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Journal articles on the topic 'Die casting operating parameters'
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1
Chechukha, V. I., and M. A. Sadokha. "Defects in castings during high‑pressure casting and measures to prevent their formation." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 1 (April 10, 2024): 26–31. http://dx.doi.org/10.21122/1683-6065-2024-1-26-31.
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The article presents a list of defects in castings formed during high‑pressure casting. It has been established that each cause that creates conditions for the formation of specific defects in castings is interconnected with the incorrect setting of specific casting technological parameters. Measures to prevent the formation of defects have been determined depending on the casting technological parameters, operating modes of the mold, application of release lubricant, and alloy preparation. To ensure high quality of produced castings, it is necessary to minimize the influence of the human factor during the casting process. This can be achieved by using modern foundry equipment, high‑quality charge and auxiliary materials, and by applying automated high‑pressure casting complexes in serial and mass production.
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Mäsiar, H., L. Repka, P. Lipták, and O. Híreš. "Investigate the Possibility of Tekcast Methods Used for Casting Polymeric Resin Materials." Archives of Foundry Engineering 14, no. 2 (2014): 119–22. http://dx.doi.org/10.2478/afe-2014-0049.
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Abstract Contribution gives an overview of knowledge about the method of centrifugal casting with orientate on Tekcast system. Company Tekcast Industries has developed a device for centrifugal casting, extending the area of production of castings or prototyping of metal or plastic. Materials suitable for the centrifugal casting with flexible operating parameters may include non-ferrous metal alloy based on zinc or aluminum or non-metallic materials such as polyester resins, polyurethane resins, epoxy resins, waxes and the like. The casting process is particularly suitable for a wide range of commercial castings and decorative objects.
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Doos, Qasim M., and Ihsan K. A. Al-Naimi. "INVESTIGATION OF PARAMETERS AFFECTING LOST FOAM CASTING." Journal of Engineering 15, no. 04 (2009): 4241–57. http://dx.doi.org/10.31026/j.eng.2009.04.10.
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The lost-foam casting process using expanded polystyrene foam pattern allows more complex and detailed passages to be cast directly into the part. The advantages of the lost-foam casting process involve, forms complex internal and external shapes without cores, reduces part mass with near net-shape capability, eliminates parting lines, and reduces machining operation and costs, Complex shapes with various sizes castings were produced in this technique in the foundry of the State Company for Electrical Industrials to evaluate the process. Successful complete castings were made. Many experimental works were done to further complements about fluidity parameter dealing with lost-foam casting process. Empirical linear and non-linear formulas were obtained from those experimental works to find the minimum temperature for pouring molten metal. Aluminum alloys were the material of choice for this work, due to the best combination of mechanical properties and castability, but the performance requirements and manufacturability issues will drive the choice of a specific aluminum that was aluminum-silicon alloy, which were used in this work.The macroscopic properties of the alloy depend strongly on the microstructure. Therefore, photomicrographs of microstructures of various castings with different foam pattern densities were done and made comparisons with common sand castings. Mechanical tests were conducted on the castings which produced by the common sand casting and the lost-foam casting processes. These tests include tensile, hardness, and impact. Because of using the expandable polystyrene as a pattern that gave, more gasses in the cavity of the mold during casting, so the mechanical tests show some differences between the two processes.
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Ardelean, Erika, Marius Ardelean, Florin Drăgoi, and Erika Popa. "Study on Continuous Casting of Steel by Sizes." Solid State Phenomena 188 (May 2012): 285–92. http://dx.doi.org/10.4028/www.scientific.net/ssp.188.285.
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Continuous casting of steel has gradually replaced traditional casting, due to many advantages such as: casting to a close form to the finished product, low steel losses, the possibility of sequential casting of steel, high productivity, quality of continuously cast product. To benefit of all these advantages, the continuous casting machine must be flexible relative to the demands of customers. This paper presents a comparative analysis relative to main parameters of steel continuous casting for more type of semi-finished product, by processing of data collected from a continuous casting plant with five casting wires. From this study, can be pointed reliable conclusions relatively to the correlation of casting factors and the operating parameters for casting machine and with quality indicators for semi-finished continuous casting product.
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Gavariev, R. V., and I. A. Savin. "Improvement of Surface Quality of Casting Produced by Casting under Pressure." Solid State Phenomena 265 (September 2017): 988–93. http://dx.doi.org/10.4028/www.scientific.net/ssp.265.988.
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The article considers the surface roughness of compression molds castings received by casting under pressure depending on the condition of the form-building surface. The technological process of casting under pressure is presented for the "Strike plate" product, concrete technological parameters values are specified. The pilot studies of the roughness of the castings throughout the entire period of operation of a compression mold are conducted. Based on the received values the recommendations about improvement of quality of a surface of castings by drawing sheetings are submitted by phisical vapour deposition method.
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Pandit, Harshwardhan, and Anand Deshpande. "Investigations into the Mould Variability of Process Parameters in Green Sand Moulds for Mould Characterization in the Casting Process." E3S Web of Conferences 430 (2023): 01244. http://dx.doi.org/10.1051/e3sconf/202343001244.
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In this study, the time-temperature behaviour of selected process parameters is established. The paper describes a new approach to understanding the defect generation phenomena in castings by considering the uniqueness of individual green sand moulds. It also explains the changing values of process parameters by experimental investigation. Foundry is the science of experiments. The aim is to achieve the right quality, quantity, and cost with minimum rejections. The casting quality results from several interconnected, dynamic, and complicated processes that are part of a foundry operation. Quality castings are produced by exercising proper control over several process parameters involved in the casting process. Despite taking several control measures regarding proper casting design, methoding and processing, casting defects are still observed. Defect reduction continues to be the primary goal in sand casting foundries due to the same. This paper investigates the essential parameters of the Green Sand casting process for understanding the influence over the generation of the casting defect in green sand moulding grey cast iron components. This study also adopts the time series method of recording the process parameters and finding the values of process parameter sets for individual moulds. The results showed a systematic predictive behaviour of the selected process parameters. By recording the process parameters under given conditions, it is found that they are time and temperature-dependent. Values can be obtained by building regression equations. It has been found that values of per cent moisture and green compressive strength reduce, whereas permeability and mould hardness increase.
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Łatas, Waldemar, Rafał Dańko, and Przemysław Czapla. "Application of 3-D Drucker–Prager Material Model to Determine Optimal Operating Parameters of Centrifugal Regeneration Device." Materials 13, no. 9 (2020): 2134. http://dx.doi.org/10.3390/ma13092134.
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The process of metal casting indisposable sand molds is associated with the generation of large amounts of waste, mainly used molding and core sands, from which the molds and cores reproducing the external and internal shapes of the castings were made. It is estimated that about 600 kg of waste can come from the production of 1 ton of casting. The main component of the waste is quartz matrix, which after undergoing appropriate reclamation treatments can be recovered and reused in the production process. This article presents the theoretical foundations regarding the existing methods of quartz matrix recovery and an experimentally justified model of the regeneration process occurring in one of the varieties used in the practice of mechanical regenerators. The goal is to improve the quality of regenerated molding sand by means of liberating the sand grain’s surface from the layer of the used binding component. The elastic-plastic material model characterized by the Drucker–Prager yield criterion was used to describe the deformation of the sand layer during treatment performed in a centrifugal regenerator. Conclusions based on the results of numerical calculations, obtained with the use of the software adopting the material point method, enable us to find out how to control the device in a way that ensures a permanent reclamation effect which is independent of the working components that wear out over time.
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Yu, Wenda, Defang Zou, Dong Li, Qingyuan Wang, and Peng Peng. "Development of Models Relating Screw Conveying Capacity of Concrete to Operating Parameters and Their Use in Conveyor Operating Strategies to Consider Batch Production." Applied Sciences 14, no. 14 (2024): 6351. http://dx.doi.org/10.3390/app14146351.
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The screw conveyor is the key equipment used to realize the casting and forming of concrete in prefabricated components (PC), and its performance affects the PC shape, quality, and cost. In batch production, there is a process variable, the residence time. It is affected by the quality of the downstream vibration process. This also results in operating parameters that are difficult to match to the time scales. Eventually, it can lead to problems such as low casting efficiency or poor molded quality. In this paper, the DEM simulation method is used to explain and quantify the relationship between the screw conveying capacity and three important operating parameters: the screw’s outer diameter, residence time, and screw speed. The axial and radial velocity vectors are used as features to analyze the changing rule of particle motion trajectory and mass flow rate. Based on the simulation data, the operating parameters and the mass flow rate are forward-fitted to establish the prediction model of the screw conveying capacity. In addition, the residence time is backward fitted from the screw speed and mass flow rate. It is used to estimate the concrete workability. Furthermore, the fitted forward and backward models explore how to propose feasible operational strategies to achieve automatic discharge during batch production.
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Banganayi, Farai Chrispen, Didier Kasongo Nyembwe, and Hartmut Polzin. "Optimisation of an Environmentally Friendly Foundry Inorganic Binder Core Making Process for the Replacement of an Organic Binder." MRS Advances 5, no. 25 (2020): 1323–30. http://dx.doi.org/10.1557/adv.2020.225.
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ABSTRACTThere is a need to introduce modern sand binder systems in the South African foundry industry as a means of improving its competiveness through the reduction of scrap castings and compliance to environmental regulations. According to the Industrial Policy Action Plan (IPAP). The foundry industry will play an important role with regards to the economic infrastructure priority advocated in the National Development Plan (NDP) of South Africa. In this study, a new generation water glass binder is introduced in a local foundry for production of cores for export plumbing casting production. The new water glass introduced is unique in that it contains an inorganic breakdown agent. The core making operating parameters including binder content, temperature and cycle time are optimised through core making trials without any alterations on the coremaking machines. Production data was evaluated using an optimization feature of Microsoft excel software. The results provided a set of optimum operating variables to manufacture 80-100% good quality sand cores for casting applications with an environmentally friendly binder. The most favourable binder content is above 2.60%.The most favourable operating temperature range is 160-174 0C. Therefore temperature and related energy costs can be reduced. The shortfall is reduction in cycle time.
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Kalitaev, A. N., V. D. Tutarova, and A. N. Shapovalov. "Effect of Continuous Casting Parameters on Quality of Billets Manufactured by UMMC Steel LLC." Solid State Phenomena 265 (September 2017): 952–61. http://dx.doi.org/10.4028/www.scientific.net/ssp.265.952.
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The analysis of the production records on casting 150õ150mm billets at UMMC Steel LLC has made it possible to define the basic factors worsening the billet quality and increasing the rejection of the rolled materials: steel casting in case the sulfur and phosphorus content exceeds 0.015 % and overheat is more than 30°Ñ. In order to minimize the formation of local nonuniformity in the billets manufactured from low carbon and medium carbon steel, open cast by CCM, it is necessary to maintain a maximum [Mn]:[S] ratio with [Mn]:[Si] ratio at the level less than 2-3, which ensures the formation of fusible deoxidation products and prevents the formation of solid conglomerates in steel. In order to reduce the formation of axial porosity it is advisable to retain the carbon content at the lower limit for the steel grade and avoid overheating of steel above the specified values. In order to minimize the consequences of the overheated steel casting it is necessary to adjust the billet casting rate in accordance with the operating procedures.
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Peti, Ferencz, and Gabriela Strnad. "The Effect of Squeeze Pin Dimension and Operational Parameters on Material Homogenity of Aluminium High Pressure Die Cast Parts." Acta Marisiensis. Seria Technologica 16, no. 2 (2019): 7–12. http://dx.doi.org/10.2478/amset-2019-0010.
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Abstract The present paper is an experimental study on the squeeze pin effect on the high pressure die cast aluminium parts, as a way of improvement of material homogenity on various and big wall thickness castings. Squeeze is used in high pressure die casting technology for optimizing homogenity of big wall thicknesses of die cast parts working as structural, mechanical and hydraulic components, made of different aluminium alloys such AlSi alloys. The objective of this research is to highlight the primary and secondary effects of squeezing on the structural homogenity of high pressure die cast aluminium parts, as well as the dependence of the effects on the squeeze pin dimensions and the operating parameters.
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Binczyk, Franciszek. "Solidification Process, Microstructure, Density and Hardness of the Mg-Al Alloys with Zn, Cu, Ni and AlTiB Additions." Solid State Phenomena 176 (June 2011): 91–98. http://dx.doi.org/10.4028/www.scientific.net/ssp.176.91.
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The paper presents the results of the investigations of the solidification process of magnesium alloys containing 5 and 10 wt.% Al, the additions of Zn, Cu, Ni, and of an AlTiB master alloy. The plotted DTA (derivative thermal analysis) curves were used for the determination of solidification parameters Tliq, Teut and Tsol. Knowledge of these parameters is very important in determination of alloy pouring temperature and maximum casting operating temperature. On samples taken from the area of temperature measurements, the chemical composition and microstructure were determined. The density and hardness HB were measured as well. Applying the method of multiple regression analysis at the significance level α = 0.1, the intensity and direction of the effect of alloying elements on the solidification parameters, density and hardness HB of castings were evaluated.
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Gašpár, Štefan, Ján Majerník, and Jan Kolínský. "Analysis of Causes of Porosity Change of Castings under the Influence of Variable Biscuit Height in the Filling Chamber." Materials 14, no. 22 (2021): 6827. http://dx.doi.org/10.3390/ma14226827.
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Quality properties of castings produced in a die casting process correlate with porosity that is conditioned by a number of factors, which range from input melt quality to setup of technological factors of the die casting, and through structural design of the gating system. One of the primary parameters conditioning the inner soundness of the casting is the liquid metal dose per single operation of die casting. This paper examines the issue of metal dose. The experiments are performed with casting a gate system of an electromotor flange. The gating system examined was die cast with a variable volume of metal dose per single operation. The metal dose was adjusted to reach the height of a biscuit of 10, 20, and 30 mm. The examination of the inner homogeneity of the castings of the individual variants of gating systems with variable height of the biscuit proved that decreasing biscuit height results in an increase of porosity share in the casting volume. The programme MagmaSoft 5.4 revealed the main causes of changes in porosity share. The simulations detected that the change in biscuit height and volume of liquid metal directly influence thermal conditions of the melt in the filling chamber, and in the mould by means of the period in which the holding pressure action is influenced. Simultaneously, the melt flow mode in the sprues and gas entrapment in the melt volume are affected as well. Correlation of the factors consequently influences the final porosity of castings.
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Czekaj, E., J. Zych, Z. Kwak, and A. Garbacz-Klempka. "Quality Index of the AlSi7Mg0.3 Aluminium Casting Alloy Depending on the Heat Treatment Parameters." Archives of Foundry Engineering 16, no. 3 (2016): 25–28. http://dx.doi.org/10.1515/afe-2016-0043.
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Abstract Issues connected with high quality casting alloys are important for responsible construction elements working in hard conditions. Traditionally, the quality of aluminium casting alloy refers to such microstructure properties as the presence of inclusions and intermetallic phases or porosity. At present, in most cases, Quality index refers to the level of mechanical properties – especially strength parameters, e.g.: UTS, YS, HB, E (Young’s Modulus), K1c (stress intensity factor). Quality indexes are often presented as a function of density. However, generally it is known, that operating durability of construction elements depends both on the strength and plastic of the material. Therefore, for several years now, in specialist literature, the concept of quality index (QI) was present, combines these two important qualities of construction material. The work presents the results of QI research for casting hypoeutectic silumin type EN AC-42100 (EN AC-AlSi7Mg0.3), depending on different variants of heat treatment, including jet cooling during solution treatment.
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Furu, Trond, and Idar Kjetil Steen. "Hydro Casthouse Reference Centre." Materials Science Forum 630 (October 2009): 9–16. http://dx.doi.org/10.4028/www.scientific.net/msf.630.9.
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Since October 2006 the Hydro Casthouse Reference Centre has been operating. The centre is a full scale state of the art pilot casting centre for extrusion ingot, sheet ingot and foundry alloys, consisting of a 17Mtons furnace with a metal loop, a launder system including modular in-line melt treatment units such as ceramic foam filters (CFF) and inline melt refining units (Hycast SIR) and a casting pit with the possibility to cast full size geometries and a casting length of 5.5m. A two strand horizontal casting machine further adds the possibility of continuous casting of extrusion ingot and foundry alloy ingot. The centre has a state of the art superior control system (SCS) and a lay-out, including control room facilities, well suited for training and demonstration purposes. In addition the centre has access to state of the art software codes for simulating the casting process (Alsim) and the as cast microstructure (Alstruc). The present paper gives some examples on how the centre is operating and the support that is offered to casthouses in Hydro. This includes (i) simulation of the casting processes (hot tearing and as cast structures) applying the Alsim and Alstruc codes, (ii) pilot scale testing of casting and melt treatment equipment, (iii) testing of new parameters and procedures for melt treatment and casting (iv) production of trial orders of new alloys and (v) practical training of casthouse operators (basic for molten metal handling, emergency situations and response, casting principles and trouble shooting, etc.).
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Huang, Pei-Hsing, Jenn-Kun Kuo, Te-Hua Fang, and Wei-ren Wu. "Numerical simulation and design of casting system for stainless steel exhaust manifold." MATEC Web of Conferences 185 (2018): 00008. http://dx.doi.org/10.1051/matecconf/201818500008.
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During operation, exhaust manifolds must bear the corrosion of high temperatures and repeated stress, which can easily lead to cavitation, corrosion, and creeping damage in the casting structure and affect product safety. To improve the structure of exhaust manifolds and increase their service life, we employed AnyCasting mold flow analysis to SUS304 stainless steel exhaust manifolds. We examined the influence of casting system design and process parameters such as ceramic shell temperature, casting temperature, and pouring speed on the filling and solidification processes of the liquid metal. Finally, we used the Niyama criterion to predict the probability and distribution of shrinkage porosity defects in the exhaust manifold and made improvements to enhance the quality of exhaust manifold castings. Keywords: exhaust manifold, mold flow analysis, casting system.
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ZHUMADILOVA, Z. O., S. T. KALDYBAYEVA, G. Zh NURULDAEVA, and D. B. KUMAR. "STUDY OF THE THERMOPHYSICAL AND PHYSICAL - MECHANICAL PROPERTIES OF HIGH-ALLOYED ALUMINUM CAST IRON CHYU22SH." Periódico Tchê Química 16, no. 33 (2019): 30–40. http://dx.doi.org/10.52571/ptq.v16.n33.2019.45_periodico33_pgs_30_40.pdf.
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Highly alloyed alloys, in which expensive chromium and nickel are alloying elements, are widely used as heat-resistant materials. Their total content in heat-resistant alloys reaches 30% or more. However, the life of working parts made of heat-resistant alloys is limited. Moreover, the higher the operating temperature, the shorter it is. This leads to increased costs for maintaining the units in working condition. Examples of such parts are the grate of agglomeration machines, details of boiler plants, roasting, heating, and glass melting furnaces, casting molds, exhaust manifolds of forced automobile engines, etc. In this regard, reducing the cost of heatresistant products, while maintaining their operating characteristics and life, becomes very actuality. One of the promising options to solve it is to manufacture these parts made of high-alloyed heat-resistant aluminum cast iron CHYU22SH (CHYU22SH - standard cast iron). Castings made of cast iron CHYU22SH differ, first of all, by being heat resistance at high temperatures in air (up to 1100°C) and in media containing sulfur, sulfur dioxide, oxides of vanadium, and water vapor. In addition, they can functionally operate as a wear-resistant product having high strength at normal and elevated temperatures. The paper presents the thermal and mechanical properties of casting, as well as the results of microstructure analysis of aluminum cast irons. The results of analyses and tests show that cast iron CHYU22SH can be obtained by casting with long walls of a thickness of 4 mm without external and internal defects. By doing so the castings have a uniform structure, high and stable mechanical properties, as well as lower by ~17-24% weight than similar cast of gray iron. The results of experimental - industrial testing laboratory studies confirm the influence of solidification conditions on the parameters of the structure of cast iron CHYU22SH.
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Xu, Lin, Meiling Tang, Ze Lyu, Nan Li, Cong Liu, and Qunwu Pei. "Influence of operating parameters on metal flow and thermal characteristics in an EMBr-single-ruler controlled CSP funnel-shaped mould." Metallurgical Research & Technology 121, no. 3 (2024): 316. http://dx.doi.org/10.1051/metal/2024036.
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Electro-magnetic brake (EMBr), as a necessary technique to adjust the metal flow within the mould, has been extensively applied in the continuous casting (CC) production. The EMBr technique, if appropriately applied, can take the benefit of braking effect to weaken jet impingement effect, suppress fluid disturbance and stabilize surface fluctuation. As a result, to obtain a reasonable flow pattern within the CC mould, the braking performance of EMBr technique needs to be flexibly adjusted according to the variation of operational parameters. In this article, to obtain a braking performance of a commonly used EMBr-single-ruler technique within an optimal range, the effect of operating parameters on the metal liquid flow and thermal characteristics in a compact strip production (CSP) thin slab mould is described through a 3-D mathematical modeling of multi-physical field coupling. The results illustrate that the braking performance of the EMBr-single-ruler device is weakened with the increase of the casting speed or the mould width. For the effect of the casting speed and mould width on the metal flow with the application of an EMBr device, an optimum braking performance of the EMBr-single-ruler device can be obtained under the matching parameters of a magnetic induction intensity of 0.30 T and a casting speed of 4.5 m ∙ min‒1 together with a mould width of 1500 mm. Relative to the absence of the EMBr-single-ruler device, the maximum surface fluctuation height is controlled at 6.2 mm, and the mean surface temperature is raised to 1803.6 K. Based on these findings, we conclude that the proper utilization of the EMBr-single-ruler device can avoid the entrainment of flux powder and improve the melting performance of flux powder.
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Pribylov, A. V., Yu P. Shapovalov, and E. M. Glushen. "Experience in the use of absorption and biochemical installations for cleaning ventilation emissions in foundry production." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 2 (July 9, 2021): 105–8. http://dx.doi.org/10.21122/1683-6065-2021-2-105-108.
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The relevance of the use of gas cleaning equipment in foundry production is considered. Examples are given of equipping the casting, cooling and knocking areas of molds and rods manufactured according to ALFASET and Cold-box-amin processes with absorption-biochemical installations (ABCHI) for cleaning the ventilation air from pollutants. The technical and economic parameters of the ABCHI operation are considered. The list of the enterprises successfully operating ABHI is given. The advantages of using ABCHI in comparison with alternative methods are considered.
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Doridot, Emiliane, Stéphane Hans, Alain Jardy, and Jean-Pierre Bellot. "Industrial applications of modelling tools to simulate the PAMCHR casting and VAR process for Ti64." MATEC Web of Conferences 321 (2020): 10011. http://dx.doi.org/10.1051/matecconf/202032110011.
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The PAMCHR (Plasma Arc Melting Cold Hearth Refining) process followed by a VAR (Vacuum Arc Remelting) melting is used to recycle Ti64 scrap for aeronautical applications. The produced ingot quality is linked to the quality of charging materials and to numerous operating parameters. Ecotitanium (a company created by UKAD, a joint-venture between Aubert & Duval and UKTMP, ADEME and Crédit Agricole Centre France) launched a program with the Institut Jean Lamour dedicated to the development of specific modelling tools in order to get a better understanding of operating parameters effect on the final ingot quality. A model of the PAMCHR casting was developed and used to describe the heat transfer, liquid metal flow and alloying elements behavior during mixing in the liquid pool followed by segregation during solidification. The effect of PAMCHR electrode composition on the final VAR ingot composition is also studied using the SOLAR VAR model. Model validation by comparison with industrial ingots is presented with some examples of operating parameters sensitivity study.
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Pastirčák, R., J. Ščury, and J. Moravec. "The Effects of Pressure During the Crystallization on Properties of the AlSi12 Alloy." Archives of Foundry Engineering 17, no. 3 (2017): 103–6. http://dx.doi.org/10.1515/afe-2017-0099.
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Abstract The paper deals with the impact of technological parameters on the mechanical properties and microstructure in AlSi12 alloy using squeeze casting technology. The casting with crystallization under pressure was used, specifically direct squeeze casting method. The goal was to affect crystallization by pressure with a value 100 and 150 MPa. From the experiments we can conclude that operating pressure of 100 MPa is sufficient to influence the structural characteristics of the alloy AlSi12. The change in cooling rate influences the morphology of the silicon particles and intermetallic phases. A change of excluded needles to a rod-shaped geometries with significantly shorter length occurs when used gravity casting method. At a pressure of 100 MPa was increased of tensile strength on average of 20%. At a pressure of 150 MPa was increased of tensile strength on average of 30%. During the experiment it was also observed, that increasing difference between the casting temperature and the mold temperature leads to increase of mechanical properties.
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Liu, Yu, Yuanpeng Tian, Xudong Wang, and Yali Gao. "Influence of processing parameters on slab stickers during continuous casting." High Temperature Materials and Processes 39, no. 1 (2020): 228–35. http://dx.doi.org/10.1515/htmp-2020-0065.
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AbstractIn this study, the parameters of 44 sticker breakout samples were analysed. The research mainly focused on the steel grades and slab thickness of stickers. Other processing parameters, such as slab width, casting speed, mould fluctuation, heat flux and operation, were also discussed. The results show that the number of stickers of low carbon steel and low alloy steel was 16 and 28, respectively. The stickers of low carbon steel were less than those of low alloy steel regardless of the thickness and width. The ratio of stickers per 1,000 casting heats of 220, 260 and 320 mm thickness slabs was 2.5, 0.5 and 0.6, respectively. The higher casting speed of 220 mm thickness slabs made the casting status unsteady and caused more stickers. From the perspective of width, the stickers were gradually increased along with the increase in width due to the worse mould slag. This study provides a foundation to reduce slab stickers and is helpful for a more efficient technology of continuous casting.
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Scharf, Stefan, Niklas Bergedieck, Eric Riedel, Hans Richter, and Norbert Stein. "Unlocking Sustainability Potentials in Heat Treatment Processes." Sustainability 12, no. 16 (2020): 6457. http://dx.doi.org/10.3390/su12166457.
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Energy consumption, greenhouse gas emissions, environmental impact levels, and the availability of materials as well as their sustainable usage are all topics of high current interest. The energy intensive processes of casting production such as heat treatment are particularly affected by the pursuit of sustainability. It has been estimated that up to 20% of the total energy demand in a non-ferrous foundry is required to provide the heat energy necessary during heat treatment processes. This paper addresses the application-oriented development of a sustainable configuration of the heat treatment process at the example of the aluminium-casting alloy A356 (AlSi7Mg0.3). Based on calculations of the physically necessary operating modes and under investigation of previous parameter recommendations, experimental studies were carried out to investigate the effects of various heat treatment parameters on the ultimate mechanical properties of the alloy. Since the achievable mechanical properties of the finished casting are decisive, the static and dynamic casting properties resulting from the heat treatment with optimized process parameters were compared with those of conventional process control. Significant optimization potential is shown for reducing the treatment time and thus lowering the energy consumption.
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Dúl, Jenő, Zsolt Leskó, and Borbála Juhász. "Effect of the Technological Parameters on the Thermal Conditions of Die-Casting Tool." Materials Science Forum 752 (March 2013): 183–92. http://dx.doi.org/10.4028/www.scientific.net/msf.752.183.
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The heat balance of a casting cycle can be ensured in short times by the annealing of the die-casting tool, by which the well-constructed and well-functioned cooling system can enhance productivity. Incorrect cooling, however, can lead to heat unbalance in the die casting tool, thus causing the destruction of casting quality, reduction of the lifetime of die casting tool and irreversible production-reduction. Beside the theoretical examination of construction and function of cooling system, the evaluation of the effectively removed heat quantities has great importance. The paper presents an analysis of the function of the cooling system of a scraggy thin casting of AlSi9Cu3 alloy, in case of different cooling parameters. Based on the measured results of the inlet and outlet temperatures and the volume flow of the cooling agents, the heat quantities belonging to the cooling circles are determined and an optimization of the cooling system is proposed. The findings of the analysis can be utilized for the construction and optimum operation of die-casting cooling systems.
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Roy, Snehangshu, R. K. Singh, Kiran Kumar Keshari, et al. "Reduction in Surface Defect in Continuous Cast Slab through Intervention in Process Parameters." Materials Science Forum 978 (February 2020): 91–96. http://dx.doi.org/10.4028/www.scientific.net/msf.978.91.
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Occurrence of defects like crack on the surface of the cast products has long been recognized as a critical challenge for steelmakers in the continuous casting. Cracks on the surface can severely reduce yield and required further operations like salvage and scarfing. Depending on the severity of defect slabs can be diverted or in worst cases a slab can be rejected altogether if the defect cannot be removed by surface conditioning. Rourkela Steel Plant (RSP) of Steel Authority of India Limited (SAIL) produces continuously cast slabs as feed material for plate mills and hot strip mill. Sometimes the slabs produced through continuous casting are faced issues intermittently due to presence surface defects like midface longitudinal cracks (LC) and transverse edge crack (EC) etc. A systematic investigation of the operating parameters of these casters e.g. monitoring of oscillation parameters, slabs and mould flux, simulation and analysis of fluid flow inside mould, steel chemistry and role of dissolve gases in steel. Based on the investigation critical parameters responsible for crack formation have been identified and key areas identified where modification need to be done. Modifications has been done in terms of mould flux addition practice, optimization of the grade chemistry, optimization of process route, optimization of casting speed, checking of strand thermal profile, mould & machine allignment etc. It was observed that the crack incidences are significantly lower after the modifications were done.
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Dai, Wei, Li Bing Fu, and Wei Zhang. "A Constructed PQ2 Chart for Calculating the Optimized Process Parameters in Die Casting of Aluminum Alloy." Advanced Materials Research 998-999 (July 2014): 518–21. http://dx.doi.org/10.4028/www.scientific.net/amr.998-999.518.
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According to the elementary principle of fluid dynamics, the process of die casting formation of the machine line, die line, optimized operating point is discussed in this paper. Use Access to link the data with functions for each part of these, fix them together in a PQ2 chart, form a production window which could be used in all aluminum alloy achieved is illustrated in this paper.
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Larouche, André, Malcom Lane, Massimo DiCiano, Daan M. Maijer, Steve CockCroft, and Roger Thiffault. "Understanding T-Ingot Horizontal DC Casting Using Process Modelling." Materials Science Forum 519-521 (July 2006): 1461–66. http://dx.doi.org/10.4028/www.scientific.net/msf.519-521.1461.
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Horizontal continuous casting process has been successfully implemented in Alcan for the production of T-ingots of primary aluminium and foundry alloys. Ability to achieve increased productivity targets and reduce production costs relies on a fundamental understanding of key process characteristics and operating parameters. Thanks to the long-standing experience in vertical DC Casting, numerical modelling appeared as a powerful approach to understand phenomena related to metal flow, solidification and ultimately defect formation. As part of a collaborative R&D program, a global model of horizontal casting process, integrating specialized sub-models on critical aspects of the process such as meniscus dynamics, is being developed. Experimental characterization of primary and secondary cooling is performed in parallel with modelling work to provide the information necessary to properly characterize mould heat transfer. This paper will present the development of a 3D process model of T-ingot casting along with its application to solve specific process challenges that have emerged during the first years of production in the plant.
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Panwar, N., S. Bala, and A. Chauhan. "Performance optimization of operating parameters: Al 6061-Red Mud composite under sliding wear." IOP Conference Series: Materials Science and Engineering 1225, no. 1 (2022): 012007. http://dx.doi.org/10.1088/1757-899x/1225/1/012007.
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Abstract Aluminium 6061-red mud composite has been fabricated by using stir casting method. Uniform distribution of red-mud particles has been observed by Scanning electron microscopy. Energy dispersive spectroscopy confirms presence of constituent elements of red mud. Wear testing of samples has been done on pin-on-disk type wear tester. The weight loss due to wear first decrease then increase with increasing percentage reinforcement. From experimentation, authors have found that the weight loss first decreases and then increase with aging time. Also, weight loss increases with applied load, sliding speed and sliding distance. In ANOVA analysis, the variables: load and sliding distance are found significant while particle size, aging time, percentage reinforcement and sliding velocity are not found significant. The order of significance is load, sliding distance, percentage reinforcement, sliding speed, aging time and particle size. Optimum value of weight loss is predicted by using Taguchi technique and confirmed by experimentally obtained results.
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Chang, Xing Yang, Qi Shen, Wen Xue Fan, and Hai Hao. "Optimization of Magnesium Alloy Casting Process: An Integrated Computational Materials Engineering (ICME) Approach." Materials Science Forum 1035 (June 22, 2021): 808–12. http://dx.doi.org/10.4028/www.scientific.net/msf.1035.808.
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Traditional casting process optimization usually adopts empirical trial and error method. Process parameters were modified repeatedly within a certain range until a satisfactory solution is obtained, which is costly and inefficient. Therefore, based on integrated computational materials engineering, Magnesium Alloy Simulation Integrated Platform (MASIP) was constructed. MASIP completed the automatic operation of the entire simulation process from the CAD model data input to the process-microstructure-performance. It realized the rapid optimization simulation prediction of process-microstructure-performance, and solved the problems of long cycle and low efficiency of traditional process optimization. This paper studied the low-pressure casting optimization process of magnesium alloy thin-walled cylindrical parts based on MASIP. The calculation took casting temperature, mold temperature and holding pressure as the optimized variables, and the yield strength of the casting as the target variable. The experimental results showed that MASIP can fairly complete the structure simulation and performance prediction of castings, greatly reduce the time cost of the calculation process, and improve the efficiency of process optimization.
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Zhang, Tao, Jian Yang, Gang-jun Xu, Hong-jun Liu, Jun-jun Zhou, and Wei Qin. "Effects of operating parameters on the flow field in slab continuous casting molds with narrow widths." International Journal of Minerals, Metallurgy and Materials 28, no. 2 (2021): 238–48. http://dx.doi.org/10.1007/s12613-020-1988-1.
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Anisiuba, Vitalis, Haibo Ma, Armin Silaen, and Chenn Zhou. "Computational Studies of Air-Mist Spray Cooling in Continuous Casting." Energies 14, no. 21 (2021): 7339. http://dx.doi.org/10.3390/en14217339.
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Due to the significant reduction in water droplet size caused by the strong air-water interaction in the spray nozzle, air-mist spray is one of the promising technologies for achieving high-rate heat transfer. This study numerically analyzed air-mist spray produced by a flat-fan atomizer using three-dimensional computational fluid dynamics simulations, and a multivariable linear regression was used to develop a correlation to predict the heat transfer coefficient using the casting operating conditions such as air-pressure, water flow rate, casting speed, and standoff distance. A four-step simulation approach was used to simulate the air-mist spray cooling capturing the turbulence and mixing of the two fluids in the nozzle, droplet formation, droplet transport and impingement heat transfer. Validations were made on the droplet size and on the VOF-DPM model which were in good agreement with experimental results. A 33% increase in air pressure increases the lumped HTC by 3.09 ± 2.07% depending on the other casting parameters while an 85% increase in water flow rate reduces the lumped HTC by 4.61 ± 2.57%. For casting speed, a 6.5% decrease in casting speed results in a 1.78 ± 1.42% increase in the lumped HTC. The results from this study would provide useful information in the continuous casting operations and optimization.
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Pastirčák, Richard, and Denis Martinec. "Simulation Fluidity Test for Semisolid Squeeze Casting." MATEC Web of Conferences 328 (2020): 02006. http://dx.doi.org/10.1051/matecconf/202032802006.
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The paper deals with semi solid squeeze casting technology. Fluidity tests were designed for the selected technology. The shape of the test casting was designed in the shape of test bars with different thicknesses and also in the shape of a stepped casting. The thickness of the individual elements was chosen on the basis of a selected / preferred numbers R10 EN STN 17. As a result, the thickness of the elements was 2.0, 2.5, 3.15, 4.0, 5.0 and 6.3 mm. Designed fluidity tests were verified by using ProCast simulation software. The selected process parameters were: operating pressure 80 MPa, mold temperature 200 °C, piston speed 30 mm.s-1. The experimental material was an AlSi7Mg0.3 alloy with a different solid phase content. The initial solid amount were 50, 55 and 60 %. The effect of solidus and liquidus, temperature distribution and pressure was monitored during the evaluation of fluidity.
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Berezovskiy, Alexander V., Michael P. Shalimov, and Ekaterina B. Votinova. "The Repair of Defects in High-Manganese Steel Castings by Welding Technology." Defect and Diffusion Forum 410 (August 17, 2021): 209–14. http://dx.doi.org/10.4028/www.scientific.net/ddf.410.209.
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Welding technologies are used to repair defects in cast parts of high - manganese austenitic steel (Hadfield steel). These include repair welding for newly manufactured castings, welding the formed defects in the old operating cast parts and, finally, for cladding layer of wear-resistant metal on the surface of the cast parts. Manual metal arc welding (MMAW) are used as often as gas metal arc welding (GMAW) and of flux-core wire welding (FCAW-S). These welding processes make possible to obtain a weld metal with the expected quality of the restored surface and a slight distortion of the base metal structure. The article presents methods of the casting repair by welding and surfacing. The parameters of welding and surfacing procedures are given, welding materials are recommended, and the methods for nondestructive testing of welds are prescribed.
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Han, Zhan Guang, and Jia Quan Zhang. "An Advanced Dynamic Secondary Cooling Control Model for Bloom Castings." Advanced Materials Research 154-155 (October 2010): 171–78. http://dx.doi.org/10.4028/www.scientific.net/amr.154-155.171.
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For bloom casting, typical quality defects such as midway crack usually occur upon improper cooling control during non-steady casting conditions specially for the production specialty steels,. A key measure to eliminate the defects formation has been presented by the adoption of more sophisticated secondary cooling strategies to balance the surface reheating due to casting speed fluctuation. With the consideration of the complex casting conditions and the characteristics of bloom casters, a dynamic control model for the secondary cooling has been developed in the paper to obtain a reasonable temperature profile and solidification progress for the bloom casting process, which is based on a slice residence time method combined with a multi-level control strategy. The feedback system, based on the difference between the calculated surface temperatures and the predetermined or measured surface temperatures, has been integrated into two-dimensional thermal model. The interlocking protection system between level-1 and level-2 is included in the model together with the data diagnosis and processing. Furthermore, the control model also offers technological interface for the introduction of new steel grades in production and the related modification to the secondary cooling parameters. It is shown from online application that the dynamic control system of secondary cooling for bloom casting is robust during operation and adaptable to any change of real casting conditions. Sound quality bloom castings according to acid etched tests have been obtained from the caster accordingly.
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Kulikov, Vitaliy, Shynggys Baibekov, Kvon Svetlana, Aristotel Issagulov, and Pavel Kovalev. "Investigation of the use of variable pressure in the formation of sand-resin casting moulds." Acta Metallurgica Slovaca 31, no. 1 (2025): 16–21. https://doi.org/10.36547/ams.31.1.2128.
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Consumer demand increases the efficiency of the operation of cast parts of various equipment, necessitating the development of new technological processes for manufacturing castings. One of the important tasks currently facing the foundry is to increase the purity of the surface of castings and reduce defects due to casting defects. Such properties are possessed by castings obtained by casting into shell molds. Sand-resin mixtures are used for their manufacture. Molds from such mixtures allow the obtaining of high-quality castings from various alloys. The relatively high cost of a pulverbakelite binder prevents its widespread use in industry. In this regard, research aimed at improving the technological processes for manufacturing durable sand-resin moulds while reducing the binder content in the mixture without compromising other parameters is relevant. The disadvantage of the available technological modes of manufacturing shell moulds with the required strength is the high content of binder pulverbakelite (7-9%). Therefore, reducing the pulverbakelite content in the mixture by using the most optimal modes of shell formation, primarily variable pressure, to obtain high-quality castings of the widest range is very relevant.
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Herna´ndez, J., J. Lo´pez, and F. Faura. "Influence of Unsteady Effects on Air Venting in Pressure Die Casting." Journal of Fluids Engineering 123, no. 4 (2001): 884–92. http://dx.doi.org/10.1115/1.1412234.
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The influence of unsteady effects on the evacuation of air through vents in pressure die casting processes is analyzed. A model is proposed which considers the air flow as one-dimensional and adiabatic, and which retains friction effects. Venting conditions for wide ranges of the relevant dimensionless parameters are analyzed for both atmospheric and vacuum venting systems. The model is solved numerically using the method of characteristics and its results are compared with those obtained for quasi-steady models. It is shown that wide ranges of operating conditions can exist in practical situations, for which unsteady effects, neglected in previous models, are important and must be taken into account to determine the air mass entrapped at the end of the filling process. The selection of parameters which will reduce the amount of trapped air and thus porosity in manufactured parts is also discussed.
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Zhao, Hong Jin, Gui Huan An, Wen Feng Zeng, and Xin Luo. "Numerical Simulation on the Influence of Heated Mold Continuous Casting Process Parameters to Solid-Liquid Interface." Applied Mechanics and Materials 217-219 (November 2012): 2006–11. http://dx.doi.org/10.4028/www.scientific.net/amm.217-219.2006.
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The effect of the position and shape of solid-liquid interface on process parameters has been studied by the numerical simulation method, and the reasonable process parameters have been given. The results shows that the position and shape of solid-liquid interface is mainly affected by mold temperature, casting speed and cooling distance. It were moved to the mold export with the improvement of the mold temperature, casting speed or the reduce of cooling capacity. And the reasonable process parameters are that the mold temperature is 1363-1373 K, casting speed is 80-100mm/min, cooling distance is 40-50mm. The research results would obtain stable operation conditions and improve the billet quality.
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Corabieru, Petrică, Stefan Velicu, Anişoara Corabieru, Dan Dragos Vasilescu, and Ionel Păunescu. "Research on Combined Processing Technology of Superficial Layers Hardened Steel." Applied Mechanics and Materials 841 (June 2016): 21–28. http://dx.doi.org/10.4028/www.scientific.net/amm.841.21.
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The novelty technology lies in the fact that the hardening of the surface layers is carried out both in liquid phase and in the solid state. Technology comprises three main stages with 12 technological phases.Experimentation highlights the viability of the technological procedure. The results of tests and verifications are the basis of the analysis of combined machined parts behavior in conditions similar to the operating conditions and of the analysis of the dependence between operation behavior and durability. Analysis of the results revealed the fact that failure to technological parameters: casting temperature; hold time at high temperatures; cooling rate after microalloying in liquid phase, gives rise to possible faults of the combined treated parts.
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Pacha-Gołębiowska, H., and W. Piekarska. "Key Determinants for High-Alloyed Cast Irons for Mechanical Engineering." International Journal of Applied Mechanics and Engineering 27, no. 1 (2022): 146–67. http://dx.doi.org/10.2478/ijame-2022-0010.
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Abstract This work presents the factors determining cast iron, and particularly austenitic high-alloy cast iron as a construction material, which is ranked among the leading casting alloys of iron with carbon, mainly due to its very good service properties, which makes it dedicated as a material for automotive castings, pipe and fitting castings and components resistant to elevated temperatures, corrosion and abrasive wear. Construction materials currently used in industry have increasingly better properties and their potential is depleting quickly. This forces the manufacturers to adjust the requirements and production capabilities of cast iron using the most modern technologies that give the expected beneficial economic and operating effects. The paper quotes the results of research in the field of the offered technologies that give special surface features to machine parts made of cast iron by modernising the parameters of the technological process of obtaining high-alloy austenitic cast iron, i.e., by applying coatings, as well as by appropriate surface treatment, the aim of which is and reinforce the material surface with those properties which are important in a given application.
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Taylor, John A., and Ian F. Bainbridge. "Improved VDC Casting of Aluminium Alloys through an Understanding of the Surface Properties of the Molten Metal." Materials Science Forum 519-521 (July 2006): 1693–98. http://dx.doi.org/10.4028/www.scientific.net/msf.519-521.1693.
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Vertical direct chill (VDC) casting of aluminium alloys is a mature process that has evolved over many decades through gradual change to both equipment design and casting practice. Today, air-pressurised, continuous lubrication, hot top mould systems with advanced station automation are selected as the process of choice for producing extrusion billet. Specific sets of operating parameters are employed on these stations for each alloy and size combination to produce optimal billet quality. The designs and parameters are largely derived from past experience and accumulated know-how. Recent experimental work at the University of Queensland has concentrated on understanding the way in which the surface properties of liquid aluminium alloys, e.g., surface tension, wetting angle and oxide skin strength, influence the size and shape of the naturally-stable meniscus for a given alloy, temperature and atmosphere. The wide range of alloyand condition-dependent values measured has led to the consideration of how these properties impact the stability of the enforced molten metal meniscus within the hot top mould cavity. The actual shape and position of the enforced meniscus is controlled by parameters such as the upstream conduction distance (UCD) from sub-mould cooling and the molten metal head. The degree of deviation of this actual meniscus from the predicted stable meniscus is considered to be a key driver in surface defect formation. This paper reports on liquid alloy property results and proposes how this knowledge might be used to better design VDC mould systems and casting practices.
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Ablyaz, Timur, Vladimir Blokhin, Evgeniy Shlykov, Karim Muratov, and Ilya Osinnikov. "Manufacturing of tool electrodes with optimized configuration for copy-piercing electrical discharge machining by rapid prototyping method." Metal Working and Material Science 26, no. 4 (2024): 138–52. https://doi.org/10.17212/1994-6309-2024-26.4-138-152.
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Introduction. This paper presents the results of obtaining a complex-profile tool electrode (TE) for copy-and-pierce electrical discharge machining by casting technology. This method consists in using a master model by rapid prototyping method. The purpose of the work: experimental study of accuracy assurance in manufacturing of complex-profile TE by casting with the use of rapid prototyping technology for copy-piercing electrical discharge machining. Research Methods. The master model of TE was produced on the Envisiontec Perfactory XEDE machine using stereolithography technology. Si500 photopolymer was used as a starting material. Intermediate and final surface deviation measurements were performed on a Contura Carl Zeiss G2 CMM. Calculation of the gutter and feed system was performed in ProCast software. A casting was obtained from casting brass LC40S (Cu-40 Zn-Pb). The study of the process of copy-piercing electrical discharge machining of TE made by casting with the use of rapid prototyping technology was carried out with the help of Smart CNC copy-piercing machine in the environment of transformer oil. Operating parameters: pulse turn-on time (Ton, μs), voltage (U, V), current (I, A). Results and discussion. The methodology of design and manufacturing of complex-profile TE with application of rapid prototyping technology for copy-piercing electrical discharge machining is developed. The analysis of shape deviation shows that errors occur during the manufacturing of the master model by stereolithography. An experimental study of the shape deviation of the master model shows surface concavity in the range of 0.03 to 0.07 mm depending on the arrangement of the sides. It is shown that the optimized master model has 25 % less shape deviation. A sprue-feeding system (SFS) is developed for the fabrication of TE by casting technology. When porosity is evaluated, it is found that pores are concentrated in the SFS and riser, which positively affects the quality of the casting. Manufacturing of the tool electrode with the help of casting technology showed that all accuracy and roughness parameters are within the specified tolerance and correspond to the initial drawing data. Experimental study of the process of electroerosion machining of the profile groove of the TE manufactured by casting on the investment casting model obtained with the use of rapid prototyping technology is carried out. It is established that the dimensions of the obtained groove meet the stated requirements.
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Zaba, K., S. Nowak, M. Kwiatkowski, M. Nowosielski, P. Kita, and A. Sioma. "Application of Non-Destructive Methods to Quality Assessment of Pattern Assembly and Ceramic Mould in the Investment Casting Elements of Aircraft Engines/ Zastosowanie Nieniszczących Metod Do Oceny Jakości Woskowych Zestawów Modelowych Oraz Ceramicznych Form W Procesie Odlewania Precyzyjnego Elementów Silników Lotniczych." Archives of Metallurgy and Materials 59, no. 4 (2014): 1517–25. http://dx.doi.org/10.2478/amm-2014-0250.
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Abstract The aim of this paper is manufacturing of turbocharger engine jet blades made of nickel superalloys. Processes for producing molds and casting realized in a production line are special processes. It means that the results are known only after inspection of the finished product. There is lack of the methods and techniques of effective and efficient quality control of the work in stock, above all molds. Therefore, the unknown is the state ceramic mold for the precision casting, which resulting in risk of referral to a defective mold of the casting process and thus give the product does not comply, is eliminated in the final inspection. One method of reducing this risk is particularly thorough monitoring of all parameters of each process and keeping them in the desired operating point. Operating point is a set of parameters of processes. Such monitoring is possible with the commitment to the methods and techniques to automatically, without human intervention, data collection and processing methods appropriate for use in operational control. The paper presents results of research on the attitude to the problem of a special process. This change is the introduction to the process efficient and effective form of quality control tools in the course of its preparation. In this case, the method of photogrammetry, thermal imaging and computed tomography were used. With the infrared camera will be possible to determine the temperature field, the disorder in relation to the pattern indicates the type of defect. Computed tomography and will be used to develop patterns of correlated defects associated with thermal imagers. Photogrammetry is the use of a model set of quality control (comparison of the actual state of the model *.CAD). It also allows the designation of a wall thickness of the mold.
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Sotnik, S. V. "DEVELOPMENT OF AUTOMATED CONTROL SYSTEM FOR CONTINUOUS CASTING." Radio Electronics, Computer Science, Control, no. 2 (June 27, 2024): 181. http://dx.doi.org/10.15588/1607-3274-2024-2-18.
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Context. Today, automated continuous casting control systems are developing rapidly, as process of manufacturing billets (products) of same size from metal in casting mold in mass production has long been outdated and “continuous casting stage” is coming. This process is suitable for non-ferrous metals and steel. However, each time during development, task of improving quality of resulting billet arises, which directly depends on optimizing efficiency and reliability of automated systems themselves. Optimization is key stage in development process, as it is aimed at ensuring accuracy and stability of casting process, which includes development of parametric model and accurate algorithms that ensure optimal temperature, metal pouring rate, oscillation frequency, oscillation amplitude, metal level in crystallizer, and position of position of industrial bucket stopper for each casting stage. In particular, this problem has not yet been fully solved in literature known to authors, so it is necessary to formulate problem and develop algorithm for system operation for specific safety casting unit. Objective. The aim of study is to develop automated control system to ensure accuracy and stability of casting process. Method. The developed control system for continuous casting plant is based on proposed parametric model, which is formalized on basis of set theory. The model takes into account key parameters for particular casting process: metal pouring rate, oscillation frequency, oscillation amplitude, metal level in crystallizer, and position of industrial bucket stopper. Results. The problem was formulated and key parameters were determined, which are taken into account in system’s algorithm, which made it possible to develop control system for continuous casting plant to solve problem of improving quality of resulting billet. Conclusions. A parametric model and generalized black box model representation were created, which are necessary for both new continuous casting projects and existing units to optimize metal casting process. To set up continuous casting system, controlled parameters such as pouring speed, oscillation frequency and amplitude, metal level in crystallizer, and position of industrial bucket stopper were determined. The algorithm of control system for continuous casting plant was developed, on basis of which system was developed that allows monitoring, regulation and control of obtaining steel process or non-ferrous billets. The developed user interface of control system is simple and easy to use.
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Głuchowski, W., Z. Rdzawski, J. Sobota, and J. Domagała-Dubiel. "Effect of the Combined Heat Treatment and Severe Plastc Deformation on the Microstructure of Cunisi Alloy." Archives of Metallurgy and Materials 61, no. 2 (2016): 1207–14. http://dx.doi.org/10.1515/amm-2016-0200.
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Abstract The aim of this work was to study the microstructure and functional properties of CuNi2Si1 alloy. The material was prepared classically by melting, casting, hot rolling and cold rolling. The obtained strips were processed with combined operations of supersaturation, ageing and one of the intensive deformation method - repetitive corrugation and straightening. The efficiency of RCS operation in shaping of functional properties in precipitation hardened copper alloys depends not only on tool geometry and operating parameters but also on whether and at what stage of strip production the supersaturation operation was applied. Application of the supersaturation before RCS operation broadens the potential to shape the set of functional properties. Comparable functional properties of the precipitation hardened copper alloy strips can be reached without application of the supersaturation operation in their manufacturing processes. The process of RCS applied after annealing, and the potentially slightly lower mechanical properties would be compensated by higher electrical conductivity.
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Wang, Bingpeng, Xinyan Qin, Jin Lei, et al. "Parameter Optimization and Experimental Study of Drum with Elastic Tooth Type Loss-Reducing Picking Mechanism of Pepper Harvester." Agriculture 15, no. 6 (2025): 600. https://doi.org/10.3390/agriculture15060600.
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To reduce harvest losses of a pepper harvester with a drum of elastic tooth type picking mechanism, this paper proposes an optimization method using AHP (Analytic Hierarchy Process) and RSM (Response Surface Methodology), thereby identifying the optimal harvesting parameters. Based on Hertz’s contact theory and projectile motion theory, dynamic and kinematic models were established for the picking and casting stage. Key parameters influencing harvest loss were identified as drum rotational speed, operating speed, and tooth spacing. A simulation model was constructed, and solved within LS-DYNA of ANSYS Workbench. A Box–Behnken design in RSM was employed to investigate the effects of drum rotational speed, operating speed, and tooth spacing on the picking rate, breakage rate, and loss rate. The optimal parameters, obtained through RSM optimization after AHP weighting, were determined to be a drum rotational speed of 182 r/min, an operating speed of 0.42 m/s, and a tooth spacing of 40 mm. A test bench was designed for validation, with simulation results deviating from experimental results by less than 5%. With optimized parameters, the picking rate increases from 89.73% to 95.13%, the breakage rate decreases from 3.21% to 2.66%, and the loss rate decreases from 5.16% to 3.95%. This study provides a theoretical foundation and practical reference for optimizing the drum with elastic tooth type picking mechanism in pepper harvesters.
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Kafle, Abishek, Nishan Sapkota, Raman Silwal, Pratisthit Lal Shrestha, Nischal Sharma, and Bhola Thapa. "Determination of Casting Parameters for Affirmative Directional Solidification in 750 KW Francis Runner." IOP Conference Series: Earth and Environmental Science 1037, no. 1 (2022): 012010. http://dx.doi.org/10.1088/1755-1315/1037/1/012010.
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Abstract Entangled by a web-like pattern of rivers and rivulets, Nepal’s energy sector currently is dominated by hydroelectricity which sustains a major portion of the country’s economy. But still, after more than a hundred years of its operation, the sector’s dependence on imports is uncanny. This not only upsizes the project cost but also the time and human resources. The research, therefore, aims to aid the cause by examining the prospect of manufacturing runners using local industrial expertise in synchronization with available data and research. Here, the paper focuses on the sand casting of a 750KW Francis runner and the design of its parameters namely gating and feeding system to ensure directional solidification. Apart from the conventional procedure, the casting of the runner was proceeded as three separate parts: hub, shroud, and blade which were later welded together. The gate and riser placement for each of the parts was designed independently and analysed for any shrinkage porosities and possible voids using computer simulation with several iterations each. Specifically, temperature variations during three major stages of solidification assigned as 0, 50, and 100 were tested for a total of 195 nodes. The design was then transferred into the mould and casting was performed. The procedure resulted in a cast with a clean surface finish and minimal visible defects. The study, thus, suggests the possibility of manufacturing runners through metal casting and its substantial implications in the improvement of the hydropower industry in Nepal.
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Knyazev, S. V., A. I. Kutsenko, A. A. Usol’tsev, N. A. Kozyrev, and A. A. Kutsenko. "Prospects and directions of digital transformation in foundry." Izvestiya. Ferrous Metallurgy 66, no. 2 (2023): 140–47. http://dx.doi.org/10.17073/0368-0797-2023-2-140-147.
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The time of information technology determines its priorities, which are a prerequisite for building a competitive production and economy. The ubiquitous spread of digitalization is one of the basic principles of new economy, a new type of socio–economic structure that is gradually being formed in the modern world through the introduction of scientific and technological progress and innovative methods of management, intellectualization and capitalization of human knowledge, the use of advanced new information and material technologies, accelerated development of knowledge-intensive sectors of the economy, the formation of creative, efficient, rational information and material production. Currently, at large foundries with mass and large-scale production of castings, the task of automating the control of technological processes using digital control systems was solved in general. They implement algorithms for controlling technological processes of casting in closed circuits (locally). The systems under consideration allow to implement optimal control strategies and automatically perform sequences of operations (start and stop of equipment; calculation and input of metal charge; calculation of formulations, dosing and mixing of molding and core mixtures) of multi-stage periodic casting processes. Digital transformation can significantly change the established practice of foundry production (from direct control and management of technological processes to business planning and document management). The transformation will have an impact on all parameters of the enterprise: economic efficiency of production (productivity, operating costs); reliability (operational readiness); safety (number of incidents); compliance with legislative norms on ecology. The technological criterion for success of the digital transformation of foundry production will be the release of a nomenclature of castings with a minimum level of defect, commercial – the release of a nomenclature of castings in demand on the market (machine parts and mechanisms), with a minimum self-cost, which is determined by the technological level of preparation of the production and its implementation and, as a consequence, low costs and optimal quality of molds, metal and castings.
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Vynnycky, M. "An asymptotic model for the formation and evolution of air gaps in vertical continuous casting." Proceedings of the Royal Society A: Mathematical, Physical and Engineering Sciences 465, no. 2105 (2009): 1617–44. http://dx.doi.org/10.1098/rspa.2008.0467.
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The formation of an air gap at the mould–metal interface in vertical continuous casting has long been known to have a detrimental effect on the efficiency of the process, and has therefore attracted attempts at mathematical modelling. While almost all current efforts consist of complex three-dimensional numerical simulations of the phenomenon, this paper considers instead an asymptotic model that captures the essential characteristics. The model is thermomechanical and is derived for a geometry, where the generalized plane strain approximation is appropriate. Although two-way coupling between the thermal and mechanical problems is accounted for, it is found that the problems decouple at leading order anyway, and that the thickness of the air gap does not depend on the constitutive relation used for describing the inelastic strains. Furthermore, a criterion for the onset of air-gap formation is derived in terms of the process operating parameters. Mathematically, we obtain a moving boundary problem for a parabolic partial differential equation with a degenerate initial condition and a non-standard Neumann-type boundary condition. Sample computations are performed using parameters for the continuous casting of the copper, and the results, qualitative trends and possible extensions are discussed.
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Suhas Prakashrao Patil, Sandeep Sadashiv Kore, Satish Suresh Chinchanikar, and Shital Yashwant Waware. "Characterization and Machinability Studies of Aluminium-based Hybrid Metal Matrix Composites – A Critical Review." Journal of Advanced Research in Fluid Mechanics and Thermal Sciences 101, no. 2 (2023): 137–63. http://dx.doi.org/10.37934/arfmts.101.2.137163.
Full textAbstract:
Metal matrix composites (MMCs) are attracting automobile and aeronautical sector because of their superior mechanical and physical characteristics which ultimately reduce the weight of components and hence the energy requirements. These composites are prepared by adding various reinforcements into the base metal by the methods like stir casting, squeeze casting, stir and squeeze casting, sand casting, in-setu method, powder metallurgy etc. When more than one particle is added into the base metal; these composites are called as Hybrid Metal Matrix Composites (HMMCs). The machinability of these hard to cut materials is a challenging task in front of manufacturing industry. Present study considers turning operation of HMMC done on either lathe or CNC machine by using different cutting tool materials. This review focuses on effect of various cutting parameters like speed, depth of cut, feed and also the parameters like reinforcement particle type, particle size and weight percentage on the machinability issues like surface roughness, MRR, cutting forces, tool wear etc. Further the various optimization methods used to suggest the cutting parameters to obtain minimum surface roughness, minimum cutting forces, minimum tool wear and maximum Material Removal Rate (MRR) are addressed.
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Kopyciński, D., and S. Piasny. "Influence of Tungsten and Titanium on the Structure of Chromium Cast Iron." Archives of Foundry Engineering 12, no. 1 (2012): 57–60. http://dx.doi.org/10.2478/v10266-012-0011-3.
Full textAbstract:
Influence of Tungsten and Titanium on the Structure of Chromium Cast Iron The paper analyses the as-cast state structure of chromium cast iron designed for operation under harsh impact-abrasive conditions. In the process of chromium iron castings manufacture, very strong influence on the structure of this material have the parameters of the technological process. Among others, adding to the Fe-Cr-C alloy the alloying elements like tungsten and titanium leads to the formation of additional carbides in the structure of this cast iron, which may favourably affect the casting properties, including the resistance to abrasive wear.