are provided and discussed. The present work can provide some useful guidelines in designing and optimizing a vertical DC slab caster for producing good quality casts for the common aluminum alloy AA-2024.

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