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Journal articles on the topic 'Metal castings industry'
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1
Pasko, Ján, Stefan Gaspar, and Juraj Ružbarský. "Die Casting Defects of Castings from Silumin." Applied Mechanics and Materials 510 (February 2014): 91–96. http://dx.doi.org/10.4028/www.scientific.net/amm.510.91.
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The production of die castings cast into a metal mold has in recent years achieved an expansive growth in the volume as well as the range of production and that is particularly in aviation and automobile industry. A primary criterion for achieving reliability, efficiency and quality of production is to ensure minimization of the castings defects occurrence. For this reason it is necessary to describe the type, scope and frequency of die castings defects and to define the cause of their occurrence.
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Eperješi, Š., M. Matvija, ľ. Eperješi, and M. Vojtko. "Evaluation of Cracking Causes of AlSi5Cu3 Alloy Castings." Archives of Metallurgy and Materials 59, no. 3 (October 28, 2014): 1089–92. http://dx.doi.org/10.2478/amm-2014-0187.
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Abstract Recently, the castings made from aluminum-silicon alloys by pressure die casting are increasingly used in the automotive industry. In practice, on these castings are high demands, mainly demands on quality of their structure, operating life and safety ensuring of their utilization. The AlSi5Cu3 alloy castings are widely used for production of car components. After the prescribed tests, the cracks and low mechanical properties have been identified for several castings of this alloy, which were produced by low pressure casting into a metal mould and subsequent they were heat treated. Therefore, analyses of the castings were realized to determine the causes of these defects. Evaluation of structure of the AlSi5Cu3 alloy and causes of failure were the subjects of investigation presented in this article.
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Gaspar, Stefan, Jan Pasko, and Slavko Pavlenko. "Research on the Impact of Increase Pressure on the Homogeneity of the Cast in Die Casting Technology." Advanced Materials Research 1091 (February 2015): 77–82. http://dx.doi.org/10.4028/www.scientific.net/amr.1091.77.
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The production of die castings cast into a metal mold has in recent years achieved an expansive growth in the volume as well as the range of production and that is particularly in aviation and automobile industry. In the process of die casting the final quality of a cast is influenced by a great number of factors. The main factors of die casting are: pressing velocity, increase pressure, the melt temperature and the mold temperature. A primary criterion for achieving reliability, efficiency and quality of production is to ensure minimization of the castings defects occurrence in castings correct setting technological factors of die casting. The presented paper deals with the experimental assessment of the impact of increase pressure on the mechanical properties and homogeneity of a die cast.
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Gaspar, Stefan, and Jan Pasko. "Homogeneity of Aluminum Castings and Dependency on Increasing Pressure." Key Engineering Materials 669 (October 2015): 134–41. http://dx.doi.org/10.4028/www.scientific.net/kem.669.134.
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The production of die castings cast into a metal mold has in recent years achieved an expansive growth in the volume as well as the range of production and that is particularly in aviation and automobile industry. In the process of die casting the final quality of a cast is influenced by a great number of factors. The main factors of die casting are: pressing velocity, increase pressure, the melt temperature and the mold temperature. A primary criterion for achieving reliability, efficiency and quality of production is to ensure minimization of the castings defects occurrence in castings correct setting technological factors of die casting. The presented paper deals with the experimental assessment of the impact of increase pressure on the mechanical properties and homogeneity of a die cast.
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Gnatush, V. "THE WORLD MARKET OF METAL CASTINGS 2019―2021: COUNTRIES, ALLOYS, TECHNOLOGIES." Casting processes 152, no. 2 (June 1, 2023): 56–75. http://dx.doi.org/10.15407/plit2023.02.056.
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The analysis of the world market of metal castings in 2019–2021 is presented. Due to the fact that as of January 2022 the publication of the world statistics of the production of metal castings did not take place, an analysis of information was carried out regarding the results in the countries that are part of the global Top-10. Among them are China, India, USA, Germany, Japan, Turkey and Brazil. It is noted that in 2021 in China, 54.05 million tons of castings were produced, which is 4.0% more than in 2020. In terms of cast alloys: gray cast iron (share 41.7%), cast iron with nodular graphite (29.5%), aluminum and magnesium alloys (13.3%) and steel (12.2%). In India, the export of metal castings in terms of value for the period from 2016/2017 financial year (FY) to 2020/2021 F. increased from 2.366 to 2.865 billion USD, i.e. with a CAGR of 3.9%. In the USA for the period from 2013 to 2019 the income of the foundry industry increased from 38.7 to 44.3 billion USD, that is, with an average annual growth rate (CAGR) of 1.9%. Under the influence of the COVID-19 pandemic and the slowdown of the economy in 2020. industry revenue decreased to USD 36.7 billion (-17.1% vs. 2019). However, in 2021 the situation improved somewhat ― 43.4 billion USD (18.3% against 2020). In Germany, the production of castings from ferrous metal alloys (gray cast iron, with nodular graphite, malleable and steel) in 2021. amounted to 3.2 million tons, which is 16.4% more than in 2020. At the same time, for the period 2019-2021 production of the specified castings decreased at an average annual rate (CAGR) of -6.0%, and their export ― by -7.0%. In Japan, as a result of the changing economic situation in the world, which was formed after 2019, the production of castings during 2019-2021. is characterized by a downward trend. The production of castings from copper alloys decreased with an average annual rate (CAGR) of -5.6%, castings from aluminum alloys ― -5.1% and castings from iron alloys ― -1.5%. In Turkey in 2021 1.108 million tons of nodular cast iron castings (by 29.6% vs. 2020), 0.921 million tons of gray iron castings (by 49.1%) and 0.279 million tons of steel castings (by 45, 4%). In general, during 2019–2021 the production of castings from ferrous metal alloys in the country increased at an average annual rate (CAGR) of 9.9%. In Brazil, in 2021, foundry enterprises produced 2.5 million tons of castings, which is 21.1% higher than in 2020. At the same time, the production of castings from cast iron increased by 25.5%, from non-ferrous metal alloys ― by 7.0%, and steel ― by 3.9%. In general, during 2019–2021 the production of castings in the country increased at an average annual rate (CAGR) of 3.1%. The presented data indicate that in 2021 the global foundry industry developed in a positive trend. Estimated global production of castings from ferrous and non-ferrous metals by the end of 2021. may amount to 109.2...118.5 million tons against 105.5 million tons in 2020. However, as a result of the war between Russia and Ukraine, a number of negative factors have arisen that will cause a slowdown in foundry production in 2022–2023. The review also presents information about the world’s leading foundry companies, as well as examples of the use of 3-D printing in foundry production in the United States and Great Britain.
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Adamiec, Janusz. "Repairing the WE43 Magnesium Cast Alloys." Solid State Phenomena 176 (June 2011): 99–106. http://dx.doi.org/10.4028/www.scientific.net/ssp.176.99.
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In addition to aluminium and titanium alloys, the magnesium alloys comprise the group of lightweight alloys which have the highest practical importance in structural applications. The WE43 alloy with the addition of rare earth elements and yttrium is used mainly for the sand mould castings for the aerospace industry. The castings for aerospace industry have complicated shapes and varying wall thickness, as a result of which they often have casting effects such as misruns, micro-shrinkages and cracks. The frequency of defect occurrence in the complicated shape casting may exceed 50%. The defects are repaired by means of welding and pad welding. Such practice is often used in foundries. The paper presents the results of repair evaluation of the WE43 alloy castings in the as-cast state by means of the TIG welding. The welding tests have been performed on the joints bevelled to “I”, “Y” and “V” and the technological repair guidelines have been formulated. The defect has been repaired and the non-destructive and structural tests have confirmed that the technology is correct. The WE43 alloy should be welded and pad welded with maximum linear arc energy of 3.0 kJ/cm, straight beads, with filler metal of a similar chemical composition, in the as-delivered state.
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Yamshinskij, Mikhail, Grigoriy Fedorov, and Anatoliy Verkhovliuk. "THE DEVELOPMENT OF NEW CASTING ALLOYS INTENDED FOR OPERATION UNDER EXTREME CONDITIONS AND SOME TECHNIQUES OF MAKING CASTINGS FROM THEM." EUREKA: Physics and Engineering 2 (March 31, 2016): 51–60. http://dx.doi.org/10.21303/2461-4262.2016.00033.
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The article studies new heat-resistant and wear resistant materials for operation under extreme conditions, especially in the power industry. The methods that improve the quality of a metal in metal castings through the influence of alloying elements on its structure and properties have been considered. These methods are very effective for reducing the tendency of a metal to form a coarse–grained structure. The paper describes optimal techniques for melting special alloys in induction and electric furnaces. A set of rules for the selection of a melting temperature before pouring a metal into the casting forms depending on the dimensions, wall thickness, geometry of castings have been determined. The behavior of new alloys under the conditions of high temperatures, aggressive environments has been studied. It has been established that heat–resistant Cr–Al steels exhibit high heat resistance and wear resistance properties; they 6–8 times surpass Cr–Ni steels in oxidation resistance. The proposed Cr–Mn cast iron processed in an integrated manner with REM (rare earth metals) and Ti is superior to a basic cast iron in conditions of a heavy wear. Numerous industrial trials confirm the usefulness of recommended new casting materials for use under extreme conditions.
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Gnatush, V. A., V. S. Doroshenko, and S. I. Klymenko. "Trends of the foundry market of Ukraine in the first quarter of the XXI century." Metal and Casting of Ukraine 31, no. 2 (2023): 83–90. http://dx.doi.org/10.15407/steelcast2023.02.083.
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An analysis of the state of foundry production in Ukraine is presented. The foundry industry of Ukraine in the 21st century significantly reduced its production indicators, which is due to the influence of such factors as the stagnation of industries that consume metal castings, as well as a decrease in exports. This situation has been negatively affected by the COVID-19 pandemic, as well as the global foundry industry, due to a decrease in demand for castings from end manufacturers. It was predicted that positive developments should be expected in the near future. However, russia's attack on Ukraine on February 24, 2022 made a significant correction in the development of the global economy, and, accordingly, in the functioning of the world foundry industry. Ukrainian companies in the foundry industry felt the impact of the war, some of them suffered partial destruction of their production premises. Large foundry enterprises of Ukraine are mostly located in the south-eastern regions, which were the most affected by hostilities. At the same time, in order to reflect the real situation in the foundry industry of Ukraine, it is advisable to organize the collection of real data regarding the production of castings from various alloys in the country, as well as regarding the export and import of foundry products. This will make it possible to make effective decisions regarding the program of modernization of the industry and the development of industries that consume domestic metal castings. Ultimately, this will help increase the competitiveness of Ukrainian products and increase revenues to the budget of Ukraine. To assess the direction of development of foundry production in advanced countries of the world, the statistical data of the leading countries regarding the production of castings and in more detail such countries as Poland, Germany and the USA are given. The structure of cast products produced in the world is in constant dynamics and there is a constant change in the ratio of the volumes of castings produced from various alloys. Recent years have been characterized by a tendency to reduce the production of castings from steel and gray iron with a simultaneous increase in the share of castings from highstrength cast iron and aluminum alloys.
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Mhamane, Digvijay A., Suyog B. Rayjadhav, and Vasudev D. Shinde. "Analysis of Chemically Bonded Sand Used for Molding in Foundry." Asian Journal of Science and Applied Technology 7, no. 1 (May 5, 2018): 11–16. http://dx.doi.org/10.51983/ajsat-2018.7.1.1025.
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In casting industry the selection of mold material and molding method is challenging task. There are several types of molding methods, but over 70% of all metal castings are generally developed by means of sand molding (sand casting). Sand casting has two processes such as, green sand casting and chemically bonded sand casting process. This paper focuses on chemically bonded sand casting i.e. no-bake sand system (self-hardening system), among from all types of no-bake sand system, alkaline phenolic ester cured (ALPHASET) and furan acid cured no-bake system are preferably discussed. Curing mechanism of all type of no-bake systems are shown along with detailing about ALPHASET and furan no-bake sand system.
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Залюбовський, М. Г., and І. В. Панасюк. "ЕКСПЕРИМЕНТАЛЬНЕ ДОСЛІДЖЕННЯ ВПЛИВУ ГЕОМЕТРІЇ МЕТАЛЕВИХ ВІДЛИВОК ДЕТАЛЕЙ ЗАМКА «БЛИСКАВКА» НА ОСОБЛИВОСТІ ЇХ ОБРОБКИ В ГАЛТУВАЛЬНІЙ МАШИНІ." Bulletin of the Kyiv National University of Technologies and Design. Technical Science Series 144, no. 2 (October 14, 2020): 24–32. http://dx.doi.org/10.30857/1813-6796.2020.2.2.
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Experimentally investigate the intensity and specificity of the processing of different types of metal castings of the zipper in a tensile machine with complex spatial movement of the working capacity, to obtain the appropriate calculation dependencies to determine the processing time. An experimental study of the separation from the casters of three types of metal castings of the zipper (casting with two, with eight fixed details-cases and outflow with sixteen fixed details by clamps) in a tensile machine with a complex spatial movement of the working capacity by observing the change in the number of machined parts during the process. Further mathematical processing of the obtained results is carried out. The types of castings for which the maximum and minimum technological time are spent in the toughening machine with complex spatial movement of the working capacity are determined. It is established that for processing castings with fixed parts-locks it takes twice more technological time, which is spent to clean the separated parts from the remnants of the wrap and burrs. Compared with conventional rotating shredding machines, using machines with complex spatial movement of the working capacity, you can increase the productivity of this technological operation by almost ten times. The dependences between different types of metallic castings of the zipper and the intensity of separation of parts from them during processing in a caulking machine with a complex spatial movement of the working capacity with providing a waterfall mode of movement and 50% filling the capacity. Appropriate design dependencies were obtained to determine the processing time. Guidelines on the implementation of rational technological parameters in the processing of various types of metal castings of the zipper in a tensile machine with a complex spatial movement of the working capacity. These guidelines can be used at the design stage of technological processes and equipment in the relevant machine-building and light industry enterprises specializing in the manufacture of hardware.
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Eperješi, Š., J. Malik, I. Vasková, and D. Fecko. "Increasing of Utility Properties of Grey Cast Iron Castings with Heat Treatment." Archives of Foundry Engineering 15, no. 2 (June 1, 2015): 13–16. http://dx.doi.org/10.1515/afe-2015-0029.
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Abstract Grey cast iron belongs to materials for casting production, which have wide application for different industry branches. Wide spectrum of properties of these materials is given by the structure of base metal matrix, which can be influenced with heat treatment. Processes of annealing can be applied for grey cast iron without problems. During heat treatment processes, where higher cooling rates are used, the thermal and structural strains become important. Usage and conditions of such heat treatment for grey cast iron castings of common production are the subject of evaluation of this article.
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Xu, Jingying, Jinwu Kang, Yongkang Hu, Houfa Shen, and Weimin Mao. "Study on the Mechanical Properties of 3D-Printed Sand Mold Specimens with Complex Hollow Structures." Materials 17, no. 5 (February 21, 2024): 996. http://dx.doi.org/10.3390/ma17050996.
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Casting, as a fundamental process in metal forming, finds widespread applications in the manufacturing industry. The advent of 3D printing hollow sand mold technology presents a novel method for casting technology to revolutionize traditional dense sand molds, offering increased flexibility in achieving quality control and improvement in casting processes. Consequently, this study delves into an examination of the mechanical strengths of 3D-printed sand molds with complex hollow structures and further investigates the influence of hollow sand mold concession on castings. The results indicate that compressive and high-temperature residual tensile and bending strengths vary in hollow structures. Multi-layer shells have greater high-temperature residual tensile, compressive, and bending strengths than truss hollow sand molds with roughly the same hollow volume fraction. Compared to dense sand molds, hollow sand molds, which have a lower mechanical strength, have better retractability, which helps reduce the residual stress and crack tendency of castings. The breaking of hollow structures is limited to local areas, unlike the penetrative cracking of dense sand molds. The I-beam-shaped casting test results indicate that a hollow structure is beneficial for the preservation of the integrity of a sand mold during the casting process. Compared to dense and truss hollow molds, a multi-layer shell hollow sand structure has the comprehensive advantages that it improves retractability while maintaining strength relatively well, reduces the residual stress, and avoids cracks in castings and itself.
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Opsal Bakke, Aina, Arne Nordmark, Lars Arnberg, and Yanjun Li. "Interfacial microstructure formation in A356/steel compound castings using metal coating." MATEC Web of Conferences 326 (2020): 06005. http://dx.doi.org/10.1051/matecconf/202032606005.
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Compound castings between aluminum and steel have great potential for applications in the automotive industry. However, due to large differences in thermal and mechanical properties between steel and aluminum, and the formation of stable aluminum oxides at the interface, it is difficult to form high strength metallic bonding between the two metals. In this work, A356/steel compound castings were produced through a gravity casting process. Various metal coatings, including galvanizing, aluminizing and brass-coating, were applied on the steel inserts to ensure that the A356 aluminum melt could react sufficiently with an oxide-free steel surface, resulting in a high-quality metallurgical bond. The reaction layer formed between the alloys was investigated using Optical Microscopy (OM), Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS). In addition, Vickers Micro-hardness was measured across the aluminum-steel interface. Results showed that metallurgical bonding could be achieved with all three coatings. However, for the brass-coated components only local bonding areas were found. In the aluminized and galvanized components, thick reaction layers consisting of binary Al-Fe and ternary Al-Fe-Si phases formed in the aluminum-steel interface. Between the A356 aluminum and aluminized layer, nearly no reaction layer formed. The mechanism for the formation of the various intermetallic phases at the reaction layers are discussed.
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Sulaiman, Shamsuddin, M. K. A. M. Ariffin, S. H. Tang, and A. Saleh. "Influence of Pattern Coating Thickness on Porosity and Mechanical Properties of Lost Foam Casting of Al-Si (LM6) Alloy." Applied Mechanics and Materials 300-301 (February 2013): 1281–84. http://dx.doi.org/10.4028/www.scientific.net/amm.300-301.1281.
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The combination of Aluminum alloy with lost foam casting (LFC) process is best applied in automotive industry to replace steel components in order to achieve light weight components for reducing fuel consumption and to protect the environment. The LFC process involves process parameters such as the degree of vacuum, foam degradation, expanded polystyrene (EPS) foam density, permeability of foam pattern coatings, pouring temperature, filling velocity, cooling rate, and pressure. The effect of polystyrene foam pattern coating thickness on the porosity and mechanical properties of Aluminum Al-Si LM6 alloy were evaluated experimentally. The coating thickness was controlled by slurry viscosity at range between 18sec to 20sec using Zahn viscosity cup No.5 and the foam pattern was coated up to fifth layer. Aluminum Al-Si (LM6) molten metal was poured into expandable mould and castings were examined to determine porosity distribution, mechanical properties and microscopic observation. Results from X-ray testing reveal the porosity distribution on Aluminum Al-Si LM6 castings is greater at thicker foam pattern coating sample. Meanwhile, the tensile strength of casting decreases when foam pattern coating thickness increases. Microscope observation portray the present of porosity on the casting which shows more gas defects present at thicker foam pattern coating sample. The source of porosity in LFC process is due to air entrainment or the entraining gases from polystyrene foam decomposition during pouring of molten metal. As a conclusion, mechanical strength has inverse relationship with porosity.
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Liao, Dun Ming, Li Liang Chen, Jian Xin Zhou, and Rui Xiang Liu. "CAD/CAE Technology and its Application on Nonferrous Alloy Casting." Advanced Materials Research 139-141 (October 2010): 1113–16. http://dx.doi.org/10.4028/www.scientific.net/amr.139-141.1113.
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The nonferrous alloy castings will be much demanded with the development of aerospace, light-weight weapons and automotive industry. Casting CAD/CAE technology has played an increasingly important role in foundry. It can help technician to design casting process and simulate heat transferring and molten metal flowing before actual production. Firstly, the main contents and basic principles, mathematical models of casting CAD and CAE were introduced. Secondly, the casting CAD/CAE technology route was interpreted, and then several CAD/CAE applications of casting process design and simulating were carried out on nonferrous alloys, such as aluminum, magnesium and copper. The results indicate that CAD/CAE technology can be applied to casting process design and predict casting defects which usually occur during the casting mold filling and solidification process, it can provide references to optimize casting process, so as to improve casting quality, reduce the rejection rate and shorten the development cycle of new products.
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Ciućka, T. "Influence of Vibrations During Crystallization on Mechanical Properties and Porosity of EN AC-AlSi17 Alloy." Archives of Foundry Engineering 13, no. 1 (March 1, 2013): 5–18. http://dx.doi.org/10.2478/afe-2013-0001.
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Abstract Today’s industry aims at such situation, where number of defective products, so called defects shall approach to zero. Therefore, one introduces a various changes in technology of production, introduces improvements which would help in accomplishment of this objective. Another important factor is introduction of different type of testing, which shall help in assessment which factor has significant effect on quantity of rejects, and which one could be neglected. Existence of casting rejects is unavoidable; therefore a new ideas, technologies and innovations are necessary in the entire widely understood foundry branch, in order to minimize such adverse effect. Performance of tests aimed at unequivocal determination of an effect of vibrations during crystallization on mechanical properties and porosity of the EN ACAlSi17 alloy was the objective of the present work. To do this, there were produced 36 castings from EN AC-AlSi17 alloy. All the castings underwent machining operations. Half of the casting was destined to strength tests, the other half served to determination of an effect of vibrations on porosity of the alloy. The specimens were divided into 12 groups, depending on amplitude of vibrations and tilt angle of metal mould during pouring operation.
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Novich, Kaelee A., Samuel V. Pedersen, RA Borrelli, R. Christensen, and Brian J. Jaques. "Synthesis of boron carbide reinforced aluminum castings through mechanical stir casting." Journal of Composite Materials 55, no. 16 (January 11, 2021): 2165–77. http://dx.doi.org/10.1177/0021998320987597.
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Nuclear energy is the leading clean energy source in the United States with 99 nuclear power plants generating approximately 20% of the country’s electricity. While the growth of the industry helps to reduce our reliance on fossil fuels, there is also an increase in nuclear waste. The demand for on-site dry cask spent nuclear fuel storage has increased due to complications with the Yucca Mountain Project and diminishing pool capacity. A novel dry cask consisting of an aluminum metal matrix for effective thermal conductivity with boron carbide as a neutron absorbing additive was investigated using gravity sand casting techniques. X-ray diffraction, Raman spectroscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy, and optical microscopy were used to characterize the resultant microstructure, including boron carbide incorporation and heterogeneity. Results indicate vortex and nonvortex mixing in air with boron carbide (1–10 µm diameter) produces large amounts of porosity and insufficient wetting. Use of a larger particle size distribution of boron carbide (20–60 µm diameter) during high speed vortex mixing prior to casting has shown significant dispersion of up to 12 wt% sufficient for neutron shielding with appropriate wall thickness. These results validate the use of gravity sand casting as a means to produce borated aluminum for an effective alternative to fuel storage.
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Neuser, M., O. Grydin, Y. Frolov, and M. Schaper. "Influence of solidification rates and heat treatment on the mechanical performance and joinability of the cast aluminium alloy AlSi10Mg." Production Engineering 16, no. 2-3 (January 23, 2022): 193–202. http://dx.doi.org/10.1007/s11740-022-01106-1.
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AbstractIn modern vehicle chassis, multi-material design is implemented to apply the appropriate material for each functionality. In spaceframe technology, both sheet metal and continuous cast are joined to castings at the nodal points of the chassis. Since resistance spot welding is not an option when different materials are joined, research is focusing on mechanical joining methods for multi-material designs. To reduce weight and achieve the required strength, hardenable cast aluminium alloys of the AlSi-system are widely used. Thus, 85–90% of aluminium castings in the automotive industry are comprised of the AlSi-system. Due to the limited weldability, mechanical joining is a suitable process. For this application, various optimisation strategies are required to produce a crack-free joint, as the brittle character of the AlSi alloy poses a challenge. Thus, adapted castings with appropriate ductility are needed. Hence, in this study, the age-hardenable cast aluminium alloy AlSi10Mg is investigated regarding the correlation of the different thicknesses, the microstructural characteristics as well as the resulting mechanical properties. A variation of the thicknesses leads to different solidification rates, which in turn affect the microstructure formation and are decisive for the mechanical properties of the casting as well as the joinability. For the investigation, plates with thicknesses from 2.0 to 4.0 mm, each differing by 0.5 mm, are produced via sand casting. Hence, the overall aim is to evaluate the joinability of AlSi10Mg and derive conclusions concerning the microstructure and mechanical properties.
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Pastierovičová, Lucia, Lenka Kuchariková, Eva Tillová, Mária Chalupová, and Richard Pastirčák. "Quality of automotive sand casting with different wall thickness from progressive secondary alloy." Production Engineering Archives 28, no. 2 (May 19, 2022): 172–77. http://dx.doi.org/10.30657/pea.2022.28.20.
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Abstract This paperwork is focused on the quality of AlSi6Cu4 casting with different wall thicknesses cast into the metal mold. Investigated are structural changes (the morphology, size, and distribution of structural components). The quantitative analysis is used to numerically evaluate the size and area fraction of structural parameters (α-phase, eutectic Si, intermetallic phases) between delivered experimental material and cast with different wall thicknesses. Additionally, the Brinell hardness is performed to obtain the mechanical property benefits of the thin-walled alloys. This research leads to the conclusion, that the AlSi6Cu4 alloy from metal mold has finer structural components, especially in small wall thicknesses, and thus has better mechanical properties (Brinell hardness). These secondary Al-castings have a high potential for use in the automotive industry, due to the thin thicknesses and thus lightweight of the construction.
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Futáš, Peter, Alena Pribulová, Gabriel Fedorko, Vieroslav Molnár, and Nikoleta Mikušová. "Computer simulation of railway wagon brake disc casting." MATEC Web of Conferences 235 (2018): 00026. http://dx.doi.org/10.1051/matecconf/201823500026.
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CAD systems serving as the model for real industrial processes are almost an inseparable part of manufacturing in many industry branches. The use of simulation programs in the foundry industry is perceived as a tool for the visualization of the processes involved in the production of castings. They are also used to resolve possible issues and imperfections before the production begins. Consequently, it enhances the quality and reduces product-manufacturing-related financial costs. The paper tackles the issue of how to resolve the occurrence of defects – shrinkages in the railway wagon disc casting while using a simulation program. The 3D model of the casting and of the system of gates was constructed in the CATIA CAD system. The mere simulation of the casting and solidification process was done in the NovaFlow&Solid program. After evaluating the results of the simulation, the correction of the casting and gates was made in order at once to enhance the quality of the casting and reduce the production costs in the manufacturing of this casting. In the production of the brake disk casting, the main issues are little usage of molten metal during casting and the considerable occurrence of shrinkages, which causes the increased economic costs of its production.
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Maj, M., J. Werrtz, and J. Piekło. "Environmental Protection Versus Foundry Engineering Practice." Archives of Foundry Engineering 17, no. 2 (June 27, 2017): 202–6. http://dx.doi.org/10.1515/afe-2017-0075.
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Abstract • Theory and practice of environmental protection in the case of foundries in Europe and Asia • Experience resulting from the cooperation with the foundries in a few European countries, China and India • Phenomena and factors affecting the pollution of the natural environment and the implementation of measures aiming at the environmental protection. Every specialist dealing with foundry processes and their impact on environmental pollution must have encountered in their professional careers numerous situations in which the theory of environmental protection confronts the stark reality. The discrepancy between theory and practice can particularly be noticed in foundry engineering in developing countries where the contrasts between different countries and casting plants are extremely striking. The comparison of working conditions in European and Asian foundries provides a vast scope for further observations and analyses. Environmental protection seems not only a concern of manufacturers of castings, but also of their customers whose opinion exerts a significant influence on both the acceptability of working conditions and on the approach to environmental pollution adopted in metal casting industry. The article presents a number of examples of various outlooks on environmental issues in foundries manufacturing a wide range of cast steel and cast iron castings, where different technologies and production processes are applied.
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Lomakin, Viktor, Viktor Pukalov, Viktor Dubodelov, and Maksim Goryuk. "Automation of Batch Casting of Cast Iron Melts in the Chill Mold in the Production of Castings of Machine Parts for the Mining Industry." Central Ukrainian Scientific Bulletin. Technical Sciences, no. 3(34) (October 2020): 163–69. http://dx.doi.org/10.32515/2664-262x.2020.3(34).163-169.
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The analysis of the basic parameters of the dosage of molten iron in metal forms using the magnetodynamic installation MDN-6CH. A schematic diagram has been developed for controlling the electromagnetic systems of the unit. The technology of dosing and pouring metal into the chill mold has been developed in the manufacture of cast iron balls with a diameter of 40 and 120 mm. At the optimal casting temperature, the electrical parameters of the inductor (voltage Ui, current Ii, power Ri) were in the range Ui = 250-300 V, Ii = 480-520 A, Ri = 140-160 kW. When reducing the mass of metal in the crucible MDN-6CH using a control scheme made switching inductor from a voltage of 300 V to 250 V. The power was reduced by 15-20 kW, and the temperature of the metal remained within the tolerance of the technology of metal casting. Using the adopted dosing scheme, it became possible to cast metal at constant parameters of the electromagnetic system and the time of pouring. The technology of dispensing and pouring metal into the mold for the production of cast iron balls with a diameter of 40 and 120 mm was carried out at an inductor voltage of 300 V, and the electromagnet - 220 V. The initial level of metal on the drain socket was equal to 20 mm. The molding time of molds in the manufacture of balls with a diameter of 40 mm was 7.3 s, and balls with a diameter of 120 mm - 16.2 s. The operating time of the electromechanical actuator was set in the manufacture of balls with a diameter of 40 mm - 0.35 s, and balls with a diameter of 120 mm - 0.75s. The consumption of metal in the manufacture of balls with a diameter of 40 and 120 mm was in the range of 0.7-0.75 kg / s and 1.65-1.70 kg / s, respectively. The metal casting was carried out at temperatures of 1320-1340 ° C and 1360-1380 ° C. The dosage accuracy was determined by weighing the metal of the poured balls and the molding system of the mold. Mathematical processing of the results of the dosing showed that in the manufacture of balls with a diameter of 40 mm at a temperature of 1320 °C the error of dosing is 10-11%. With increasing iron temperature, the dosage error decreases and at a metal temperature of 1370 °C is 5-6%. In the manufacture of balls with a diameter of 120 mm at a temperature of iron 1330, the dosage error is 7-8%, and at a temperature of 1360 ° C - 3-4%. The study of the characteristics of the casting and dosing process of cast iron in the chill mold allowed us to develop the technology of casting cast iron melts, which provided the required metering accuracy and high productivity of the conveyor production of grinding bodies.
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Niklas, Fabian. "New Addressable Applications for Rheocasting to Escape from an Oversupplied Market." Solid State Phenomena 348 (August 28, 2023): 61–67. http://dx.doi.org/10.4028/p-k3dfyn.
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The current market change of aluminium HPDC castings started with the “Dieselgate”. First, there was a shift from diesel to petrol engines. In the second step, hybrid and battery-powered cars gained significant market shares in sales statistics. Therefore, lucrative powertrain components are falling away. As powertrain foundries still want to utilize their machines to capacity, they are pushing into the structural castings market. As a result, there is an oversupply of casting machines here, which massively depresses prices and, thus, margins for tenders. With rising energy costs, these declining margins were eaten up, bringing foundries into crisis. Implementing Rheocasting at the existing die-casting cells is the solution to move into new market shares that are now not accessible in conventional HPDC.One of the new applications is electronic housings, high wall thickness parts, and fatigue bearing parts. These parts are commonly manufactured in sand or gravity castings because of their high wall thickness and low tolerance of porosity. Rheocasting is the perfect process for high-wall thickness components. Because of the semisolid melt preparation and the lamellar filling behavior, these components can be manufactured from the same alloy without pores or voids.This flow behavior of the semisolid slurry also results in a longer flow length. Slower casting speeds and lower pressure settings result in lower clamping forces. This gives an advantage in production costs and targets battery constructions made of castings and sheet metal. Structural battery housings must be leak-tight, even in a crash event. Having it in one casting instead of an assembly reduces the leakage area and improves crash performance.Another industry that relies on Rheocasting is the telecommunications industry. The power electronics in these 5G modules are significantly larger and generate much more waste heat. Until now, many antennas have been actively cooled or milled from a block of aluminum. The milled housings are significantly too expensive to enable series production. Therefore, the goal is to reproduce the passively cooled modules in die casting. Due to the process, the thermal conductivity in conventional HPDC is around 120 to 130 W/m*K. Similarly, no slim cooling fins can be formed. Only the Rheocasting process makes it possible to cast other alloys with low proportions of alloying elements, such as AlSi2Mn. This allows fins with a wall thickness of down to 0.4 mm and thermal conductivity of up to 190 W/m*K.Rheocasting enables access to market segments out of reach. These bring an unbeatable cost advantage against the current suppliers: gravity and sand casters. The low cycle time in Rheocasting brings back the high margins needed to sustain the business. Also, these products can be delivered with even better properties on smaller casting machines.
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Sika, Robert, Michał Rogalewicz, Paweł Popielarski, Dorota Czarnecka-Komorowska, Damian Przestacki, Katarzyna Gawdzińska, and Paweł Szymański. "Decision Support System in the Field of Defects Assessment in the Metal Matrix Composites Castings." Materials 13, no. 16 (August 12, 2020): 3552. http://dx.doi.org/10.3390/ma13163552.
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This paper presented a new approach to decision making support of defects assessment in metal matrix composites (MMC). It is a continuation of the authors’ papers in terms of a uniform method of casting defects assessment. The idea of this paper was to design an open-access application (follow-up system called Open Atlas of Casting Defects (OACD)) in the area of industry and science. This a new solution makes it possible to quickly identify defect types considering the new classification of casting defects. This classification complements a classical approach by adding a casting defect group called structure defects, which is especially important for metal matrix composites. In the paper, an application structure, and the possibility of its use in casting defects assessment were introduced.
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Martikka, Heikki, and Ilkka Pöllänen. "Strength of Alloyed Metal Castings Using Multiphase Models and Non-Linear FEM." Materials Science Forum 638-642 (January 2010): 2658–63. http://dx.doi.org/10.4028/www.scientific.net/msf.638-642.2658.
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High chromium cast iron material 1.4405 GX4CrNiMo 16-5-1 is successfully used in chemical process industry components loaded with hot, highly corrosive and abrasive at high pressures. Overheating test made a discontinuous yielding knee to appear caused probably by dissolution of carbon containing smaller phases but the overall strength and ductility are not affected. Microstructures are studied by optical and SEM microscopy and hardness measurements. This alloy has three main phases appearing as a mixture of rounded and lamellar phases. The work hardening behaviour is studied by analytical composite phase models and 2D FEM models with individual bilinear hardening phase models. The results agreed reasonably. FEM models showed the weak points of the alloy. Fit to test data was better with rounded phase than lamellar phase model. Combination of these tools is useful for innovative special alloy developments.
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Doroshenko, Volodymyr S., and Olexander B. Yanchenko. "PREREQUISITES FOR THE IMPLEMENTATION OF 3D TECHNOLOGY FOR THE MANUFACTURE OF METAL PRODUCTS AND EXAMPLES OF ITS APPLICATION." Modern technology, materials and design in construction 35, no. 2 (December 29, 2023): 35–41. http://dx.doi.org/10.31649/2311-1429-2023-2-35-41.
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A brief overview of modern additive manufacturing equipment, 3D technologies and leading companies in this field is provided. Such production for the modeling and optimization of casting structures and the production of metal products corresponds to the concept of Industry 4.0, aimed at obtaining competitive products quickly, conveniently, variably, with minimal personnel and the desire to exclude the subject from the technological cycle of production, close to the requirements of the consumer, including industrial and construction hardware. 3D technology, which includes the optimization of structures by digital methods, is an effective means of reducing the cost and weight of metal structures, reducing metal consumption. At the current transition stage to mass additive production, there is a need for a gradual combination of digital and traditional technologies in the process of industrial development on an innovative basis, which is an effective mechanism for overcoming the crisis phenomena of the war and post-war periods. In this regard, the use of 3D technology for obtaining cast metal structures, in particular those made by casting according to gasifying models, has significant opportunities. There are three examples of the application of 3D technology for printing metal structures, in the process of manufacturing lightweight openwork castings, which includes printing a foundry sand mold, and during 3D milling of a one-time foundry pattern from polystyrene foam. As one of the key drivers of Industry 4.0, 3D technologies, according to experts, are capable of standing on a par with traditional technologies, and in the near future, replacing at least half of the existing machine park and procurement equipment. There is a lot of talk about what is holding back the active use of 3D printers by enterprises, but the most common limitation is the unwillingness of the enterprises themselves to rethink, engineer their production, put it on the rails of digital technologies; certainly, it is difficult, but necessary to maintain their competitiveness.
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Tshabalala, Neo, Kasongo Nyembwe, and Malan Van Tonder. "OPTIMISATION OF A RESIN-COATED CHROMITE SAND FOR RAPID SAND CASTING APPLICATIONS." South African Journal of Industrial Engineering 32, no. 3 (2021): 290–98. http://dx.doi.org/10.7166/32-3-2665.
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Applications of three-dimensional printing (3DP) to sand casting have been well-established in the last two decades. The preferred raw material is silica (quartz) sand, as it is the most readily available and cost effective sand. However, silica sand as a refractory material has some technical limitations, including high thermal linear expansion, low refractoriness, and thermal conductivity. Therefore, it is not suitable for all castings. Other refractory sand types are available, including chromite sand, which is abundantly available in South Africa. Analysis of the physical and chemical properties of in-laboratory coating of a locally available chromite sand was conducted through known metal foundry tests that provide an understanding of the quality and suitability of the use of chromite sand as a potential substitute for silica material for rapid sand-casting applications. The results of this study will inform the industry about the optimisation of parameters for the manufacturing of a resin-coated chromite sand and its use in additive manufacturing using a Voxeljet VX 1000 printer.
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Shinsky, O., P. Kaliuzhnyi, and V. Doroshenko. "Bionic approach to the manufacture of cast lightweight metal structures for the construction of modular structures." Casting processes 150, no. 4 (December 1, 2022): 63–74. http://dx.doi.org/10.15407/plit2022.04.063.
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Prefab modular building metal structures have several advantages, especially for reuse, compared to building structures made of concrete and wood. Analysis of the structure of the cost of such metal structures and their installation proved that the most effective way to reduce their cost is to reduce metal consumption. Unlike welded for bolted structures, installation is simplified and bolted connections provide the possibility of disassembling the structure with transportation to another place, which is important for hangars, warehouses that change location. Casting of lightweight metal structures can help increase the potential for new and rapid construction. For this, the most suitable method is the Lost Foam Casting (LFC) process in vacuum molds made of loose sand. No other casting method can compete with LFC in the production of frame-bearing structures of complex geometry. Examples of the optimization of metal structures by imitating the structures of nature, in particular biological and DNA structures, as a bionic approach to the design of man-made metal products are considered. Framework and cellular spatial materials obtained by the LFC method expand the existing range of properties compared to compact materials. And the described cast materials based on analogues from the macro- and micro-world of nature and on prefab models will simplify the design and production of frame lightweight products, which are classified as "materials of the future". Ukraine receives metal from its own ores and is able to transform it into a high-tech, knowledge-intensive product in the form of machines, mechanisms and building structures. The technological direction of borrowing the structural properties of natural materials is studied not only for copying them, but also for obtaining new materials and structures with optimization for specific mechanisms or buildings, promoting the use of metal structures as an effective solution in the construction industry during the reconstruction of the country. Keywords: building metal structures, modular structures, modeling, structures of nature, castings
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Li, Nai Yi. "Magnesium Advances and Applications in North America Automotive Industry." Materials Science Forum 488-489 (July 2005): 931–0. http://dx.doi.org/10.4028/www.scientific.net/msf.488-489.931.
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Magnesium is increasingly becoming an attractive alternative to steel, aluminum, and polymer composites for vehicle weight reduction due to its ability to meet vehicle performance requirements. To meet the Corporate Average Fuel Economy (CAFÉ) standard and to maximize the weight reduction of vehicles in the coming years, the magnesium applications are expected to increase significantly in both structural and powertrain components where material creep resistance is required. This first half of the paper will give an overview of recent automotive magnesium R&D programs including Light Metal Cast, Magnesium Powertrain Cast Components, and Structural Cast Magnesium Development supported by the United States Council for Automotive Research (USCAR) and the US Department of Energy. The USCAR is the umbrella organization of DaimlerChrysler Corporation, Ford Motor Company and General Motors, which was formed in 1992 to further strengthen the technology base of the US automotive industry through cooperative, pre-competitive research. During the last decade, the magnesium foundry industry has grown, yet the material and manufacturing process costs of magnesium die-casting has impeded large-scale implementation into the automotive industry. As a result, Ford Motor Company initiated a Cost Reduced Magnesium Die Castings Using Heated Runners (CORMAG) program in partnership of the Advanced Technology Program of the US National Institute of Standards and Technology. The second half of this paper will briefly present the program goal, progress and its impact. In addition, this paper will present some magnesium applications, including a 2004 Ford F-150 light truck Front End Support Assembly and a 2005 Ford GT instrument panel structure.
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Stawowy, A., and J. Duda. "Iterated Local Search for Foundry Lotsizing and Scheduling Problem with Setup Costs." Archives of Foundry Engineering 17, no. 4 (December 20, 2017): 161–64. http://dx.doi.org/10.1515/afe-2017-0150.
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Abstract The paper presents a novel Iterated Local Search (ILS) algorithm to solve multi-item multi-family capacitated lot-sizing problem with setup costs independent of the family sequence. The model has a direct application to real production planning in foundry industry, where the goal is to create the batches of manufactured castings and the sequence of the melted metal loads to prevent delays in delivery of goods to clients. We extended existing models by introducing minimal utilization of furnace capacity during preparing melted alloy. We developed simple and fast ILS algorithm with problem-specific operators that are responsible for the local search procedure. The computational experiments on ten instances of the problem showed that the presence of minimum furnace utilization constraint has great impact on economic and technological conditions of castings production. For all test instances the proposed heuristic is able to provide the results that are comparable to state-of-the art commercial solver.
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dos Santos, A. V., Mauro C. Marchetti, Carla L. Ribas, and Ayane R. de Souza. "Reuse of Sand Disposed of Foundry in Lieu of Sand Natural in the Manufacture of Structural Blocks." Advanced Materials Research 1052 (October 2014): 416–19. http://dx.doi.org/10.4028/www.scientific.net/amr.1052.416.
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With the significant progress in the, combining global industry section, new technoligies come the increased generation of solid waste and the consequent concern with the correct management. One of the major problem of the foundry industry is the generation of solid waste mainly constituided by residual sands or discarded foundry sands. (ADF). The proper disposal of this waste is a challenge for the industries that are increasinly concerned in the need to preserve the environment in pursuit of sustainable long-term development. In Brazil the production of castings in 2008 exceeded 3 millhion tons, with the generation of approximately one ton of waste for each ton of pruduced metal. The main destination of this waste currently occures in industrial landfill disposal that bisides having a high cost which is an increasing environmental concern for the companies. Solving this problem is one of the duties of this work or in other words we propose a methodology to reuse solid waste. We tested our metodology, specimens have been made with the incorporation of foundry sand at different concentrations in ascending order in every 5% replacing the natural sand for casting sand. Throught this article we have shown the proposed metodology for the use of concret blocks.
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Doroshenko, Volodymyr, and Olexander Yanchenko. "DESIGN OF METAL STRUCTURES OF MOBILE FOUNDATIONS AND FOUNDRY TECHNOLOGY FOR THEIR PRODUCTION." Modern technology, materials and design in construction 34, no. 1 (July 30, 2023): 74–78. http://dx.doi.org/10.31649/2311-1429-2023-1-74-78.
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A short overview of promising directions of development in the field of construction of metal, in particular, mobile foundations, was made. This will contribute to the cheapening and popularization of such foundations, which can become a scientific and practical basis for foundation construction, in particular for modular construction based on metal structures. Unlike welded for bolted structures, installation is simplified and bolted connections provide the possibility of disassembling the structure with transportation to another place, which is important for hangars, warehouses that change location. An example of topological optimization of a mobile foundation design is given, and a mobile foundation design that uses the strut effect is considered, as well as a promising design for manufacturing using 3D technology. It was noted that an effective means of reducing the cost of metal structures is the reduction of metal consumption. Modern foundations, which are single massive structures, can be significantly lightened thanks to the use of prefabricated hinge-rod systems or solid cast metal structures with cavities, which do not significantly affect the stress-strain state of the foundation. Applied research methods: modeling, review and generalization of the studied materials, devoted to the issues of the article. The application of cast metal constructions, in particular those made by Lost Foam casting process, has significant opportunities. Examples of modeling of large castings and manufactured models using 3D technologies from the experience of foundry practice of PTIMA of the National Academy of Sciences are given. Construction using metal structures has all the prerequisites to become an effective solution in the construction industry, which will contribute to the reconstruction of our country, which receives metal from its own ores and is able to convert it into a high-tech, knowledge-intensive product, in particular in the form of lightweight construction metal structures.
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Doroshenko, Volodymyr, and Olexander Yanchenko. "DESIGN OF METAL STRUCTURES OF MOBILE FOUNDATIONS AND FOUNDRY TECHNOLOGY FOR THEIR PRODUCTION." Modern technology, materials and design in construction 33, no. 2 (March 22, 2023): 85–89. http://dx.doi.org/10.31649/2311-1429-2022-2-85-89.
Full textAbstract:
A short overview of promising directions of development in the field of construction of metal, in particular, mobile foundations, was made. This will contribute to the cheapening and popularization of such foundations, which can become a scientific and practical basis for foundation construction, in particular for modular construction based on metal structures. Unlike welded for bolted structures, installation is simplified and bolted connections provide the possibility of disassembling the structure with transportation to another place, which is important for hangars, warehouses that change location. An example of topological optimization of a mobile foundation design is given, and a mobile foundation design that uses the strut effect is considered, as well as a promising design for manufacturing using 3D technology. It was noted that an effective means of reducing the cost of metal structures is the reduction of metal consumption. Modern foundations, which are single massive structures, can be significantly lightened thanks to the use of prefabricated hinge-rod systems or solid cast metal structures with cavities, which do not significantly affect the stress-strain state of the foundation. Applied research methods: modeling, review and generalization of the studied materials, devoted to the issues of the article. The application of cast metal constructions, in particular those made by Lost Foam casting process, has significant opportunities. Examples of modeling of large castings and manufactured models using 3D technologies from the experience of foundry practice of PTIMA of the National Academy of Sciences are given. Construction using metal structures has all the prerequisites to become an effective solution in the construction industry, which will contribute to the reconstruction of our country, which receives metal from its own ores and is able to convert it into a high-tech, knowledge-intensive product, in particular in the form of lightweight construction metal structures.
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Dyja, Robert, Elżbieta Gawrońska, Andrzej Grosser, Piotr Jeruszka, and Norbert Sczygiol. "Numerical determination of equiaxed grain radii arising in the casting during 3D simulation of solidification." Computer Methods in Material Science 16, no. 1 (2016): 27–36. http://dx.doi.org/10.7494/cmms.2016.1.0567.
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The knowledge of material structure allows to predict the mechanical properties of alloy casting. Such structure can be modelled in micro- and mesoscale. The first way is connected with alloy morphology and enables one to find out the shape of grains emerging during the solidification process. The second way allows to define the magnitude and distribution of these grains in the casting structure. Learning both of these ways greatly enhances one’s knowledge about such mechanical phenomena as emerging stresses, strains, hot cracking and many others. This information makes it possible for one to predict the behaviour of castings during the cooling process or the further product exploitation. The one of the most difficult issues in the numerical and computer simulations of solidification is the modelling of the structure evolving in the casting. These simulations are extremely important in the work of an engineer in the foundry industry. The paper deals with a numerical modelling of equiaxed microstructure formation during the solidification of two-component alloys. The basic enthalpy formulation was applied to model the solidification. The equiaxed grain size depends on the average cooling velocity at the moment when the liquid metal reaches the liquidus temperature. The experimentally determined dependence between grain radius and cooling velocity was used in the calculation of average grain radii distribution.
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Pană, Gabriela Monica, and Laura Diana Grigorie. "The Issue of Car Body Manufacture in Unibody Aluminum Alloy Design." Applied Mechanics and Materials 880 (March 2018): 183–88. http://dx.doi.org/10.4028/www.scientific.net/amm.880.183.
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Weight reduction is the present and future issue in the automotive industry. The use of aluminum for bodywork is a growing solution due to the specific properties and the recyclability it offers. The unibody design concept with high productivity is developed for steel sheet metal car bodies. They can also be made with aluminum sheets with different product shapes (sheets, extrusions, castings etc.). The aluminum offers a wide variety of design options. The most important difference between aluminum and steel models is the predominant joining technique. In order to obtain optimal solutions from a technical and economical point of view, it is necessary to apply aluminum design concepts and correspondingly adapted manufacturing technologies.
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Ni, Changjiang, Gaochun Lu, Tao Jing, and Junjiao Wu. "Flow Dynamic Analysis of Core Shooting Process through Experiment and Multiphase Modeling." Advances in Materials Science and Engineering 2016 (2016): 1–12. http://dx.doi.org/10.1155/2016/2317180.
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Core shooting process is the most widely used technique to make sand cores and it plays an important role in the quality of sand cores as well as the manufacture of complicated castings in metal casting industry. In this paper, the flow behavior of sand particles in the core box was investigated synchronously with transparent core box, high-speed camera, and pressure measuring system. The flow pattern of sand particles in the shooting head of the core shooting machine was reproduced with various colored core sand layers. Taking both kinetic and frictional stress into account, a kinetic-frictional constitutive correlation was established to describe the internal momentum transfer in the solid phase. Two-fluid model (TFM) simulations with turbulence model were then performed and good agreement was achieved between the experimental and simulation results on the flow behavior of sand particles in both the shooting head and the core box. Based on the experimental and simulation results, the flow behavior of sand particles in the core box, the formation of “dead zone” in the shooting head, and the effect of drag force were analyzed in terms of sand volume fraction (αs), sand velocity (Vs), and pressure variation (P).
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Sirenko, К. A. "Directions for the development of a methodology for regulating the chemical composition and properties of cast iron in foundry production based on a probabilistic approach." Metaloznavstvo ta obrobka metalìv 29, no. 4 (December 11, 2023): 23–33. http://dx.doi.org/10.15407/mom2023.04.023.
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From the standpoint of systemic and structural-functional approaches, the state and prospects of development of the methodology for regulating and predicting the chemical composition and mechanical properties of grey synthetic cast iron intended for casting production are analysed. Attention is focused on the key intersections of the technological process of manufacturing castings for critical applications. The features, disadvantages, and advantages of the known methods for calculating the charge and adjusting the percentage of chemical elements in the cast iron composition directly during its melting are considered. Ways to take into account the instability of the chemical composition of scrap metal, ferroalloys, and other materials when forming the charge to ensure the quality of pig iron in accordance with the requirements of finished product standards are shown. A promising way to solve this problem in foundry is to use a probabilistic approach and the Monte Carlo method. The article presents formulas for calculating the strength and hardness of cast iron castings with lamellar graphite depending on its carbon equivalent and degree of eutecticity. The peculiarity of the proposed formulas, which gives them enhanced reliability and validity, is that the carbon equivalent and the degree of eutecticity of cast iron in them are determined by the Monte Carlo method using a probabilistic approach with regard to the consideration of the ranges of variation of the content of chemical elements in the cast iron composition regulated in the standard for foundry products. It is noted that the widespread use of thermal derivative express analysis of liquid cast iron in industry is constrained by the lack of a database of reference cooling curves with certain property indicators (chemical composition, microstructure, mechanical and other properties) of cast irons at foundries. Keywords: foundry, cast iron, chemical composition, properties, control, regulation, methodology.
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Nanda Kumar, Nю, and Natarajan Muthukumaran. "Experimental Investigation on Microstructural and Wear Behaviour of Dual Reinforced Particles (DRP) Aluminium Alloy Composites." Advanced Materials Research 1159 (September 2020): 42–53. http://dx.doi.org/10.4028/www.scientific.net/amr.1159.42.
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In the present scenario, the automobile industry, and aerospace industries are considerable scuffles to strive for innovative lightweight materials among manufacturing industries. They preserve their place by reducing the cost of their products and services. For this tenacity, the demand for lightweight material, low cost, and high-performance material are needed. Aluminum matrix composite is developed to fulfill and becomes an engineer’s material. Aerospace & Automobile industries are eager to introducing compound aluminum metal matrix composites due to their excellent mechanical & tribological properties which makes a reduction in the weight of the component. In this project the LM13 as the matrix material while SiC and B4C have been considered as dual reinforcement. Stir casting is the modest and inexpensive method of fabricating an aluminum matrix composite. For the Evaluation of Mechanical &Tribological behavior of DRP composite castings (LM13/B4C/SiC) selection for experimentation tests. In this paper different specimens of the MMC with LM13 Al Alloy 2wt% SiC and 2wt% B4C, 2wt% SiC and 4% B4C, 4wt% SiC, 2wt% B4C, 4wt% SiC and 4wt% B4C are taken for carried to invention out the increase in DRP in the composites will intensification the mechanical properties of the LM13 Al Alloy SiC and B4 C composite formed.
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Seikh, Ziyauddin, Mukandar Sekh, Golam Kibria, Rafiqul Haque, and Shamim Haidar. "Density, Hardness, and Wear Responses of Rice Husk Ash Reinforced Aluminium Composites." Materials Science Forum 1074 (November 8, 2022): 67–78. http://dx.doi.org/10.4028/p-78710r.
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Nowadays, there is an ever-increasing demand for lightweight, robust, and low-cost materials. The desire for increasingly exotic and superior materials has become unavoidable as science progresses. The manufacturing industry is looking for more complex geometries. For example, composite materials are a sort of innovative material that blends the properties of its constituent materials. One of the most extensively used composite materials is metal matrix composites. Aluminium matrix composites are lightweight, high-performance structural and functional materials used in a variety of industries, including defense, aerospace, automotive, heating systems, and sports and entertainment. It is really good for the environment to use by-products from agricultural sectors, such as rice husk, as reinforcement with MMCs. The purpose of this research is to use powder metallurgy technology to build an aluminum-based composite with rice husk ash (RHA) and evaluate how its properties may be enhanced. Whereas metal casting can be used to fabricate composites, powder metallurgy is more cost-effective because it allows for the production of parts that are closer to net shape, and castings cool slowly from the liquid state, causing workability concerns as well as other restrictions such as segregation limitations. Good microstructure in the finished product is possible to obtain as powder particles are small and homogenous, resulting in improved mechanical properties. The experiment was conducted using an L27 orthogonal array with four different input parameters from prior studies: composition (wt.% of RHA), compaction pressure (CP), sintering temperatures (STE), and sintering time (ST). On the aluminium based composite, several mechanical tests, such as density and hardness, as well as tribological testing, such as the wear test, were conducted, with each test yielding noteworthy results. To satisfy the industry's needs, a comparison study was conducted.
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Doroshenko, Volodymyr, and Olexandr Yanchenko. "APPLICATION OF COMPUTER SYSTEMS FOR DESIGNING AND 3D PRINTING OF A FOUNDRY PATTERN WITH VENTILATION CHANNELS IN ITS WALLS." Information technology and computer engineering 58, no. 3 (December 29, 2023): 53–58. http://dx.doi.org/10.31649/1999-9941-2023-58-3-53-58.
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In the context of the implementation of the "Industry 4.0" concept, digitalization and automation today have become not just the basis of competitive advantage in the production of goods (works, services), in many areas they are perceived as a necessary condition for the organization of production processes. In particular, thanks to the digitization and automation of foundry production in Ukraine, there is an opportunity to create a powerful potential that will contribute to the recovery of the country. Due to the expansion of the use of computer systems for the design and 3D printing of polymer foundry patterns with ventilation channels, it became possible to develop one of the methods of metal casting according to gasifying patterns (LFC) with the use of printed patterns (models), which corresponds to the growing trend of digitalization and automation of foundries processes. This became possible due to the increase in the intensity of evacuation of the products of gasification of printed patterns in the foundry mold using the vacuum of this mold. The developed method allows you to get a total benefit both from fairly fast computer-oriented 3D processes of designing and printing a foundry pattern, as well as from short-term processes of forming and punching out castings due to the use of dry sand foundry molds at LFC. At the same time, the digital transformation of LFC is combined with the resource efficiency of the reversible use of molding materials without changing the current standards of control of metal products of foundries. And the adaptation of production to additive technologies allows direct interaction with the buyer of the product, which is designed according to his individual digital project, with the help of the Internet. The latter corresponds to the concept of "manufacturing as a service" (MaaS). Also, this implementation of the use of computer systems and new digital processes in traditional foundry processes shortens the time gap from the creation of prototypes and tools to the mass production of metal products.
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Pacana, Andrzej, and Karolina Czerwińska. "Indicator analysis of the technological position of a manufacturing company." Production Engineering Archives 29, no. 2 (April 26, 2023): 162–67. http://dx.doi.org/10.30657/pea.2023.29.19.
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Abstract A turbulent manufacturing market, especially in the metal industry, determines the quality of products and the level of production efficiency, which contributes to a company's market position and competitiveness. The aim of the study was to develop a model to define a manufacturing company's current market position using KPIs in relation to a key product - gearbox casting. The company's position was defined in terms of the relationship occurring between technological capabilities and market position. An additional aim of the study was to identify critical determinants and, ultimately, to identify conditions for strengthening market position. As a test of the proposed model, the position of the analysed company (in terms of technological capabilities and market position) was defined as "Search for occasions" - box 9 within the 3×3 matrix. Technological determinants that weaken the company's position (low level of maintenance capacity and long production cycle time) and determinants with a strong negative impact on market position (low level of human resource development) were identified. An element of novelty is the use of KPIs as variables determining the position of the company within the 3×3 matrix, which is indicative of a specific technological position in the market. Further lines of research will concern the determination of appropriate KPIs in relation to the identified critical areas of the company. Subsequent steps will concern the implications of the model in relation to the company's other key aluminium alloy castings.
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TOLSTOY, Aliaksandr V. "DEVELOPMENTS OF THE SUBPROGRAM “METALLURGY” PERFORMED IN THE INTERESTS OF INDUSTRIAL ENTERPRISES." Mechanics of Machines, Mechanisms and Materials 2, no. 63 (June 2023): 75–89. http://dx.doi.org/10.46864/1995-0470-2023-2-63-75-89.
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The main results of the implementation of the tasks of the subprogram “Metallurgy” of the State Research Program “Mechanics, Metallurgy, Diagnostics in Mechanical Engineering”, 2021–2025, with an applied orientation are presented, which are obtained by the organizations of the National Academy of Sciences of Belarus, the Ministry of Education and the Ministry of Industry of the Republic of Belarus. Their contribution to the solution of practical problems is shown. In the field of metallurgy of iron-carbon alloys, a range of new grades of steels for large gears and large castings of supporting systems of machines are developed. Distinctive features of the developed steels are the possibility to obtain higher hardness values of the hardened layer and teeth of cemented gears compared with counterparts from serial steels. A new sparingly alloyed steel for gearboxes of tractors BELARUS has been developed. The steel is characterized by high hardenability of cemented layer. In the field of metallurgy of non-ferrous metals and alloys, theoretical and technological bases for production of complex configuration castings are developed. Application of these castings improves the dimensional accuracy of products. In the field of hardening of steels and alloys, the technology of coating formation on the working surfaces of metallurgical and foundry equipment parts by mechanical cladding with flexible tool is developed. The coatings provide 1.9 times higher durability of mold parts by compared to the parts without coatings. The technological process of induction cladding on the surfaces of friction nodes parts of wear-resistant antifriction coatings is developed. The service life of bimetallic parts with coatings is 1.25–1.33 times higher than that of serial parts. Physico-chemical principles of creation of aluminomatrix composites were developed on the basis of micro- and ultradispersed oxide powders. This provided a 5-fold increase in tribomechanical properties. In the field of metal forming, the strategy of ring rolling is developed as applied to the nomenclature of rings of the Belarusian enterprises. Technological substantiation is performed for reducing deformations and residual stresses after heat treatment of low-rigid parts such as discs using dynamic stabilization based on alternating cyclic loading.
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Holtzer, Mariusz, Rafał Dańko, Angelika Kmita, Dariusz Drożyński, Michał Kubecki, Mateusz Skrzyński, and Agnieszka Roczniak. "Environmental Impact of the Reclaimed Sand Addition to Molding Sand with Furan and Phenol-Formaldehyde Resin—A Comparison." Materials 13, no. 19 (October 1, 2020): 4395. http://dx.doi.org/10.3390/ma13194395.
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Increasingly strict regulations, as well as an increased public awareness, are forcing industry, including the foundry industry, to develop new binders for molding sands, which, while being more environmentally friendly, would simultaneously ensure a high quality of castings. Until recently, binders based on synthetic resins were considered to be such binders. However, more accurate investigations indicated that such molding sands subjected to high temperatures of liquid metal generated several harmful, even dangerous substances (carcinogenic and/or mutagenic) from the benzene, toluene, ethylbenzene and xylenes (BTEX) and polycyclic aromatic hydrocarbons groups (PAHs). An assessment of the most widely used molding sands technologies at present with organic binders (synthetic resins) from the no-bake group (furan no-bake and phenolic-ester no-bake) and their harmfulness to the environment and work conditions is presented in this paper. In the first stage of this research, gases (from the BTEX and PAHs groups) emitted when the tested molds were poured with liquid cast iron at 1350 °C were measured (according to the authors’ own method). The second stage consisted of measuring the emission of gases released by binders subjected to pyrolysis (the so-called flash pyrolysis), which simulated the effects occurring on the boundary: liquid metal/molding sand. The gases emitted from the tested binders indicated that, in both cases, the emission of harmful and dangerous substances (e.g., benzene) occurs, but, of the given binder systems, this emission was lower for the phenolic-ester no-bake binder. The obtained emission factors of BTEX substances show higher values for furan resin compared to formaldehyde resin; for example, the concentration of benzene per 1 kg of binder for furan no-bake (FNB) was 40,158 mg, while, for phenol-formaldehyde no-bake (PFNB), it was much lower, 30,911 mg. Thus, this system was more environmentally friendly.
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Szymański, Michał, Damian Przestacki, and Paweł Szymański. "The Influence of Selected Laser Engraving Parameters on Surface Conditions of Hybrid Metal Matrix Composites." Materials 16, no. 19 (October 6, 2023): 6575. http://dx.doi.org/10.3390/ma16196575.
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Hybrid metal matrix composites (HMMCs) are a special type of material, possessing combined properties that belong to alloys and metals according to market demands. Therefore, they are used in different areas of industry and the properties of this type of material are useful in engineering applications, e.g., in aircraft engines and electrotechnical parts. The structure of the material requires a number of scientific studies to develop an appropriate processing technology. The paper presents the susceptibility of material from the HMMCs group with the EN AC-44300 (AISi12(Fe)) aluminum alloy matrix with a two-component reinforcement made of alumina particles (AP) and aluminosilicate fibers (AF) to thermal treatment with a laser beam. During this process, laser engraving of the researched material with variable beam power Pav and variable speed of the laser head vl were carried out. A metallographic analysis of the material was carried out. After laser engraving, surface structural changes of the material were determined. The properties of the surface geometric structure of processed material were also examined. Presented studies concern laser engraving on the surface of composite from the HMMC group, which was made by vacuum infiltration. Thanks to this method, it is possible both to produce shaped and precise composite castings with saturated reinforcement and to consequently minimize machining losses. Metal–ceramic composites from the HMMC group are hard-to-machine materials which create problems during machining. The aim of these studies was to develop a laser engraving technology with Al matrix composite with the addition of Al2O3 particles and aluminosilicate fibers, which constitute the reinforcement. The focus was on the selection of engraving parameters (beam power and speed of movement of the laser head). Clear examples of engraving, suitable for macro-assessment, were obtained with minimal change in the initial surface structure of the composite.
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Cholewa, M., and T. Szuter. "Shape Complicated Casting Defects Prediction Based on Computer Simulation." Archives of Metallurgy and Materials 58, no. 3 (September 1, 2013): 859–62. http://dx.doi.org/10.2478/amm-2013-0087.
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Abstract The impact of mould filling parameters on casting defects in shape complicated skeleton casting was investigated. Skeleton castings are low weight cellular material mainly used for energy absorption in for example automotive industry. For prediction of defects such as porosities, the computer simulations of mould filling and solidification were used. In such shape complicated structures like skeleton castings it is very difficult to predict localization of the defects. This knowledge is very important to gain information about deformation mechanisms and for impact behaviour modelling. Series of the skeleton castings were investigated by computer tomography to validate simulations results.
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Masri, Dewi, Wagiman Wagiman, and Bertha Maya Sopha. "Analisis potensi penerapan teknologi produksi bersih pada c-maxi alloycast, Yogyakarta." Jurnal Teknosains 12, no. 1 (December 22, 2022): 32. http://dx.doi.org/10.22146/teknosains.67962.
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CV C-Maxi Alloycast is an industry engaged in the manufacture of household appliances (pans) made of aluminum which is located in Yogyakarta. The aim of the study was to identify the potential application of clean production principles in CV C-Maxi Alloycast. The methods used were production process mapping, waste analysis through liquid waste testing and potential analysis of clean production principles. The results obtained for the production process were smelting aluminum and scrap, pouring molten metal into molds, lifting molds and providing coolant, lifting castings, turning, filing, quality control, storage and distribution. Based on the laboratory test, the characteristics of the liquid waste produced by the CV C-Maxi Alloycast were pH 8.9; COD 52.1 mg/L; BOD 21.4 mg/L; TSS 6660 mg/L; Fe 4,2440 mg/L; Cu 0.0130 mg/L; and Zn 0.0893 mg/L. All parameters indicate that the value meets the quality standard, but the TSS content did not meet the NAB (Threshold Value) which refers to the Regulation of the Minister of the Environment of the Republic of Indonesia No. 5 of 2014 and the Regulation of the Special Region of Yogyakarta (DIY) No. 7 of 2016. Clean production opportunities were: good housekeeping, application of 3R (Reduce, Reuse, Recycle) on solid waste, construction of B3 Waste TPS and capacity building of human resources. Environmental performance had increased based on the Green Industry Standard (SIH) from level 1 to level 2 with a value of 53% to 65% with the implementation of clean production. The economic performance of implementing clean production gains a profit of Rp. 77,412,000,-/year, then the second alternative, namely recycling aluminum scrap is an economical alternative to clean technology with a 5-year NPV value of Rp. 37,853,056,558,- Implementing clean production can have a positive impact on the environment and the economy.
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Kukartsev, Viktor Alekseevich, Alina Igorevna Trunova, Vladislav Viktorovich Kukartsev, Vadim Sergeevich Tynchenko, Sergei Olegovich Kurashkin, Yadviga Aleksandrovna Tynchenko, Ismael Flores Vivián, and Kirill Aleksandrovich Bashmur. "Increasing the Efficiency of Synthetic Iron Production by the Use of New Kit Lining." Metals 13, no. 7 (June 26, 2023): 1184. http://dx.doi.org/10.3390/met13071184.
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The production of synthetic iron castings in Russia comprises 50% of all alloys produced; therefore, increasing their smelting efficiency is an urgent task in the industry. This process depends primarily on the efficiency of industrial frequency induction crucible furnaces using acid lining. In the present study, the properties of quartzite, which forms the basis of such a lining, were investigated. An analysis of the proposed variants for changing the composition of the acid lining for use at temperatures of 1550–1600 °C was conducted. Following the preliminary temperature treatment of raw quartzite, which was then subjected to a sintering regime, we determined the conditions under which it was possible to obtain a phase state, allowing for the operation of the lining at temperatures above 1450 °C. We determined the use of an electrocorundum of two fractions as an additive to the traditional composition of the acid lining. The industrial testing of a new liner composition for the smelting of synthetic cast iron in an induction crucible melting furnace with a single steel scrap-metal filling was assessed, which required the use of an increased amount of carburizing agent. The positive results obtained can be explained by the study of the spent lining, which withstood 345 smelting methods of genophasic rent analysis. The results of the test are based on the results obtained in a study conducted on the finished coating of the product.
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Santamaría, Jon Ander, Jon Sertucha, Alberto Redondo, Ibon Lizarralde, Edurne Ochoa de Zabalegui, and Patxi Rodríguez. "Towards the Prediction of Tensile Properties in Automotive Cast Parts Manufactured by LPDC with the A356.2 Alloy." Metals 12, no. 4 (April 12, 2022): 656. http://dx.doi.org/10.3390/met12040656.
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Aluminum-silicon-magnesium alloys are commonly used in the automotive industry to produce structural components. Among usual quality controls of produced castings, microstructure characterization and determination of mechanical properties are the most critical aspects. However, important problems can be found when measuring mechanical properties in those areas of castings with geometrical limitations. In this investigation, a set of A356 alloys have been prepared and then used to manufacture test castings and automotive castings in a laboratory and in industrial conditions, respectively, using Low Pressure Die Casting (LPDC) technology. Test castings were used to predict secondary dendritic arm spacing (SDAS) by using thermal parameters obtained from experimental cooling curves. The results have been then compared to the ones found in the literature and improved methods for estimating SDAS from cooling curves have been developed. In a subsequent step, these methodologies have been checked with different industrial castings by using simulated cooling curves and experimentally measured SDAS values. Finally, the calculated SDAS values together with the Mg contents present in A356 alloys and the temperature and aging time data have been used to develop new models so as to predict the tensile properties in different areas of a given casting prototype. These developed models allow casters and designers predicting tensile properties in selected areas of a given prototype casting even during design and simulation steps and considering the processing variables expected in a given foundry plant. The structures of these new models have been described and experimentally validated using different processing conditions.
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Drotlew, A., M. Garbiak, and B. Piekarski. "Cast Steels for Creep-Resistant Parts Used in Heat Treatment Plants." Archives of Foundry Engineering 12, no. 4 (December 1, 2012): 31–38. http://dx.doi.org/10.2478/v10266-012-0103-0.
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Abstract Creep-resistant parts of heat treatment furnaces are in most cases made from high-alloyed chromium-nickel and nickel-chromium iron alloys, both cast and wrought. This paper presents the types of casting alloys used for this particular purpose, since the majority of furnace components are made by the casting process. Standards were cited which give symbols of alloy grades used in technical specifications by the domestic industry. It has been indicated that castings made currently are based on a wider spectrum of the creep-resistant alloy grades than the number of alloys covered by the standards. Alloy grades recommended by the technical literature for individual parts of the furnace equipment were given. The recommendations reflect both the type of the technological process used and the technical tasks performed by individual parts of the furnace equipment. Comments were also made on the role of individual alloying elements in shaping the performance properties of castings.
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Hadi, S., L. Agustriyana, and Subagiyo Subagiyo. "Project Based Learning on Casting of Aluminium Tensile Test Specimen for Mechanical Engineering Students, State Polytechnic of Malang on Odd Semester of Academic Year 2016/2017." Journal of Education Research and Evaluation 1, no. 1 (February 3, 2017): 6. http://dx.doi.org/10.23887/jere.v1i1.9844.
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The problem faced by students is the difficulty of understanding on metal casting topic in the lesson of Materials Technology which is conducted by lectures only. The research objective is to find out the improvement of score on metal casting topic for 1G students from Mechanical Engineering Department, State Polytechnic of Malang (Polinema) in odd Semester, Academic Year 2016/2017. Research method were facilitation of applied metal casting through pretest of metal casting, added a description of the design and modification of metal mould for Aluminium, visit to a home industry of Aluminium casting, students practice of Aluminium casting in a home industry, student groups presentation and discussion in the subtopics of (1) design and mould manufacture, (2) Aluminium casting practice, and (3) tensile testing with cast Aluminium specimen, as well as posttest on metal casting. The research result is an increasing in average score from 46.56 to 53.6 (22%) that means by adding the practice to the theory involved is increase a significant impact on understanding of Aluminium casting for students.