Journal articles: 'Casting process selection'

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Zimmermann, Juliana Ilha, Danielle Bond, and Régis Kovacs Scalice. "Web platform for casting process selection." Product Management & Development 16, no. 1 (2018): 7–15. http://dx.doi.org/10.4322/pmd.2018.002.

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Lovatt, A. M., D. Bassetti, H. R. Shercliff, and Y. Bréchet. "Process and alloy selection for aluminium casting." International Journal of Cast Metals Research 12, no. 4 (January 2000): 211–25. http://dx.doi.org/10.1080/13640461.2000.11819358.

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Mizera-Pęczek, Patrycja. "Specificity of organizing casting in the selection process of artists." Studia i Prace WNEiZ 52 (2018): 101–10. http://dx.doi.org/10.18276/sip.2018.52/3-10.

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Pan, Dong, Qing Yan Xu, and Bai Cheng Liu. "Numerical Simulation of Grain Selection Behavior of Single Crystal Ni₃Al Based Superalloy Casting." Materials Science Forum 654-656 (June 2010): 1482–85. http://dx.doi.org/10.4028/www.scientific.net/msf.654-656.1482.

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Ni3Al based superalloy has recently been used for the single crystal gas turbine blade. The grain selection behavior in grain selector directly determines the casting’s final microstructure and properties. A mathematical model based on the modified CA-FD method was developed for the three-dimensional simulation of directional solidification process of Ni3Al based single crystal superalloy castings. The microstructure evolution was simulated with the modified Cellular Automaton method. The grain selection process in the grain selector and final microstructure of casting were simulated. The results indicate that the stray grain is easy to nucleate at the middle part of the pigtail because of the discontinuous mushy zones formation. This agrees with previous published experimental results. Based on simulated results, a newly designed grain selector with optimized geometry was proposed to avoid stray grains.

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Darwish, S. M., and A. M. El-Tamimi. "The selection of the casting process using an expert system." Computers in Industry 30, no. 2 (September 1996): 77–86. http://dx.doi.org/10.1016/0166-3615(95)00089-5.

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Sirilertworakul, N., P. D. Webster, and T. A. Dean. "A knowledge base for alloy and process selection for casting." International Journal of Machine Tools and Manufacture 33, no. 3 (June 1993): 401–16. http://dx.doi.org/10.1016/0890-6955(93)90048-y.

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Kumar, Rajesh, Rupinder Singh, and IPS Ahuja. "Process capability study of three dimensional printing as casting solution for non ferrous alloys." Rapid Prototyping Journal 22, no. 3 (April 18, 2016): 474–86. http://dx.doi.org/10.1108/rpj-05-2014-0063.

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Purpose The purpose of this paper is to investigate the process capability of three-dimensional printing (3DP)-based casting solutions for non-ferrous alloy (NFA) components. Design/methodology/approach After selection and design of benchmark, prototypes for six different NFA materials were prepared by using 3DP (ZCast process)-based shell moulds. Coordinate measuring machine has been used for calculating the dimensional tolerances of the NFA components. Consistency with the tolerance grades of the castings has been checked as per IT grades. Findings The results of process capability investigation highlight that the 3DP process as a casting solution for NFA component lies in ±5sigma (s) limit, as regards to dimensional accuracy is concerned. Further, this process ensures rapid production of pre-series industrial prototypes for NFA. Final components prepared are also acceptable as per ISO standard UNI EN 20,286-I (1995). Originality/value This research work presents capability of the 3DP process supported with experimental data on basis of various process parameters for the tolerance grade of NFA castings. These statistics can help to enhance the application of 3DP-based NFA casting process in commercial foundry industry.

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Pałyga, Ł., M. Stachowicz, and K. Granat. "Effect of parameters of high-pressure die casting on occurrence of casting nonconformities in sleeves of silumin alloy EN AB 47100." Archives of Metallurgy and Materials 62, no. 1 (March 1, 2017): 373–78. http://dx.doi.org/10.1515/amm-2017-0058.

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Abstract The paper presents a research on the effect of extreme - for the technology of the considered silumin EN AB 47100 - parameters of high-pressure die casting on occurrence of casting nonconformities. Considered was influence of the way of assembling the mould cooled-down to 140-160°C, non-standard for the selected casting, and pouring temperature in the range of 705 to 720°C (higher than the recommended) of non-refined alloy. The castings were prepared with use of a high-pressure casting machine made by Kirov with mould closing force of 2500 kN. Occurrence of nonconformities was evaluated on properly prepared specimens taken from the castings manufactured with various parameters of the injection piston and various multiplication pressures. The results were subjected to quantitative and qualitative analyses of casting nonconformities and distribution of major alloying elements. It was found that proper selection of working parameters of the casting machine, in spite of disadvantageous pouring conditions, makes it possible to reduce occurrence of some casting defects, like shrinkage cavities and porosity, to improve tightness of castings even when the alloy refining process is omitted.

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Falkus, J., and K. Miłkowska-Piszczek. "Strategy of Cooling Parameters Selection in the Continuous Casting of Steel." Archives of Metallurgy and Materials 61, no. 1 (March 1, 2016): 329–34. http://dx.doi.org/10.1515/amm-2016-0061.

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This paper presents a strategy of the cooling parameters selection in the process of continuous steel casting. Industrial tests were performed at a slab casting machine at the Arcelor Mittal Poland Unit in Krakow. The tests covered 55 heats for 7 various steel grades. Based on the existing casting technology a numerical model of the continuous steel casting process was formulated. The numerical calculations were performed for three casting speeds - 0.6, 0.8 and 1 m min-1. An algorithm was presented that allows us to compute the values of the heat transfer coefficients for the secondary cooling zone. The correctness of the cooling parameter strategy was evaluated by inspecting the shell thickness, the length of the liquid core and the strand surface temperature. The ProCAST software package was used to construct the numerical model of continuous casting of steel.

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Zhang, Li Qiang, and Rong Ji Wang. "Numerical Simulation of LPDC Process for Thin-Walled Aluminum Alloy." Advanced Materials Research 538-541 (June 2012): 474–78. http://dx.doi.org/10.4028/www.scientific.net/amr.538-541.474.

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In general, the thin-walled casting with the thickness less than 2mm is not easy to be prepared using low-pressure die casting (LPDC) technology because of its poor filling-ability. In this paper, the LPDC process of A356 thin-walled aluminum alloy was simulated based on the selection of appropriate boundary conditions in order to save the cost. The simulation results compared with experimental results indicate the numerical simulation technology is an effective tool for reducing the manufacturing cost and improving the casting quality.

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Qu, Yu Hai, Kai Jin Yang, Yan Tian Zhou, Yong Mao, Wei Zhang, and Si Yong Xu. "Phase Selection in Sub-Rapidly Solidified Au-20Sn Alloys." Materials Science Forum 817 (April 2015): 325–30. http://dx.doi.org/10.4028/www.scientific.net/msf.817.325.

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The sub-rapidly solidified Au-20Sn eutectic alloys were prepared by four different solidification pathways, such as, graphite mold conventional casting, graphite mold injection casting, copper mold injection casting, and water-cooled copper mold suction casting. The precipitating sequences of competing primary phases of sub-rapidly solidified Au-20Sn alloys with four different cooling rates were investigated. The results show that phase selection process is related to the cooling rates during sub-rapid solidification process. The primary ζ'-Au5Sn phase with developed dendrites precipitate at low cooling rate (2.4×10−4.2×102K/min) and the morphologies of the primary ζ'-Au5Sn change to rosette-like at higher cooling rate (9.0×103K/min). While the cooling rate reaches to 3.5×104K/min, the primary ζ'-Au5Sn phase can be suppressed but δ-AuSn phase will precipitate prior to the ζ'-Au5Sn phase. On the basis of the classical nucleation theory and transient nucleation theory, the process of competitive nucleation between the ζ'-Au5Sn phase and the δ-AuSn phase were analyzed for sub-rapid solidified Au-20Sn alloy. The theoretical calculations are consistent with the experimental investigations.

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Ghaleb, Atef M., Husam Kaid, Ali Alsamhan, Syed Hammad Mian, and Lotfi Hidri. "Assessment and Comparison of Various MCDM Approaches in the Selection of Manufacturing Process." Advances in Materials Science and Engineering 2020 (April 9, 2020): 1–16. http://dx.doi.org/10.1155/2020/4039253.

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The selection of manufacturing processes for a given application is a complex problem of multicriteria decision-making although there have been several different approaches that can be utilized to select a suitable alternative. However, identifying appropriate multicriteria decision-making approach from the list of available methods for a given application is a difficult task. This work suggests a methodology to assess different selection approaches, which are the technique for order of preference by similarity to ideal solution (TOPSIS), analytic hierarchy process (AHP), and VIKOR: stepwise procedure. This valuation was done depending on the following factors: number of alternative processes and criteria, agility through the process of decision-making, computational complexity, adequacy in supporting a group decision, and addition or removal of a criterion. A case study in this study was presented to analyse the evaluation methodology. The criteria used to evaluate and identify the best manufacturing process were categorized into productivity, accuracy, complexity, flexibility, material utilization, quality, and operation cost. Five manufacturing processes were considered, including gravity die casting, investment casting, pressure die casting, sand casting, and additive manufacturing. The results showed that each approach was suitable for the problems of manufacturing process selection, in particular toward the support of group decision-making and uncertainty modelling. Manufacturing processes were ranked based on their respective weights for AHP, TOPSIS, and VIKOR, and sand casting is the best. In terms of computational complexity, the VIKOR method performed better than TOPSIS and AHP. Moreover, the VIKOR and TOPSIS methods were better convenient to the selection of manufacturing processes for agility during the process of decision-making, the number of alternative processes and criteria, adequacy in supporting a group decision, and addition or removal of a criterion.

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Major-Gabryś, Katarzyna, Sabina Puzio, Agata Bryłka, and Jadwiga Kamińska. "The Influence of Various Matrixes on the Strength Properties of Moulding Sands with Thermally Hardened Hydrated Sodium Silicate for the Ablation Casting Process." Journal of Casting & Materials Engineering 5, no. 2 (July 5, 2021): 31–35. http://dx.doi.org/10.7494/jcme.2021.5.2.31.

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The essence of ablation casting technology consists in pouring castings into single-use moulds made from the mixture of sand and a water-soluble binder. After pouring the mould with liquid metal yet while the casting is still solidifying, the mould destruction (washing out, erosion) takes place using a stream of cooling medium, which in this case is water. This paper focuses on the selection of moulding sands with hydrated sodium silicate for moulds used in ablation casting. The research is based on the use of water glass 145 and 150 as binders. As part of the research, loose moulding mixtures based on two silica sands from different sand mines with different content of binders were prepared. The review of literature data and the results of own studies have shown that moulding sand with hydrated sodium silicate hardened by dehydration is characterized by sufficient strength properties to be used in the ablation casting process. Our own research also confirmed the possibility of using these sand mixtures in terms of both casting surface quality and sand reclamation. The results presented in this paper prove that both sand grains and types of binder tested may be used as components in moulding sands devoted to ablation casting.

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Lai, Hua Qing. "The Methods of Extending the Serve Life of Die Casting Dies in Industry Domain." Advanced Materials Research 487 (March 2012): 375–78. http://dx.doi.org/10.4028/www.scientific.net/amr.487.375.

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Analysis of the casting mold in the casting process of the failure of several major forms of the structure from the die casting and die-casting mold design, manufacturing and processing, material selection, heat treatment technology and the use of die-casting mold, and other aspects of maintenance and maintenance to improve die-casting die life way.

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Tiwari, M. K., and Ranjan Banerjee. "A decision support system for the selection of a casting process using analytic hierarchy process." Production Planning & Control 12, no. 7 (January 2001): 689–94. http://dx.doi.org/10.1080/09537280010016783.

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Liu, Wei, Xinfu Pang, Shengping Yu, Congxin Li, and Tianyou Chai. "Steelmaking-Casting of Molten Steel by Decarburization Ladle Matching." Mathematical Problems in Engineering 2018 (2018): 1–15. http://dx.doi.org/10.1155/2018/7567591.

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Steelmaking–continuous casting is a complex process. The method of selecting a ladle, which also functions as a storage device, follows a specific process of the production plan. In ladle matching, several ladle attributes are considered. However, matching objectives are difficult to achieve simultaneously. Different molten steel properties have contributed to the complexity of matching constraints, and, thus, matching optimization is regarded a multiconflict goal problem. In the process of optimization, the first-order rule learning method is first used to extract key ladle attributes (performance indicators), including highest temperature, usage frequency, lowest-level material, and outlet. On the basis of a number of indicators, such as ladle temperature, quantity, material, and usage frequency, as well as skateboard quantity, the ladle matching model is established. Second, the rule of ladle selection is determined by the method of least-generalization rule learning. Third, a simulation experiment is carried out according to various scheduling order strategies and matching priority combinations. Finally, the heuristic ladle matching method based on the rule priority (RP) is determined for possible industrial applications. Results show that the accuracy of ladle selection can be improved. In particular, the numbers of ladles and maintenance times are reduced. Consequently, furnace production efficiency is also enhanced.

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Shen, Jiang Nan, Liu Lang Lai, and Yan Ping Li. "Study of Pre-Processing Technology for Zinc Alloy Die-Casting Numerical Simulation on Flow-3D." Applied Mechanics and Materials 184-185 (June 2012): 1232–35. http://dx.doi.org/10.4028/www.scientific.net/amm.184-185.1232.

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The technologies of computer numerical simulations on casting process has penetrated into the every field of shape process, and offer a efficient tool for casting technological design. The paper briefly introduces the characteristics of the Flow-3d software on the principle and function, which is superior to that of other casting simulation software. Then, many die casting casts have been modeled and simulated, focus on the content of Pre-processing, summed up the major principles and skills on STL Import, Mesh Building and Control parameters selection of Flow-3D software by using the means of analogy.

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Marini, Daniele, and Jonathan R. Corney. "Process selection methodology for near net shape manufacturing." International Journal of Advanced Manufacturing Technology 106, no. 5-6 (December 14, 2019): 1967–87. http://dx.doi.org/10.1007/s00170-019-04561-w.

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AbstractThis paper presents a new selection methodology that for the first time supports the identification of Near Net Shape (NNS) processes. The methodology, known as “Product, Geometry, Manufacturing and Materials Matching” (ProGeMa3), is composed of four steps, which aim to minimize raw material usage and machining by adopting a NNS approach. A key component of the methodology is the Process Selection Matrix (ProSMa) that associates a component’s shape and production volume with its material requirements to reduce the number of candidate NNS processes. A final selection is then made from this shortlist by using fuzzy logic and considering other constraints and functional requirements. The ProGeMa3 selection process is illustrated by its application to an industrial component that resulted in changes to the processes used for its commercial manufacture. The ProGeMa3 and ProSMa presented in this paper aspires to be current and comprehensive for solid metallic components produced by casting, forging and additive technologies. However, ProSMa is also accessible as an open source resource available for other researcher to extend and adapt.

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Dimitrov, D., W. van Wijck, N. de Beer, and J. Dietrich. "Development, evaluation, and selection of rapid tooling process chains for sand casting of functional prototypes." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 221, no. 9 (September 1, 2007): 1441–50. http://dx.doi.org/10.1243/09544054jem728.

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This paper discusses the results obtained from studies on different rapid tooling process chains for improved design and manufacture of foundry equipment for sand casting of prototypes in final material for functional and pre-production tests of vehicles, using the three-dimensional printing process as core technology. Subsequently, while considering aspects such as time, cost, quality (accuracy and surface roughness), and tool life, a framework for evaluation and selection of the most suitable process chain in accordance to specific requirements is presented. Apart from only using these process chains for prototype manufacturing, initial results from a study to apply one of these process chains in automated sand casting full production is also presented. This research builds on an in-depth characterization of the accuracy and repeatability of a three-dimensional printing process.

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Salonitis, Konstantinos, Mark Jolly, and Binxu Zeng. "Simulation Based Energy and Resource Efficient Casting Process Chain Selection: A Case Study." Procedia Manufacturing 8 (2017): 67–74. http://dx.doi.org/10.1016/j.promfg.2017.02.008.

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Ishfaq, Kashif, Muhammad Asad Ali, Naveed Ahmad, Sadaf Zahoor, Abdulrahman M. Al-Ahmari, and Faisal Hafeez. "Modelling the Mechanical Attributes (Roughness, Strength, and Hardness) of Al-alloy A356 during Sand Casting." Materials 13, no. 3 (January 28, 2020): 598. http://dx.doi.org/10.3390/ma13030598.

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Sand-casting is a well established primary process for manufacturing various parts of A356 alloy. However, the quality of the casting is adversely affected by the change in the magnitude of the control variables. For instance, a larger magnitude of pouring velocity induces a drop effect and a lower velocity increases the likelihood of cold-shut and mis-run types of defects. Similarly, a high pouring temperature causes the formation of hot tears, whereas a low temperature is a source of premature solidification. Likewise, a higher moisture content yields microcracks (due to gas shrinkages) in the casting and a lower moisture content results in the poor strength of the mold. Therefore, the appropriate selection of control variables is essential to ensure quality manufactured products. The empirical relations could provide valuable guidance in this regard. Additionally, although the casting process was optimized for A356 alloy, it was mostly done for a single response. Therefore, this paper aimed to formulate empirical relations for the contradictory responses, i.e., hardness, ultimate tensile strength and surface roughness, using the response surface methodology. The experimental results were comprehensively analyzed using statistical and scanning electron microscopic analyses. Optimized parameters were proposed and validated to achieve castings with high hardness (84.5 HB) and strength (153.5 MPa) with minimum roughness (5.8 µm).

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Dmitriev, Victor S., and Tamara G. Kostyuchenko. "Design of the Gating System for Production of Casting Blanks for Space Device Cases." Materials Science Forum 938 (October 2018): 89–95. http://dx.doi.org/10.4028/www.scientific.net/msf.938.89.

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Selection of an appropriate gating system for a consumable pattern is a long and time-consuming process that requires considerable effort. Advanced design technologies can be used to design the gating system and to simulate the casting process based on the design. Simulation and design of the gating system allow detection of types of defects in the casting at the development stage. Parametrical changing of the gating system 3D model and variation of its characteristics, and repeated simulation of cooling, crystallization and mold filling processes can provide high quality casting.

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Varshney, Gagan, Syed Qaisar Husain, Avinash Ravi Raja, and Girendra Bhati. "An Application of Analytical Hierarchy Process in Selection of Coating Material Composition in Lost Foam Casting Process." IOP Conference Series: Materials Science and Engineering 1168, no. 1 (July 1, 2021): 012010. http://dx.doi.org/10.1088/1757-899x/1168/1/012010.

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Zhang, Fan, Xiao Gang Hu, Da Quan Li, You Feng He, Xiao Jing Xu, and Qiang Zhu. "Simulation on the Thixocasting Process of the Turbocharger Impellers and Selection of the Viscosity Models." Solid State Phenomena 217-218 (September 2014): 219–24. http://dx.doi.org/10.4028/www.scientific.net/ssp.217-218.219.

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The thixocasting technology is chosen to produce the turbocharger impellers as it is capable of producing castings with high precision dimension, free of oxide and shrinkage porosity defects and therefore long service life. The thixocasting turbocharger impellers have the similar mechanical property to those produced by forging and machine processes, but much less costs. In the thixocasting process, the semisolid slurry with certain solid fraction is injected into mould at a high speed. Since high viscosity and thixotropic characteristics, the semisolid slurry reveals unique flow condition and characteristics in the filling process. So, its very desirable for the die design, process optimization, and defect control to visualize the high-speed filling process of semisolid slurry by numerical simulation. In this paper, several commonly used viscosity models for semisolid slurry are analysed. The Power law cut-off model (PLCO) model is selected to simulate the filling process in the thixocasting process of the impellers of 319s alloy, compared with actual results by partial filling testing. The causes of the casting defects are also analysed, indicating that the simulation results can accurately reproduce the filling process of semisolid slurry, and PLCO model is a successful choice for simulating the filling process of semisolid slurry with high solid fraction.

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Taufik, Shamsuddin Sulaiman, B. T. Hang Tuah Baharudin, M. K. A. M. Arifin, and Arep Ariff Hambali. "Design and Simulation on Investment Casting Mold for Metal Matrix Composite Material." Applied Mechanics and Materials 66-68 (July 2011): 1676–81. http://dx.doi.org/10.4028/www.scientific.net/amm.66-68.1676.

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This paper presents the design and simulation on investment casting mold for metal matrix composite material. The study was investigating the design parameters for the casting mold and simulated the temperature and pressure on the mold. Compressor impeller selected as the product of the study. Among the various types of casting techniques, investment casting process is the most suitable process to produce the compressor impeller. The alternative design of casting mold of investment casting was generated using CAD software. Concept scoring was prepared to select the suitable design for the investment casting process. Material selection of compressor is Aluminum Silicon Carbide. Stainless steel AISI H13 is selected as the material for the mold. The parameter for the mold design is included branch, gating, sprue and runner. The analysis was presented to the mold by using ANSYS simulation tool to determine the temperature and pressure of the mold. In addition, three case studies were presented and compared the static pressure in different velocity and temperature of the mold design. The result showed the runner and the branch size were important to produce the molten metal flow into the mold pattern. As a result, the design of investment casting mold was proposed.

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Tillová, Eva, Mária Chalupová, Lenka Kuchariková, Juraj Belan, and Denisa Závodská. "Selection of optimal solution heat treatment of the casting cylinder heads." MATEC Web of Conferences 157 (2018): 02053. http://dx.doi.org/10.1051/matecconf/201815702053.

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The effect of solution treatment on mechanical properties (UTS, elongation, Brinell hardness) and microstructure (Si-morphology and Si-size) of an aluminium alloy (A356) used for casting cylinder heads was studied. The tests were carried out with specimens machined from the bulkheads of V8 engine blocks cast by the low pressure process. The samples were tested in as-cast and T6 heat treating conditions (solution heat treatment at 530°C with different time - 2, 3, 4, 5, 6, 7 hours, quenching in water at 20°C and precipitation hardened for 4 hour at 160°C). The results show that used heat treatment improves mechanical properties of the cylinder head casts. Tensile strength and hardness of specimens increase with solution treatment time. The hardness is a reflection of solution strengthening and silicon particle distribution in matrix. Solution temperature 530°C and 5 hours solution time is appropriate to obtain better morphology and distribution of Si particles in microstructure. Prolonged solution treatment (more than 5 hours) leads to a coarsening of the Si particles, while the numerical Si density decreases. As the particle density decreases, a fewer number of sites are available for crack nucleation, and hence, the fracture properties are improved. The data obtained from this study will be used to improve process control, and to help the selection of heat treatment of the casting for future products.

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Hu, H. J., S. L. Gan, Y. Tian, D. F. Zhang, J. K. Feng, and Z. W. Ou. "Evaluation of chilled casting and extrusion-shear forming technology based on numerical simulation and experiments." Materials Testing 63, no. 8 (August 1, 2021): 728–35. http://dx.doi.org/10.1515/mt-2021-0002.

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Abstract Magnesium alloys on the surface of billets might be refined by chilled casting process, but the grains of the center of billets are coarse, and there are a lot of void defects in the center of billets. These defects can be eliminated by hot extrusion, while fibrous microstructures and strong basal textures might be formed. This paper presents a new short process technology which includes chilled casting and extrusion-shear (CCES). It is crucial to understand the effects of die structures on the deformation behaviors, strain distribution and load requirements. Three selections of processes and die structures were done by simulations and experiments which include CCES process with 4 times consecutive shearings plastic deformation, CCES process by lateral extrusion with 90° shearing angle, and combined CCES process mode. The research results show the third selection is recommended. Three-dimensional (3D) geometric models with different channel angles (30°, 45°) for the third selection CCES dies were designed. The heterogeneities of plastic deformation by CCES dies with different channel angles were analyzed from the simulation results. The simulation results show strains decrease with rising of channel angles. The lower channel angles improve the deformation heterogeneity of magnesium alloy billets. Smaller channel angles obtain higher strains and produce tinier sub-grains. The forces of the CCES process decrease with rising of channel angles. The analysis results showed that finer and uniform microstructures can be obtained if channel angles in the CCES dies are appropriate.

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Łopata, Kinga, Kinga Korniejenko, Brian Azzopardi, and Michał Łach. "Materials Selection and Tests for Precise Execution of Foundry Molds Designed to Geopolymer Casts." MATEC Web of Conferences 322 (2020): 01013. http://dx.doi.org/10.1051/matecconf/202032201013.

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The paper presents the results of research on the selection of material for molds intended for geopolymer castings as well as an appropriate technological process for the preparation of such castings. Three silicons with different elasticity and hardness of 30, 40 and 60Sh were tested. The above-mentioned rubbers were used to make one-piece open molds and test the performance of each material. A model having several details and a small flat surface was chosen for the replica. Based on this variation in the wall structure, it was possible to assess the accuracy of mapping, both small elements and straight cast planes. In the prepared forms 10 tests of geopolymer casting were carried out to develop the best technological process. The appropriate result was achieved when the molds covered with the divider were flooded with raw material by vibrating them on a vibrating table, and then allowed to react for an hour for free mass components and leaking gases to the surface. After a set time, the compaction was carried out again to more accurately eliminate the resulting air bubbles. The effect of this method is to obtain a cast with precisely mapped details and a smooth even surface, and almost complete elimination of air bubbles from representative surfaces.

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Ji, Xiao Yuan, Jian Xin Zhou, and Dun Ming Liao. "Flask Management in the Foundry Moulding Plan." Advanced Materials Research 291-294 (July 2011): 3195–200. http://dx.doi.org/10.4028/www.scientific.net/amr.291-294.3195.

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There are many studies about foundry process design, foundry quality control, and foundry methods selection; however few researches have been published regarding foundry production scheduling management and expert system and flask management in casting production in particular. It is difficult for a production planner to judge whether there are enough flasks to meet the moulding plan in casting companies, and it is a highly troublesome problem to provide the planned castings with the compatible flasks as well. In order to address these two issues, in this paper we analyzes the cause of the problem and finds that the difficulty is to manage assembling flasks, and then constructs a decision analysis method. The method can make a validity analysis to the made moulding plan, and make up a flask assignment solution for the valid plan. Finally, a foundry moulding plan expert system based on the method is developed to prove this study.

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Yan, Xiaohui, Zhicong Zhang, Jianwen Guo, Shuai Li, and Kaishun Hu. "A Novel Algorithm to Scheduling Optimization of Melting-Casting Process in Copper Alloy Strip Production." Discrete Dynamics in Nature and Society 2015 (2015): 1–13. http://dx.doi.org/10.1155/2015/147980.

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Melting-casting is the first process in copper alloy strip production. The schedule scheme on this process affects the subsequent processes greatly. In this paper, we build the multiobjective model of melting-casting scheduling problem, which considers minimizing the makespan and total weighted earliness and tardiness penalties comprehensively. A novel algorithm, which we called Multiobjective Artificial Bee Colony/Decomposition (MOABC/D) algorithm, is proposed to solve this model. The algorithm combines the framework of Multiobjective Evolutionary Algorithm/Decomposition (MOEA/D) and the neighborhood search strategy of Artificial Bee Colony algorithm. The results on instances show that the proposed MOABC/D algorithm outperforms the other two comparison algorithms both on the distributions of the Pareto front and the priority in the optimal selection results.

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Gowdru Chandrashekarappa, Manjunath Patel, Prasad Krishna, and Mahesh B. Parappagoudar. "Forward and Reverse Process Models for the Squeeze Casting Process Using Neural Network Based Approaches." Applied Computational Intelligence and Soft Computing 2014 (2014): 1–12. http://dx.doi.org/10.1155/2014/293976.

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The present research work is focussed to develop an intelligent system to establish the input-output relationship utilizing forward and reverse mappings of artificial neural networks. Forward mapping aims at predicting the density and secondary dendrite arm spacing (SDAS) from the known set of squeeze cast process parameters such as time delay, pressure duration, squeezes pressure, pouring temperature, and die temperature. An attempt is also made to meet the industrial requirements of developing the reverse model to predict the recommended squeeze cast parameters for the desired density and SDAS. Two different neural network based approaches have been proposed to carry out the said task, namely, back propagation neural network (BPNN) and genetic algorithm neural network (GA-NN). The batch mode of training is employed for both supervised learning networks and requires huge training data. The requirement of huge training data is generated artificially at random using regression equation derived through real experiments carried out earlier by the same authors. The performances of BPNN and GA-NN models are compared among themselves with those of regression for ten test cases. The results show that both models are capable of making better predictions and the models can be effectively used in shop floor in selection of most influential parameters for the desired outputs.

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Liu, Yun Qiang, and Yong Lv. "Study on the Welding of Feeder Hopper and Cylinder Instead of Casting Process." Applied Mechanics and Materials 599-601 (August 2014): 486–88. http://dx.doi.org/10.4028/www.scientific.net/amm.599-601.486.

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According to the specific structure of the hopper and cylinder of twin screw cone feeder machine, 16MnR and austenitic hopper and machine cylinder and stainless steel 1Cr18Ni9 are used for construction by welding process instead of cast steel ZG310-570 galvanized originally. The weld technology process is formulated. In the process of implementation of the program, the difficulties of the process as follows are solved: Selection the alternative materials; rational design of cooling water structures; form and position tolerances between double cone screw and inner sphere – conical surface, reduction of the difficulty of processing the double cone cambered, welding deformation control, post - weld heat treatment of removal residual stresses.

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Li, Yan Song, and Da Wei Wang. "Standard Simple of Tin Bronze for Casting Develepment." Advanced Materials Research 1004-1005 (August 2014): 1186–92. http://dx.doi.org/10.4028/www.scientific.net/amr.1004-1005.1186.

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The development of standard simple of tin bronze for casting is presented,design of composition, selection melting temperature 1150 °C, put into 0.2m3/kg argon gas, stirring with 100rpm for 1min, keeping temperature for 30min as the optimum process conditions, coarse and fine tests of homogeneity with data analyses, determination of standard values and standard deviation. The homogeneity and standard values of samples meet the national standard GB/T15000 and YS/T409-1998. The standard sample series has ratification as National Reference Materials (GSB 04-2707-2011) by National Technical Commission on Reference Materials.

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East, Daniel R., Michael Kellam, Mark A. Gibson, Aaron Seeber, Daniel Liang, and Jian Feng Nie. "Amorphous Magnesium Sheet Produced by Twin Roll Casting." Materials Science Forum 654-656 (June 2010): 1078–81. http://dx.doi.org/10.4028/www.scientific.net/msf.654-656.1078.

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Sheets of a Mg60Cu29Gd11 alloy were produced by twin roll casting with all operational variables, except roll speed, being kept constant. As a function of the roll speed, the structure of the as-cast sheet changed from being crystalline to fully amorphous and then back to crystalline. Through careful selection of the casting speed that is suitable for the selected alloy system and with which the exit temperature of the sheet remains within the supercooled liquid region, a malleable sheet with no surface defects is produced. This work shows that twin roll sheet casting is a viable process for the production of magnesium-based bulk amorphous sheet in a continuous manner and on an industrial scale.

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Krimpenis, A., P. G. Benardos, G. C. Vosniakos, and A. Koukouvitaki. "Simulation-based selection of optimum pressure die-casting process parameters using neural nets and genetic algorithms." International Journal of Advanced Manufacturing Technology 27, no. 5-6 (February 9, 2005): 509–17. http://dx.doi.org/10.1007/s00170-004-2218-0.

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Watson, Robert, Tayeb Zeguer, Mike Buckley, Nick R. Green, Simon Ruffle, and William D. Griffiths. "The Response of Entrainment Defect Distribution to Varied Fluid Flow Parameters in the High Pressure Die Casting of Al Alloys." Materials Science Forum 765 (July 2013): 326–30. http://dx.doi.org/10.4028/www.scientific.net/msf.765.326.

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High Pressure Die Casting is an economical means of manufacturing complex thin walled parts in high volumes. However, the process is prone to high levels of surface turbulence and fluid break-up, which results in the entrainment of bifilm defects. A study was carried out on a commercial casting to identify how changes in melt velocity and mould geometry affected the distribution of damaging bifilm defects, and the distribution of fracture stress. The statistical analysis of tensile test data indicated that two distinct defect populations existed; one of which caused relatively few failures, but often accounted for a large reduction in fracture stress when present. Where this defect population was not significant, Weibull moduli of 20 to 30 were achieved, comparable to sand castings with well-designed running systems. SEM fractography was also performed on a selection of samples to determine the probable cause of failure. A comparison of the SEM analysis to the statistical results indicated that bi-film defects initiated the fracture of those samples that failed at significantly lower stresses. Additionally, it was demonstrated that the geometric distribution of these cases was strongly correlated to changes in fluid flow conditions, suggesting that targeted modifications to mould geometry could increase the in-service reliability of High Pressure Die Castings.

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Hidayat, Taufiq, and Mastiadi Tamjidillah. "PENGARUH TEMPERATUR TUANG DENGAN JENIS MATERIAL Al PADUAN (RONGSOK WAJAN) TERHADAP KEKERASAN HASIL PENGECORAN EVAPORATIVE." Scientific Journal of Mechanical Engineering Kinematika 1, no. 1 (June 9, 2016): 47–58. http://dx.doi.org/10.20527/sjmekinematika.v1i1.86.

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The objective of this research is to know the effect of casting temperature with the kind of guide material AI alloy junk from pan on hardness (the evaporative foundry result). The recycling of used aluminum is an alternative to reduce the waste material from aluminum. Recycling is a way of processing used materials that is started with selection, collection, then the process of foundry to create a new product that is more valuable economical. Casting temperature is an variable that can effect the result of foundry where if the casting temperature is low, then there will be a quick freeze before the mold is completely filled. And if the casting temperature is too high, then shrinkage can occur anditheiporosity value may increase. This research used four casting temperature variations, namely: 650°C, 700°C, 750°C, and 800°C. The evaporative foundry method uses styrofoam pattern that is piled up into sand mold. The metal that is casted will form like styrofoam pattern. The resultiof casting temperature testing can effect on hardness.

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Rahman, Syaiful, and Rudi Siswanto. "PENGARUH TEMPERATUR TUANG DENGAN JENIS MATERIAL PADUAN Al RONGSOK (KAMPAS REM PANCI) TERHADAP POROSITAS, KEKERASAN DAN STRUKTUR MIKRO HASIL PENGECORAN EVAPORATIVE." Scientific Journal of Mechanical Engineering Kinematika 4, no. 1 (June 13, 2019): 87–94. http://dx.doi.org/10.20527/sjmekinematika.v4i1.55.

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Recycling is a way of processing used materials that is started with selection, collection, then the process of foundry to create a new product that is more valuable economical. The objective of this research is to know the effect of casting temperature with the kind of guide material AI alloy junk from brake shoe and pan on porosity, hardness, microstructure (the evaporative foundry result). The recycling of used aluminum is an alternative to reduce the waste material from aluminum. Casting temperature is an variable that can effect the result of foundry where if the casting temperature is low, then there will be a quick freeze before the mold is completely filled. And if the casting temperature is too high, then shrinkage can occur and the porosity value may increase. This research used four casting temperature variations, namely: 650°C, 700°C, 750°C, and 800°C. The evaporative foundry method uses styrofoam pattern that is piled up into sand mold. The metal that is casted will form like styrofoam pattern. The result of casting temperature testing can effect on porosity, hardness, and microstructure.

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Clausen, Jan, Milan Kelch, Franz Josef Wöstmann, and Matthias Busse. "Development of a High Pressure Die Casting Tool for Partial Integration of Glass Fiber Structures." Key Engineering Materials 742 (July 2017): 520–26. http://dx.doi.org/10.4028/www.scientific.net/kem.742.520.

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Due to the growing demand for lightweight solutions in a wide range of industries, the selection and combination of various materials is becoming more and more important. As a result, the need for suitable joining technologies is increasing along with it. Within the DFG research group "Schwarz-Silber" ("black-silver"), Fraunhofer IFAM is investigating so-called transitional structures in cooperation with the University of Bremen. In this process, glass fiber structures are integrated into aluminum by a high pressure die casting process. These structures are used for the electrochemical insulation between aluminum and carbon fiber textiles, which are connected by textile processes in a subsequent production step. A solid hybrid structure is finally achieved through a resin-impregnation process. The key challenges are the positioning, pre-tensioning and infiltration of the glass fiber structures within the high pressure die casting process. In order to meet these challenges, a customized die casting tool was developed within the project. With the aid of mold-filling simulations, the die system of the die casting tool was optimized to achieve better infiltration of the fiber bundles and to additionally support the position of the glass fibers in the casting process. After the design of the molding tool, the implementation was carried out in collaboration with a toolmaker. In subsequent, up-to-date investigations, the positioning and infiltration of different variants of glass fiber structures is evaluated. The results are compared with previous attempts to position and infiltrate the glass fiber structures to assess the effect of the optimized newly designed tool.

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Vidoni, Michele, Markus Daamen, and Gerhard Hirt. "Advances in the Twin-Roll Strip Casting of Strip with Profiled Cross Section." Key Engineering Materials 554-557 (June 2013): 562–71. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.562.

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Direct thin strip casting is an economically end energetically smart process for the production of steel strip. In a single process step, liquid steel can be cast and directly rolled to hot strip in thicknesses ranging from one to four millimeters. With the use of specifically profiled casting rolls it is possible to produce strip with optimized cross-sections, allowing this process to compete with tailor welded and tailor rolled blanks for the production of a class of products already widely applied in industry. Numerical and experimental studies proved the feasibility of this concept and additional simulations were used to optimize the profile to be used for the experiments. A thickness variation of one millimeter from the edge to the center could be successfully achieved. However, the dimensional precision and the roughness distribution along the cross section of the produced strip were not satisfactory. Additional profiles were applied for the experimental analysis leading to better roughness distribution and geometrical accuracy. In order to further improve the uniformity of properties along the profiled section it is necessary to increase the homogeneity of the microstructure. The coating and surface preparation of the casting rolls play a very important role in the strip casting process as they strongly affect the solidification behavior. This observation lead to the idea of selectively coating the casting rolls, applying a less conductive layer on the areas where the casted profile is thinner. Thus, a more homogeneous solidification front can be obtained. The effect of a locally modified casting roll coating on the solidification is numerically investigated and the results applied for the selection of the coating parameters to be used for the experiments.

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Jiang, Fan, Wei Ping Chen, Yi Jun Wang, and Xiao Chu Liu. "Collection Mode Optimization of Casting Dust Based on TRIZ." Advanced Materials Research 97-101 (March 2010): 2695–98. http://dx.doi.org/10.4028/www.scientific.net/amr.97-101.2695.

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The massive dust is produced in the casting process, need to control. This paper takes electric arc furnace dust collection way as an example, where is in Guangdong Shaoguan Foundry and Forging Group Co., Ltd., establishes the conflict matrix about selection of the dust collection way, uses the TRIZ theory to solve, and obtains the standard solution, the results should provide the reference for collection way design of the electric arc furnace dust. The structure of half airtight cover is optimized by used of CFD, and the curve type is suitable shape to collect the dust.

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Qiao, Ling, Jingchuan Zhu, Yingnan Wan, Congcong Cui, and Ge Zhang. "A Finite Element Analysis for Improvement of Shaping Process of Complex-Shaped Large-Size Silicon Carbide Mirrors." Materials 14, no. 15 (July 25, 2021): 4136. http://dx.doi.org/10.3390/ma14154136.

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In the gel-casting process, the proper selection of technological parameters is crucial for the final quality of a green body. In this work, the finite element method is used to investigate the mold characteristics in the gel-casting process, and the typical flow behaviors under different conditions are presented. Based on the distribution characteristics of temperature, pressure and flow field of gel polymer, the simulated results provide some possible reasons for the generation mechanisms of defects. Then, a series of simulations were performed to investigate the effect of process parameters on the molding quality of green gel-cast bodies. The results show that the decreasing loading speed can effectively reduce the number of defects and improve the molding quality. In addition, this paper presents a new technique by applying the exhaust hole to decrease the number of defects and, hence, improve structural integrity. The influence of the loading speed on the mold characteristics is well understood for the gating system with an exhaust hole, which suggests to us appropriate parameters for optimizing the molding design. This work provides a theoretical basis to explicate the generating mechanism of defects involved in the gel-casting process and acquires an optimized technique to produce a silicon carbide green body.

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Hafsa, M. N., Mustaffa Ibrahim, Md Saidin Wahab, and M. S. Zahid. "Evaluation of FDM Pattern with ABS and PLA Material." Applied Mechanics and Materials 465-466 (December 2013): 55–59. http://dx.doi.org/10.4028/www.scientific.net/amm.465-466.55.

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Selection of the most suitable Rapid Prototyping (RP) and manufacturing process for a specific part creation is a difficult task due to the development of RP processes and materials. Most current RP processes can build with more than one type of material. The paper presents the evaluation on Acrylonitrile Butadiene Styrene (ABS) and Polylactic acid (PLA) part produced from Fused Deposition Modeling (FDM) as a master pattern for Investment Casting (IC) process. The main purpose of this research is to evaluate the dimensional accuracy and surface roughness for hollow and solid part of FDM pattern for IC process with different layer thickness. The value were taken for both before and after the casting process. Results show that model fabricated with hollow internal pattern structure (ABS material) that produced by low layer thickness is better than other models in terms of its dimensional accuracy (-0.19666mm) and surface roughness (1.41μm). Even though the ABS built part performed better as the model, the PLA build part produces better overall casting result. Final part fabricated with solid pattern (PLA material) that produced by high layer thickness is better than other final parts which its dimensional accuracy (-0.12777mm) and surface roughness (3.07μm).

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Miłkowska‐Piszczek, Katarzyna, and Jan Falkus. "Control and Design of the Steel Continuous Casting Process Based on Advanced Numerical Models." Metals 8, no. 8 (July 30, 2018): 591. http://dx.doi.org/10.3390/met8080591.

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The process of continuous casting of steel is a complex technological task, including issues related to heat transfer, the steel solidification process, liquid metal flow and phase transitions in the solid state. This involves considerable difficulty in creating the optimal process control system, which would include the influence of all the physico‐chemical phenomena which may occur. In parallel, there is an intensive development of new mathematical models and an increase in computer performance, therefore complex numerical simulations requiring substantial computing time can be conducted. This paper presents a review of currently applied numerical methods allowing the phenomena accompanying the process of continuous casting of steel to be accurately represented. Special attention was paid to the selection of appropriate methods to solve the technological problem selected. The possibilities of applying selected numerical models were analysed in order to modify and improve the existing process or to design a new one linked to the implementation of new steel grades in the current production. The description of the method of defining the boundary conditions, initial conditions and material parameters as vital components ensuring that numerical calculations based upon them in the finite element method, which is that most frequently applied, are correct is an important element of the paper. The possibility of reliably defining the values of boundary parameters on the basis of information on the intensity of cooling in individual zones of the continuous casting machine was analysed.

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Tie, Xiao Yan, and Hua Zhang. "Mold Machining Process and Applying Technologies of Spiral Bevel Gears." Applied Mechanics and Materials 86 (August 2011): 152–55. http://dx.doi.org/10.4028/www.scientific.net/amm.86.152.

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Mold processing had been the main method of the fast development in modern industry and production, which was the way to accelerate producing efficiency and reduce the cost. The performance and accuracy was the key to realizing molding processing of spiral bevel gears. In traditional, EDM(Electrical Discharge Machining) was used in manufacturing spiral bevel gears mold, which led to low precision for large processing error in the tooth surface of electrodes. Then surface accuracy and meshing performance couldn’t achieve to the expected demands. The way of modeling by three-dimensional software became a new selection with the high surface accuracy and simple modification process to surface. There were mainly injection, powder metallurgy, precision forging, die-casting and so on.

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Świłło, S. J., and M. Perzyk. "Surface Casting Defects Inspection Using Vision System and Neural Network Techniques." Archives of Foundry Engineering 13, no. 4 (December 1, 2013): 103–6. http://dx.doi.org/10.2478/afe-2013-0091.

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Abstract The paper presents a vision based approach and neural network techniques in surface defects inspection and categorization. Depending on part design and processing techniques, castings may develop surface discontinuities such as cracks and pores that greatly influence the material’s properties Since the human visual inspection for the surface is slow and expensive, a computer vision system is an alternative solution for the online inspection. The authors present the developed vision system uses an advanced image processing algorithm based on modified Laplacian of Gaussian edge detection method and advanced lighting system. The defect inspection algorithm consists of several parameters that allow the user to specify the sensitivity level at which he can accept the defects in the casting. In addition to the developed image processing algorithm and vision system apparatus, an advanced learning process has been developed, based on neural network techniques. Finally, as an example three groups of defects were investigated demonstrates automatic selection and categorization of the measured defects, such as blowholes, shrinkage porosity and shrinkage cavity.

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Yi, Jian, Bin Du, Qiang Liu, Yun Lin, and Ke Wei Huang. "Modeling and Optimization for Steel Grade Selection Based on Hierarchical Genetic Algorithm." Advanced Materials Research 505 (April 2012): 203–8. http://dx.doi.org/10.4028/www.scientific.net/amr.505.203.

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In steel-making process, when a furnace is charged, there are many optional steel grades for each slab. It is a difficult problem to select the appropriate steel grade for each slab. In this paper, based on the analysis of technics constraints in steel-making process, the steel grade intensivism problem is described, and the mathematical model is also established. To solve the above problem, a newly designed hierarchical genetic algorithm is proposed, where the hierarchical manner is used to decrease the solution space. The effectiveness of the approach is demonstrated by a simulation. The optimal solution can be obtained in reasonable time, which will be helpful to decrease the scraps between two steel grades while casting, to decrease the sum of surplus, and eventually to cut down the stock.

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Majerník, Ján, Štefan Gašpár, Jozef Husár, Ján Paško, and Jan Kolínský. "Research and Evaluation of the Influence of the Construction of the Gate and the Influence of the Piston Velocity on the Distribution of Gases into the Volume of the Casting." Materials 14, no. 9 (April 27, 2021): 2264. http://dx.doi.org/10.3390/ma14092264.

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Distribution of gasses to the cast volume and volume of pores can be maintained within the acceptable limits by means of correct setting of technological parameters of casting and by selection of suitable structure and gating system arrangement. The main idea of this paper solves the issue of suitability of die casting adjustment—i.e., change of technological parameters or change of structural solution of the gating system—with regards to inner soundness of casts produced in die casting process. Parameters which were compared included height of a gate and velocity of a piston. The melt velocity in the gate was used as a correlating factor between the gate height and piston velocity. The evaluated parameter was gas entrapment in the cast at the end of the filling phase of die casting cycle and at the same time percentage of porosity in the samples taken from the main runner. On the basis of the performed experiments it was proved that the change of technological parameters, particularly of pressing velocity of the piston, directly influences distribution of gasses to the cast volume.

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Ezatpour, HR, M. Torabi Parizi, SA Sajjadi, and GR Ebrahimi. "Optimum selection of A356/Al2O3 nano/microcomposites fabricated with different conditions based on mathematical method." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 231, no. 4 (August 7, 2015): 373–81. http://dx.doi.org/10.1177/1464420715598172.

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Aluminum matrix composites reinforced with micro- and nano-sized Al2O3 particles provide desirable characteristics for high-performance applications in aerospace, automobile, and military industries, because of their improved physical and mechanical properties. Selection of the best combination of ultimate strength and formability properties of the composites is a multiple attribute decision making problem where some criteria must be considered. In this study, A356/Al2O3 composites were prepared with different conditions such as the fabrication method, size, and weight fraction of reinforcement. These alternatives were ranked by analytic hierarchy process method. Analytic hierarchy process results revealed that the composite with 2 wt% nano-Al2O3 fabricated by compo-casting method was the preferred composite material.

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Patel, M. G. C., P. Krishna, and M. B. Parappagoudar. "Prediction of Secondary Dendrite Arm Spacing in Squeeze Casting Using Fuzzy Logic Based Approaches." Archives of Foundry Engineering 15, no. 1 (March 1, 2015): 51–68. http://dx.doi.org/10.1515/afe-2015-0011.

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Abstract The quality of the squeeze castings is significantly affected by secondary dendrite arm spacing, which is influenced by squeeze cast input parameters. The relationships of secondary dendrite arm spacing with the input parameters, namely time delay, pressure duration, squeeze pressure, pouring and die temperatures are complex in nature. The present research work focuses on the development of input-output relationships using fuzzy logic approach. In fuzzy logic approach, squeeze cast process variables are expressed as a function of input parameters and secondary dendrite arm spacing is expressed as an output parameter. It is important to note that two fuzzy logic based approaches have been developed for the said problem. The first approach deals with the manually constructed mamdani based fuzzy system and the second approach deals with automatic evolution of the Takagi and Sugeno’s fuzzy system. It is important to note that the performance of the developed models is tested for both linear and non-linear type membership functions. In addition the developed models were compared with the ten test cases which are different from those of training data. The developed fuzzy systems eliminates the need of a number of trials in selection of most influential squeeze cast process parameters. This will reduce time and cost of trial experimentations. The results showed that, all the developed models can be effectively used for making prediction. Further, the present research work will help foundrymen to select parameters in squeeze casting to obtain the desired quality casting without much of time and resource consuming.

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Journal articles on the topic 'Casting process selection'

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