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Journal articles on the topic 'Sand casting'
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1
Major-Gabryś, Katarzyna, Małgorzata Hosadyna-Kondracka, Adelajda Polkowska, and Małgorzata Warmuzek. "Effect of the Biodegradable Component Addition to the Molding Sand on the Microstructure and Properties of Ductile Iron Castings." Materials 15, no. 4 (February 18, 2022): 1552. http://dx.doi.org/10.3390/ma15041552.
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In this work, the results of the examinations of the effect of the mold material and mold technology on the microstructure and properties of the casts parts of ductile cast iron have been presented. Four different self-hardening molding sands based on fresh silica sand from Grudzen Las, with organic binders (no-bake process), were used to prepare molds for tested castings. A novelty is the use of molding sand with a two-component binder: furfuryl resin-polycaprolactone PCL biomaterial. The molds were poured with ductile iron according to standard PN-EN 1563:2018-10. The microstructure of the experimental castings was examined on metallographic cross-sections with PN-EN ISO 945-1:2019-09 standard. Observations were made in the area at the casting/mold boundary and in a zone approximately 10 mm from the surface of the casting with a light microscope. The tensile test at room temperature was conducted according to standard PN-EN ISO 6892-1:2016-09. Circular cross-section test pieces, machined from samples taken from castings, were used. In the present experiment, it was stated that interactions between the mold material of different compositions and liquid cast iron at the stage of casting solidification led to some evolution of casting’s microstructure in the superficial layer, such as a pearlite rim observed for acidic mold sand, a ferritic rim for alkaline sand, and graphite spheroids degeneration, especially spectacular for the acidic mold with polycaprolactone (PCL) addition. These microstructural effects may point to the interference of the direct chemical interactions between liquid alloy and the components released from the mold sand, such as sulfur and oxygen. Particularly noteworthy is the observation that the use of molding sand with furfuryl resin with the addition of biodegradable PCL material does not lead to an unfavorable modification of the mechanical properties in the casting. The samples taken from Casting No. 2, made on the acidic molding sand with the participation of biodegradable material, had an average strength of 672 MPa, the highest average strength UTS-among all tested molding sands. However, the elongation after fracture was 48% lower compared to the reference samples from Casting No. 1 from the sand without the addition of PCL.
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Major-Gabryś, Katarzyna, Sabina Puzio, Agata Bryłka, and Jadwiga Kamińska. "The Influence of Various Matrixes on the Strength Properties of Moulding Sands with Thermally Hardened Hydrated Sodium Silicate for the Ablation Casting Process." Journal of Casting & Materials Engineering 5, no. 2 (July 5, 2021): 31–35. http://dx.doi.org/10.7494/jcme.2021.5.2.31.
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The essence of ablation casting technology consists in pouring castings into single-use moulds made from the mixture of sand and a water-soluble binder. After pouring the mould with liquid metal yet while the casting is still solidifying, the mould destruction (washing out, erosion) takes place using a stream of cooling medium, which in this case is water. This paper focuses on the selection of moulding sands with hydrated sodium silicate for moulds used in ablation casting. The research is based on the use of water glass 145 and 150 as binders. As part of the research, loose moulding mixtures based on two silica sands from different sand mines with different content of binders were prepared. The review of literature data and the results of own studies have shown that moulding sand with hydrated sodium silicate hardened by dehydration is characterized by sufficient strength properties to be used in the ablation casting process. Our own research also confirmed the possibility of using these sand mixtures in terms of both casting surface quality and sand reclamation. The results presented in this paper prove that both sand grains and types of binder tested may be used as components in moulding sands devoted to ablation casting.
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Kaila, Vishal N., and Indravadan B. Dave. "An Investigation into the Effect of Backup Coat Sands on Investment Casting Products." Jurnal Kejuruteraan 34, no. 1 (January 30, 2022): 109–15. http://dx.doi.org/10.17576/jkukm-2022-34(1)-10.
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Investment casting is a well-known method for producing precise and finished products. The shell-making process takes a long time and consumes a large amount of coating sands. On the wax pattern tree, the ceramic coating sands are used as a primary coat and several backup coats. Zirconia sand is used for primary coating on a shell in this work. Backup coat sands are made up of fused silica and alumina silica. Colloidal silica is used as a binding material in the formation of all shells. In the work, the effect of fused silica and alumina-silica sand as a backup coat on casting properties was determined. The experimental work evaluated casing properties such as microstructures, grain size measurement, gas porosity, and shrinkages. On the dried, de-waxed, and fired shell, the porosity of the shell mold was determined for the permeability level. Alumina-silica sand has a porosity of 27 to 31 percent, whereas fused silica has a porosity of 22 to 25 percent. It produces better casting properties in alumina–silica casting products than fused silica. Casting grain sizes range from 22 to 38 microns. The grain size of alumina-silica casting is finer than that of fused silica shell casting. Gas porosity and shrinkage in the casting were found to be moderate in all castings.
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Singh, Rupinder, and T. Lal. "Effect of Moulding Sand Properties on Cost Effective Hybrid Rapid Casting Solution for Zinc Alloy." Advanced Materials Research 264-265 (June 2011): 1637–42. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.1637.
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The purpose of the present experimental investigations is to study the effect of moulding sand properties on reducing the shell wall thickness of mould cavity for cost effective, hybrid rapid casting solution of zinc alloy. Starting from the identification of component/benchmark, technological prototypes were produced, with three different moulding sands (dry, green and molasses), at different shell wall thickness of mould cavity using hybrid rapid prototyping technique (combination of three dimensional printing and conventional sand casting). Measurements on the coordinate measuring machine helped in calculating the dimensional tolerances of the castings produced. Some important mechanical properties were also compared to verify the suitability of the castings. The study suggested that for the shell thickness, having value less than the recommended one is more suitable from dimensional accuracy and economic point of view, for all three moulding sands. Further best shell wall thickness of the mould cavity for different moulding sands, for the selected component/benchmark has been highlighted for rapid casting solution of zinc alloy.
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Jeon, Joo Mae, Soo Jo Lee, Kyeong Hwan Choe, and Jeung-Soo Huh. "Gas Pressure Effect on Sand Collapse in Kinetic Zone of Lost-Foam Casting." Advances in Materials Science and Engineering 2020 (April 25, 2020): 1–9. http://dx.doi.org/10.1155/2020/5861017.
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Pressure of the kinetic zone is an essential factor for making defect-free castings in lost-foam casting process. The extremely high pressure causes many problems, such as reducing the melt velocity and inclusion of residual decomposition of the pattern in the castings, and very low pressure causes sand collapse. Therefore, the minimum gas pressure for preventing sand collapse is required. When the minimum gas pressure can be predicted, computer simulation becomes possible. Successful computer simulations can help reduce the number of trials and the lead time while designing new casting products. A preliminary sand experiment was conducted to predict the gas pressure and reduce the number of actual casting experiments. In this preliminary sand experiment, compressed air was used instead of gas in the kinetic zone. A new mathematical equation was proposed from the results of the preliminary sand experiment. The void ratio of the sand effect on the minimum gas pressure was included in the equation. An actual casting experiment was conducted by melting nodular cast iron to verify this equation. In the actual casting experiment, pressure of the kinetic zone in front of the metal tip was directly measured. The results obtained from the preliminary sand experiment and the actual casting experiment validated the equation.
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Holtzer, M., A. Bobrowski, D. Drożyński, and J. Mocek. "Investigations of Protective Coatings for Castings of High-Manganese Cast Steels." Archives of Foundry Engineering 13, no. 1 (March 1, 2013): 39–44. http://dx.doi.org/10.2478/afe-2013-0008.
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Abstract When cast steel castings are made in moulding sands on matrices of high-silica sand, which has a low fire resistance the problem of the so-called chemical penetration is distinctly visible. Whereas this effect appears to a small degree only when moulding sand matrices are of chromite, zircon or olivine sands. Therefore in case of making castings of high-manganese cast steel (e.g. Hadfield steel) sands not containing free silica should be applied (e.g. olivine sand) or in case of a high-silica matrix protective coatings for moulds and cores should be used. Two protective coatings, magnesite alcoholic (marked as coating 1 and coating 2) originated from different producers and intended for moulds for castings of the Hadfield steel, were selected for investigations. Examinations of the basic properties were performed for these coatings: viscosity, thermal analysis, sedimentation properties, wear resistance. In order to estimate the effectiveness of protective coatings the experimental castings were prepared. When applying coating 1, the surface quality of the casting was worse and traces of interaction between the casting material (cast steel) and the coating were seen. When protective coating 2 was used none interactions were seen and the surface quality was better.
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Łucarz, M. "Analysis of Spent Moulding Sands with Binders of Various Thermal Degradations, in an Aspect of a Possibility of a Directional Mould Degassing." Archives of Foundry Engineering 16, no. 2 (June 1, 2016): 21–26. http://dx.doi.org/10.1515/afe-2016-0020.
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Abstract The results of investigations of spent moulding sands taken from the mould in which the metal core cooling system - to increase the cooling rate of the ladle casting - was applied, are presented in the hereby paper. The changes of the spent moulding sand at the casting external side being the result of degradation and destruction processes of organic binder, were analysed in this publication. Since the reclaimed material, obtained as a result of the mechanical reclamation of spent sands of the same type, is used as a grain matrix of the moulding sand, the amount of a binder left from the previous technological cycle is essential for the sound castings production. On the bases of investigations of the thermal analysis, ignition losses, dusts contents and pH values of the samples taken from the spent sand the conditions under which the process of gases displacing in the casting mould was realised as well as factors limiting the efficient mould degassing - were considered in this study. The possible reason of a periodical occurrence of an increased number of casting defects due to changing gas volume emission, being the reason of the realised technological process, was indicated.
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Chang, Qing Ming, Jing Yuan, Yin Kai Yang, and Xia Chen. "Modeling Analysis and Optimization of Sand Casting Process." Advanced Materials Research 479-481 (February 2012): 226–29. http://dx.doi.org/10.4028/www.scientific.net/amr.479-481.226.
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In this research paper, the sand casting process of a cover-type part for wind turbine was investigated with ProCAST software . The cover-type casting part is big in two dimensions and it is heavy in some local positions where shrinkage cavity and porosity are very likely to from. A non-uniform mesh is used corresponding to the non-uniform wall thickness. Different casting processes are employed, simulated and optimized to obtain sound castings. Simulation results reveal that with appropriate pouring temperature, correct number, size and location of chills and risers, a smooth mold filling, reduced shrinkage and other defects are available and desired sound castings can be produced
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Luo, Yi Lan, Shi Gen Zhu, Zheng Gang Yang, and Rui Zhang. "Study on the Mechanism of the Strippable Sintering Layer of the Natural Yellow Clay-Bonded Sand for Iron Casting." Applied Mechanics and Materials 66-68 (July 2011): 1622–27. http://dx.doi.org/10.4028/www.scientific.net/amm.66-68.1622.
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The distinguished characteristic of casting process of natural yellow clay-bonded green sand is a strippable sintering layer formed at the interface of casting and mould. Hot shake-out can be realized because this sintering layer can firmly attach to the casting surfaces to protect castings at elevated temperature. Better surface quality of castings is achieved after the sintering layer easily shed from the casting surface at room temperature. In this study, a series of tests were carried out to reveal the characteristic of this sintering layer. First, thermal gravimetric/differential thermal analysis (TG/DTA) method was used for detailed analysis the thermal property of natural yellow clay-bonded green sand. And, X-ray diffraction (XRD) analysis was employed to define the phase composition at variable temperatures. Then, sintering experiments were carried out on mixtures of natural yellow clay-bonded sand with iron powder or iron oxides under different conditions. Finally, the mechanical performances of sinter layer of natural yellow clay-bonded sand at elevated and room temperatures were investigated. The result revealed that natural yellow clay-bonded green sand is a kind of low grade molding sand, and iron oxides participate in the forming of sintering layer. The sintering layer of natural yellow clay-bonded sand were proved both excellent plastic at elevated temperature and brittle at room temperature, which coincides with its behavior in the casting process.
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Hendronursito, Yusup, and Yogi Prayanda. "POTENSI PASIR LOKAL TANJUNG BINTANG PADA ALUMINIUM SAND CASTING TERHADAP POROSITAS PRODUK HASIL COR ALUMINIUM." JURNAL KAJIAN TEKNIK MESIN 1, no. 2 (September 21, 2016): 60–68. http://dx.doi.org/10.52447/jktm.v1i2.336.
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Green sand is one of the most important components in the process of metal casting. The sand in Indonesia region is varied level of subtlety, size of sand, and shape of sand. Green sand used in the process of metal casting is possible can affect the quality of casting product. This aims to determine the potential of Tanjung Bintang sand as green sand and the quality of the product in terms of porosity defects. The research was conducted by varying sand river from Tanjung Bintang and sand from Maringgai. Composition made varying is 100%,75%, 50%, and 25% Tanjung Bintang sand compared Maringgai sand with bentonit and water is 10% and 5% constantly .The Examine of the green sand by SNI 15-0312-1989 among other water content, clay content, Grain Finnest Number (GFN), Shape of grain. The result said aluminium casting product with 50% Tanjung Bintang sand has the lowest value of porosity, 5.08% and the higher value with 75% composition of Tanjung Bintang sand, 6.98%.
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Al-Zuhairi, Haitham Mohammed Ibrahim, Iqbal Alshalal, Auday Awad Abtan, Baha Sami Mahdi, and Muna Khalil Asmail. "Influence of the mold type on the mechanical properties of the piston alloy with nano alumina in casting and metal mold." Eastern-European Journal of Enterprise Technologies 5, no. 12 (119) (October 30, 2022): 21–30. http://dx.doi.org/10.15587/1729-4061.2022.266263.
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This research is an experimental comparison study to show the influence of mold type casting on mechanical properties. The study considers the aluminum alloy of a gasoline engine piston with nanoparticles alumina Al2O3 size 25 nm manufactured in two types of molds. Sand mold and cast-iron mold were selected to cast the aluminum composite components. A systematic comparative study of tensile strength and hardness properties of cast aluminum components is made on sand and metal molds production. The nano powder can add to enhance the mechanical properties must not exceed 4 % for metal and sand mold casting. According to data for hardness, adding nano alumina powder has minimal impact on metal mold casting, but it significantly improves sand casting. From a financial standpoint, metal casting provides higher economic values for making piston aluminum castings. The hardness rises as the alumina content does in two molds as compared to the obtained specimen. It demonstrates that the highest hardness occurs at 4 % alumina in the sand-casting mold and at 6 % alumina in the metal. When the compositions of the casting materials are the same, a comparison of the fracture morphology between sand and mold casting reveals more ductile fractures for metal molds compared to brittle fractures in sand cast by large silicon separation grains because of higher grain growth in sand casting by longer solidification time. The same is seen in mold casting, which exhibits reduced ductility due to the alumina nanoparticles' dispersion strengthening process in the aluminum matrix. This arises as a result of nano alumina dispersion acting as barriers to dislocation motions in the aluminum matrix, enhancing strength but reducing ductility.
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Korenchenkova, D. E., and N. А. Polyakov. "Features of the technology of obtaining a propeller screw casting from BrAZHN bronze." Transactions of the Krylov State Research Centre S-I, no. 1 (December 8, 2021): 287–88. http://dx.doi.org/10.24937/2542-2324-2021-1-s-i-287-288.
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Peculiarities of propeller propeller castings production are considered with indication of unique properties and requirements. Shown is a diagram of a one-time sand mold for casting blades. All possible variants of the molding sand, inspection and acceptance of the cast blades are given. The measures for checking, accepting and inspecting the castings of propellers and blades are indicated. A full cycle of propeller screw casting technology is considered.
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Asano, Kazunori, Takeshi Nagase, Shigeo Kashiwai, Takahiro Kaneyoshi, and Kazuhiro Kitamura. "Metal Casting and Sand Mold: (3) Sand Casting Practice at University." Materia Japan 61, no. 8 (August 1, 2022): 493–98. http://dx.doi.org/10.2320/materia.61.493.
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Dybowski, B., A. Kiełbus, and R. Jarosz. "Mould Components Impact on Structure and Quality of Elektron 21 Alloy." Archives of Foundry Engineering 13, no. 2 (June 1, 2013): 17–23. http://dx.doi.org/10.2478/afe-2013-0029.
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Abstract Magnesium alloys due to their low density and high strength-to-weight ratio are promising material for the automotive and aerospace industries. Many elements made from magnesium alloys are produced by means of sand casting. It is essential to investigate impact of the applied mould components on the microstructure and the quality of the castings. For the research, six identical, 100x50x20mm plates has been sand cast from the Elektron 21 magnesium casting alloy. Each casting was fed and cooled in a different way: one, surrounded by mould sand, two with cast iron chills 20mm and 40mm thick applied, another two with the same chills as well as feeders applied and one with only the feeder applied. Solid solution grain size and eutectics volume fraction were evaluated quantitatively in Met-Ilo program, casting defects were observed on the scanning electron microscope Hitachi S3400N. The finest solid solution grain was observed in the castings with only the chills applied. Non metallic inclusions were observed in each plate. The smallest shrinkage porosity was observed in the castings with the feeders applied.
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Solonenko, L. I., S. I. Repiakh, K. I. Uzlov, A. V. Dziubina, and S. O. Abramov. "Sand-sodium-silicate mixtures structured in steam-microwave environment effective values of thermo-physical properties." Naukovyi Visnyk Natsionalnoho Hirnychoho Universytetu, no. 6 (2021): 66–71. http://dx.doi.org/10.33271/nvngu/2021-6/066.
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Purpose. Sand-sodium-silicate mixtures, structured by steam-microwave solidification, thermo-physical properties integral-effective values during Al-Mg alloy and graphite cast iron pouring determination. Sand-sodium-silicate mixture apparent density changing according to quartz sand, cladded with sodium silicate solute, fractional composition and its influence on BrA9Zh3L bronze microstructure establishment. Methodology. Quartz sand with 0.23 mm average particle size, sodium silicate solute, aluminum alloy with 8.5% Mg, flake graphite cast iron SCh200 (DSTU 8833:2019), bronze BrA9Zh3L (GOST 493-79) were used. Mixtures structuring was carried out in 700 W magnetron power microwave furnace. Sand-sodium-silicate mixture thermo-physical properties integral-effective values were calculated by G.A.Anisovich method, using castings results and molds thermography. Structured mixtures apparent density was determined on samples 50 120 mm dimension. Metallographic studies were realized using Neophot-21 optical microscope. Findings. It was found that with sodium silicate solute, used for sand cladding, amount increasing from 0.5 to 3% mold material apparent density decreases and thermal activity lowers. This leads to castings grains size increasing. Mixture sodium silicate solute content was recommended limiting 1.5% for fine-grained microstructure castings obtaining and cladded sand using, which particles pass through mesh side less 0.315 mm sieve. Sands with sodium silicate solute content more than 1.5%, which dont pass through sieve 0.4 mm mesh side, were recommended as casting molds heat-insulating material using. Originality. For the first time, when aluminum-magnesium alloy and graphite cast iron pouring, quartz sand cladded with sodium silicate solute in amount from 0.5 to 3.0% (weight, over 100% quartz sand), steam-microwave radiation structured, thermo-physical properties integral-effective values were determined. Practical value. Data obtained using will improve castings solidification time and rate analytical calculations accuracy, forecast level and residual stresses sign in them, shrinkage defects locations. This will reduce casting technology developing time and costs and castings manufacturability.
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Niakan, Ali Asghar, M. H. Idris, A. Ourdjini, and Majid Karimian. "Effect of Applying Air Pressure on Gas Porosity in Lost Foam Casting of Al-Si Alloy." Advanced Materials Research 628 (December 2012): 150–55. http://dx.doi.org/10.4028/www.scientific.net/amr.628.150.
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The paper presents the result of investigation on aluminum-silicon (LM6) alloy cast using pressurized lost foam casting process. The study investigated the effect of pressure and sand size on porosity of the casting produced. Air pressure of 1, 2, 3 and 4 bars was applied on the solidifying alloy poured in mould of sand sizes 16-30, 40-60, 60-100 (AFS). The porosities of casting were measured using optical microscope which was equipped with image analyzer. For porosity of castings, all surfaces of solidified castings were captured by digital camera for better observation. The results show that applying pressure during solidification of the LM6 alloy has significant influence on casting porosity of the alloy. By increasing the applied pressure, the porosity percentage based on gas porosity decreased when pressure was applied. Consequently, the removal rate of gas porosity improved by increasing the sand size to finer size 60-100 (AFS), so there is less gas porosity in samples. Besides, rising air pressure lead to fulfilling of molten which improves the casting porosity.
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Kashiwai, Shigeo, Takahiro Kaneyoshi, Takeshi Nagase, Kazunori Asano, and Kazuhiro Kitamura. "Metal Casting and Sand Mold: (2) Education Materials for Sand Mold Castings." Materia Japan 61, no. 7 (July 1, 2022): 437–42. http://dx.doi.org/10.2320/materia.61.437.
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Niakan, Ali Asghar, M. H. Idris, Ali Ourdjini, and Majid Karimian. "Properties of Pressurized Lost Foam Casting of Al-11Si Alloy." Advanced Materials Research 383-390 (November 2011): 1730–34. http://dx.doi.org/10.4028/www.scientific.net/amr.383-390.1730.
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Lost Foam Casting, pressurized casting, solidification, mechanical properties. Abstract. The paper presents the result of investigation on aluminum-silicon (LM6) alloy cast using pressurized lost foam casting process. The study investigated the effect of pressure and sand size on hardness and roughness of the casting produced. Air pressure of 1, 2, 3 and 4 bars was applied on the solidifying alloy poured in mould of sand sized 40-60(AFS). The roughness and hardness of the casting was measured using Hobson (Surtronic 3+) and Vickers hardness testing machine respectively and reported in the average of ten readings. For roughness measurement of the solidified castings, measurement was conducted in 25mm run whilst 11kgf was applied for Vickers hardness indentation test. The results show that using of finer sand size besides applying pressure during solidification of LM6 alloy has significant influence on roughness and hardness of the alloy. Increasing the applied pressure and used of fine sand size expedited heat transfer from the melt to the mould and surrounding thus decreasing solidification time. Consequently, reduced casting surface roughness as well as increased in hardness.
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Zeng, Jian Min, and Yao He Zhou. "A New Sand Casting Process with Accelerated Solidification Rate." Materials Science Forum 686 (June 2011): 765–69. http://dx.doi.org/10.4028/www.scientific.net/msf.686.765.
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In order to solve the problems involved in coarse grains, macro and micro porosities initiated by low solidification rate in sand casting, an innovative counter-gravity sand casting process, Casing under Adjustable Pressure with Accelerated Solidification (CAPAS) was put forward in this paper. The hydrodynamics of mold filling for CAPAS is based on Bernoulli's principle. The mold and crucible were placed separately in the upper and lower chambers, with the feed tube connected between them. High-speed jet flow of air made negative pressure in the upper chamber. In this way, pressure differential was created between the two chambers. Thereby the molten metal in the crucible was forced to flow upward smoothly to fill the mold cavity. After mold filling, cold air was introduced into sand mold through aisles that are set within the mold, which results in strong convective heat exchange at the casting/mold interface. So solidification rate of casting increased dramatically. The microstructures of the aluminum castings were compared between CAP (Low pressure sand casting) and CAPAS by optical microscope. The results showed that the microstructure of CAPAS aluminum casting was much finer than that of CAP casting and tensile strength markedly increased.
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Hebsur, Naveen, and Sunil Mangshetty. "Casting Simulation for Sand Casting of Flywheel." IOSR Journal of Mechanical and Civil Engineering 11, no. 4 (2014): 37–41. http://dx.doi.org/10.9790/1684-11473741.
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Saleem, M., and M. Makhlouf. "Helium-Assisted Sand Casting." International Journal of Metalcasting 6, no. 4 (October 2012): 43–59. http://dx.doi.org/10.1007/bf03355538.
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Lee, Jeong-Min, Moon-Jo Kim, Kyeong-Hwan Choe, and DongEung Kim. "A Study on the Prediction of Characteristics of Molding Sand Using Machine Learning and Data Preprocessing Techniques." Korean Journal of Metals and Materials 61, no. 1 (January 5, 2023): 18–27. http://dx.doi.org/10.3365/kjmm.2023.61.1.18.
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The main components of molding sand used in sand casting are sand, clay and water. The composition of the molding sand has a great influence on the properties of the casting. In order to obtain high-quality castings, it is important to manage the components that affect the properties of the molding sand such as especially green compression strength and compactability. In this work, green compression strength and compactability are predicted through a machine learning technique using the processing data obtained from a foundry and the properties of molding sand as the input variables. Through the correlation analysis between the input variables and the response variable, we investigated the relationship between the processing data and the properties of the molding sand. The possibility of predicting the characteristics of molding sand with high accuracy was confirmed using a model created through data preprocessing with the real foundry data. If the composition of the molding sand is adjusted in the foundry using the generated model, it is expected that higher quality castings can be produced and the productivity can be increased.
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I Ketut Gede Sugita, Ketut Astawa, and I Gusti Ngurah Priambadi. "The characteristics of the mechanical and acoustic bronze cu20sn as traditional bell material." Global Journal of Engineering and Technology Advances 16, no. 1 (July 30, 2023): 058–63. http://dx.doi.org/10.30574/gjeta.2023.16.1.0140.
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This study is aimed to find out the mechanical and acoustic characteristics of casting traditional bell's result using metal mold and sand mold. The mechanical and acoustic characteristics of casting traditional bell's result are compared between metal molded and sand molded casting. The bronze alloy was smelted in a crucible furnace at the casting temperatures of 1000, 1050, and 1100 °C. The melted alloy is poured into a sand mold and a preheated metal mold at a temperature of 200 °C. Specimens were formed into bell and billet. The bell form was for acoustic testing. The Billet casted was cut into a few parts and were manufactured as a specimen for hardness test. This study has showed that mechanical characteristic specifically the hardness of metal molded casting is better than sand molded casting. The Acoustic properties of particular damping characteristicsis depended on the porosity of casting’s result. The bell’s tone isn’t produced by the mono frequency but it’s generated by more than one frequency domain. Similarly, the subjective test of acoustic characteristic didn’t show a significant obvious difference.
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He, Bin Feng. "Simulation and Optimization of Steel Casting by Sand Casting." Advanced Materials Research 706-708 (June 2013): 258–61. http://dx.doi.org/10.4028/www.scientific.net/amr.706-708.258.
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Casting defects will always occurred in the cast-steel castings. In order to eliminate the shrinkages more and more risers had been used which increased the final cost sharply. The traditional method was used to the designing process; besides that, the foundry simulation software was introduced to prove the rationality of the technique. The software helps to predict the proper position of the shrinkages. The cooling system was optimized after the analyzed and the final simulation results show the rationality of foundry technique.
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Grabowska, Beata, Sylwia Cukrowicz, Artur Bobrowski, Dariusz Drożyński, Sylwia Żymankowska-Kumon, Karolina Kaczmarska, Bożena Tyliszczak, and Alena Pribulová. "Organobentonite Binder for Binding Sand Grains in Foundry Moulding Sands." Materials 16, no. 4 (February 14, 2023): 1585. http://dx.doi.org/10.3390/ma16041585.
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A series of studies related to the production of organobentonite, i.e., bentonite-poly(acrylic acid), and its use as a matrix grain-binding material in casting moulding sand is presented. In addition, a new carbon additive in the form of shungite was introduced into the composition of the moulding sand. Selected technological and strength properties of green sand bond with the obtained organobentonite with the addition of shungite as a new lustrous carbon carrier (Rcw, Rmw, Pw, Pw, PD) were determined. The introduction of shungite as a replacement for coal dust in the hydrocarbon resin system demonstrated the achievement of an optimum moulding sand composition for practical use in casting technology. Using chromatographic techniques (Py-GC/MS, GC), the positive effect of shungite on the quantity and quality of the gaseous products generated from the moulding sand during the thermal destruction of its components was noted, thus confirming the reduced environmental footprint of the new carbon additive compared to the commonly used lustrous carbon carriers. The test casting obtained in the mould of the organobentonite moulding sand and the shungite/hydrocarbon resin mixture showed a significantly better accuracy of the stepped model shape reproduction and surface smoothness compared to the casting obtained with the model moulding sand.
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Puga, Hélder, Joaquim Barbosa, and Joana Oliveira. "Use of Acoustic Energy in Sand Casting of Aluminium Alloys." Advanced Materials Research 690-693 (May 2013): 2366–70. http://dx.doi.org/10.4028/www.scientific.net/amr.690-693.2366.
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During the last years, some researchers have focused the development of ultrasonic microstructure refinement /modification techniques of die-casting aluminium alloys, to improve their properties. The developed techniques are highly efficient when applied to the die-casting process, but their capability with sand and ceramic moulding are unknown. Sand/ceramic aluminium castings are prone to coarse microstructure, porosities and inclusions due to low cooling rates and turbulent gravity pouring, and suitable processing techniques are required to eliminate those drawbacks. This article reports some results of a research work aiming the development of a reliable, low-cost and environmentally friend casting process, for geometrically complex and massive high strength sand/ceramic aluminium castings, to eliminate traditional soundness related defects and simultaneously promote the development of refined microstructures. The article presents the effect of applying ultrasound to AlSi9Cu3 alloy during solidification on a sand mould on the resultant microstructure. Results include microstructure characterization and its relationship with thermal analysis data collected from the center of the cast samples during cooling.
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Xu, Jingying, Jinwu Kang, Haolong Shangguan, Chengyang Deng, Yongyi Hu, Jihao Yi, and Weimin Mao. "Chimney Structure of Hollow Sand Mold for Casting Solidification." Metals 12, no. 3 (February 26, 2022): 415. http://dx.doi.org/10.3390/met12030415.
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The hollow sand mold can affect the cooling of the casting during the solidification process. A chimney structure of a hollow sand mold that mainly consists of a two-layer shell with through channels was proposed. The design method was proposed for the chimney structure. Due to the chimney effect, cool air can enter the chimney from the bottom entrance, and hot air flows out from its top opening. Air transfers heat from the sand mold and forms a temperature gradient from bottom to top. A hollow sand mold with a chimney structure was applied to the wedge plate casting. During the solidification process, natural cooling and forced air cooling through open channels were applied. The effects of the chimney on the microstructure, mechanical properties, and residual stress of the castings under these two different cooling conditions were analyzed and compared with those of the casting in a dense mold. During the solidification stage of the castings, the chimney structure prolonged their solidification time. After solidification, the chimney structure under forced air condition increased the cooling rate of the castings by 61% and the temperature gradient along the vertical direction by a factor of three. The Si content in the Al matrix increased by 20.4%, and the tensile strength increased by 32.66%.
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Łucarz, M., and D. Drożyński. "Influence of the reclamation method of spent moulding sands on the possibility of creating favourable conditions for gases flow in a mould." Archives of Metallurgy and Materials 62, no. 1 (March 1, 2017): 359–64. http://dx.doi.org/10.1515/amm-2017-0055.
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Abstract The results of investigations concerning the influence of the applied sand matrix (fresh sand, reclaim) on the properties of moulding sands used for production of large dimensional castings (ingot moulds, ladles), are presented in the hereby paper. The performed investigations were aimed at determining the influence of various reclamation methods of spent moulding sands on the quality of the obtained reclaimed material. Moulding sands were prepared on the fresh quartz matrix as well as on sand matrices obtained after various reclamation methods. The selected moulding sand parameters were tested (strength, permeability, grindability, ignition losses, pH reactions). It can be stated, on the basis of the performed investigations, that the kind of the applied moulding sand matrix is of an essential meaning from the point of view of creating conditions minimising formation of large amounts of gases and their directional migration in a casting mould.
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Ajay, R., and S. Lovneesh. "Experimental Study on Effect of Sand Grain Size and Heat Dissipation on the Properties of Moulding Sand." IOP Conference Series: Earth and Environmental Science 1110, no. 1 (February 1, 2023): 012078. http://dx.doi.org/10.1088/1755-1315/1110/1/012078.
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Abstract The rate of heat dissipation affects the solidification of the casting. A controlled cooling rate is necessary to produce defect-free castings. Sand qualities such as green compression strength, permeability, flow ability, mould hardness, and compactibility play a key role in controlled cooling or uniform heat flow across the casting. A research is executed in this paper to see how these properties affect the heat dissipation rate. The coarse grain and fine grain sand particle sizes are the most important influencing elements. The solidification time for casting in coarse, medium, and fine grains was noted in the results, and it was discovered that the cooling rate is better for coarse sand grains, as well as a relationship between solidification time and sand qualities was developed. During the experimental results it was observed that highest value of compactability was found to be 72% in case of medium sand, highest value of flowability was found out to be 87% in case of medium sand and highest value of permeability number was found in case of course sand particles i.e. 471.
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Marukovich, E. I., V. M. Iljushenko, V. A. Pumpur, and V. M. Andrienko. "INVESTIGATION OF CARBON INFLUENCE IN CROMIUMIUM CAST IRONS FOR FORMING CASTINGS IN SAND AND COMBINED MOLDS." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 1 (April 6, 2018): 41–46. http://dx.doi.org/10.21122/1683-6065-2018-1-41-46.
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The results of research to determine the influence of the amount of carbon in chromium cast irons on the formation of castings in sand and combined molds are described in the article. Experimental studies were carried out with casting samples from wearresistant cromium cast iron with different carbon contents. The microstructure of the obtained samples is presented, and its analysis is performed. Numerical studies have been carried out to evaluate the effect of the carbon content on the dynamics and kinetics of hardening of castings in sand and combined molds. The influence of the carbon content on the hardening process of cromium cast iron castings during foundry casting in sand and combined molds is established. The results of the research were used for the manufacture parts of crushing and grinding equipment.
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Fukihara, Makoto, Hiroyasu Makino, and Kunihiro Hashimoto. "Automation in Green Sand Processing Equipment." International Journal of Automation Technology 2, no. 4 (July 5, 2008): 280–84. http://dx.doi.org/10.20965/ijat.2008.p0280.
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Green sand molding is indispensable in the mass production of iron castings such as those used for automobiles. Green sand processing equipment, which plays an important role in maintaining casting quality by supplying steadily mixed sand, includes that used in mold removal and sand recovery, sand cooling, storage, mixing, and supply to the molding machine, as detailed in the sections that follow.
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Svidró, J., A. Diószegi, L. Tóth, and J. T. Svidró. "The Influence of Thermal Expansion of Unbonded Foundry Sands on the Deformation of Resin Bonded Cores." Archives of Metallurgy and Materials 62, no. 2 (June 1, 2017): 795–98. http://dx.doi.org/10.1515/amm-2017-0118.
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AbstractDepending on the preparation and the applied materials, moulds and cores can be of high rigidity or can be flexible. Although, chemically bonded moulding materials have relatively good flexibility, their high temperature behaviour determines the dimensional accuracy, the stresses in the castings and can induce several casting defects, such as rattail, veining, etc. The phenomenon is based on two major effects: the thermal expansion of the unbonded foundry sands and the deformation of the sand mixtures. The main objective of the present work was to study the relationship between these two effects, and to improve the knowledge related to the thermo-mechanical interactions between the casting and the mould. Dilatometric analysis of unbonded sand samples were performed and compared to the results of hot distortion tests of moulding mixture specimens. The results showed, that the thermal expansion of foundry sand largely influences the hot distortion behaviour, but depending on the type of binder used.
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Kaskani, Mehdi, and Behzad Niroumand. "On Non-Dendritic Microstructure Formation during Sand Casting of A356 Alloy." Solid State Phenomena 192-193 (October 2012): 433–40. http://dx.doi.org/10.4028/www.scientific.net/ssp.192-193.433.
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The purpose of this study was to develop a new method for formation of non-dendritic microstructure during sand casting of aluminum alloys without any previous special processing. For this purpose, sand molds with three different types of running systems were designed. The first design included a traditional reverse tapered vertical sprue. The second design was similar to the first one except for a conical sand core placed inside the lower half portion of the sprue creating a narrow gap for the flow of the melt into the mold. In the third design, the core was fitted with metal chills. Molten A356 alloy was then cast from fully liquid state under gravity and centrifugal casting conditions in the molds and the microstructures of the castings were studied. The results showed that non-dendritic microstructure could be achieved by using the last design under low superheat temperature and centrifugal casting conditions. The findings can pave the way for small quantity production of semisolid castings in expendable molds.
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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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Kolokoltsev, V. M., A. S. Savinov, and A. S. Tuboltseva. "Calculation of Impeded Shrinkage Casting Processes in Sand Layer." Materials Science Forum 870 (September 2016): 516–22. http://dx.doi.org/10.4028/www.scientific.net/msf.870.516.
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The paper considers the issue of shrinkage stresses of elastic-plastic deformation in the casting ‘Slag bowl’ resulting in a discontinuity and hot crack formation. The stress-strain state of the wall of the as-cast billet during the process of power interaction between the casting and the mould has been analysed according to the existing algorithms. Quantitative indicators of the components of the total stress state in the wall of the casting at the time of hot crack formation were determined. It was found that the bending stress greatly affects the defect, comprising 96 % of the tensile strength of the casting material at the time of destruction. The techniques aimed at reducing hot crack formation in a body of as-cast billet based on the results from the calculations are recommended. In accordance with the proposed recommendations, the changes in the technological parameters in production of a batch of pilot castings showed a decrease in the defect on hot cracks by 73 %.
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Żymankowska-Kumon, S., M. Holtzer, J. Lelito, and R. Dańko. "Determination of the Overheating Degree of Moulding Sand with Bentonite - on the Grounds of Simulation Investigations." Archives of Foundry Engineering 12, no. 4 (December 1, 2012): 176–80. http://dx.doi.org/10.2478/v10266-012-0128-4.
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Abstract A determination of the heating degree of the moulding sand with bentonite on the grounds of simulating investigations with the application of the MAGMA program, constitutes the contents of the paper. To this end the numerical simulation of the temperature distribution in the virtual casting mould was performed. It was assumed that the mould cavity was filled with a moulding sand with bentonite of a moisture content 3,2 % and bentonite content 8 %. A computer simulation can be used for predicting the heating degree of moulding sands with bentonite. Thus, prediction of the active bentonite (montmorillonite) content in individual layers of the overheated moulding sand can be done by means of the simulation. An overheating degree of a moulding sand with bentonite, and thus the bentonite deactivation depends on a temperature of a casting alloy, casting mass, ratio of: mass : masscasting, moulding sand amount in the mould and contact area: metal - mould (geometry of the casting shape). Generally it can be stated, that the bentonite deactivation degree depends on two main factors: temperature of moulding sand heating and time of its operation.
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Sertucha, Jon, and Jacques Lacaze. "Casting Defects in Sand-Mold Cast Irons—An Illustrated Review with Emphasis on Spheroidal Graphite Cast Irons." Metals 12, no. 3 (March 16, 2022): 504. http://dx.doi.org/10.3390/met12030504.
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Cast irons are known to be easy to shape by sand casting due to their high eutectic fraction. Despite this fact, together with cost benefits, obtaining good quality castings is not an easy task, although it depends on the level of defects allowed in each case. Casting defects are here reviewed and classified into three classes according to their known main origin: (1) related to the sand mixtures used to make the molds; (2) associated with the mold design and the geometry of the castings; (3) related to the casting alloy itself. The present work is an illustrated description of these defects, with details of their origin when well established, and of known remedies. In addition, an attempt has been made to clarify the possible cross-effects of the above three origins.
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Haque, Mohammad M., and Ahmad Faris Ismail. "Effect of Cooling Rate on Strength and Fracture Surfaces of Alpha Brass Casting." Advanced Materials Research 33-37 (March 2008): 7–12. http://dx.doi.org/10.4028/www.scientific.net/amr.33-37.7.
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Green sand casting and chill mould casting methods are representing the slow and fast cooling rates of the brass casting, respectively. The compositions of the raw material for this study were about Cu70 and Zn30, which falls under alpha (α) brass. Slow cooling rate casting shows coarse dendritric structures with large spacing between the dendrites. On the other hand, faster cooling rate casting shows finer grains with shorter dendrite spacing. The developed structure during solidification influences the properties of the cast samples. As grain size decreases, the strength of the cast brass increases; micro-porosity in the casting decreases and the tendency for the casting to fracture also decreases. However, the macro-examinations of fracture surfaces of these castings show the differences in the cast samples. Fracture surfaces of the sand cast specimen show larger dimples taking longer time to break indicating higher elongation. However, chill cast specimen shows smaller dimples and cleavage type fracture surface having higher strength and lower elongation.
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Dańko, R. "Assessment Method of Overheating Degree of a Spent Moulding Sand with Organic Binder, After the Casting Process." Archives of Foundry Engineering 13, no. 2 (June 1, 2013): 11–16. http://dx.doi.org/10.2478/afe-2013-0028.
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Abstract A proper management of sand grains of moulding sands requires knowing basic properties of the spent matrix after casting knocking out. This information is essential from the point of view of the proper performing the matrix recycling process and preparing moulding sands with reclaimed materials. The most important parameter informing on the matrix quality - in case of moulding sands with organic binders after casting knocking out - is their ignition loss. The methodology of estimating ignition loss of spent moulding sands with organic binder - after casting knocking out - developed in AGH, is presented in the paper. This method applies the simulation MAGMA software, allowing to determine this moulding sand parameter already at the stage of the production preparation.
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WAKHI ANUAR, NUR FARAH BAZILAH BINTI, M.L. Mohd Khusairi, R.M. Saad, S.A. Hassan, Z. Marjom, and A.H. Abdul Rasib. "Green strength properties of waterjet abrasive waste as potential composition in green mould by Taguchi and ANOVA approach." Journal of Mechanical Engineering and Sciences 15, no. 4 (December 15, 2021): 8529–39. http://dx.doi.org/10.15282/jmes.15.4.2021.06.0672.
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The sand casting process still continues today due to the cost-effectiveness of materials and processes. There is a wide variety of castings related to composition and size, but silica sand is widely available from coastal line mining and has a negative impact on the environment. Moreover, waste from waterjet cutting of non-ferrous and ferrous metals is practically unhazardous and may potentially be used in sand casting mould. The aim of this paper is to optimize the proportion of coal dust, water and bentonite added to the silica sand mixture and the waterjet cutting abrasive waste as a new way of handling waste with the potential to be used in sand casting manufacturing. The method used was L9 orthogonal array optimization and the composition was qualitatively measured using a green compression strength test and a green shear strength test. Factors were evaluated using the analysis of variance (ANOVA) to find the the critical factors while confirmation test was conducted for the optimal material proportion. The study concluded that the ideal ratio for silica sand mixture with waterjet abrasive waste is bentonite-12%, coal dust-5%, and water-7% for green compression strength while bentonite-12%, coal dust-6%, water-7% for green shear strength. With proper selection, the incorporation of waterjet abrasive waste into the green sand mixture is promising to potentially be used in green sand mould casting without undermine the quality of mould.
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Izman, S., Amirreza Shayganpour, and M. H. Idris. "Effect of Casting Parameters on Porosity in LFC." Applied Mechanics and Materials 148-149 (December 2011): 1198–201. http://dx.doi.org/10.4028/www.scientific.net/amm.148-149.1198.
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Cast aluminium alloys often contain microstructural defects resulting from the casting process such as porosity. Developments of Lost foam casting (LFC) process is considered as one of the most rapid in casting technology owing to its unique advantages on energy savings and capabilities to produce castings with thin sections. In the present research, experimental investigations in lost foam casting of aluminium-silicon cast alloy, LM6, were conducted. The main objective of the study was to evaluate the effect of different pouring temperatures, slurry viscosities, vibration times and sand sizes on the porosity of castings. A stepped pattern was used in the study and the focus of the investigations was at the thinnest 3 mm section. A full 2-level factorial design experimental technique was employed to plan the experiment and subsequently identify the significant factors which affect the casting porosity. The result shows that increasing in the pouring temperature decreases the porosity in the thin-wall section and finer sand size is more favourable than coarse size for LFC mould making process.
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Maekawa, Tatsuya, Mitsuaki Furui, Susumu Ikeno, Tomoyasu Yamaguchi, and Seiji Saikawa. "Microstructure Observation of AM60 Magnesium Alloy Solidified by Rapidly Quench." Advanced Materials Research 409 (November 2011): 339–42. http://dx.doi.org/10.4028/www.scientific.net/amr.409.339.
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In solidification theory, with a slow cooling rate such as sand mold casting, it is easy to segregate the solute aluminum near the grain boundary of primary α-Mg phase under the solidification in Mg-Al system alloys. Thus, volume fraction of none-equilibrium crystallized β-Mg17Al12 phase showed the higher value compared with metal mold casting with faster cooling rate. However, in our microstructure observation results, the volume fraction of β phase in permanent mold castings was larger than that of sand mold castings. In the present study, these contradictory behavior was investigated by observation of as-solidified microstructure obtained from rapid cooling castings at the just below the solidus temperature of 723, 773 and 823K.
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Abadi, Zainal, Andre Kurniawan, Andril Arafat, Nur Ichsan Abdillah, and Daffa Raihan Senthot. "Analysis of riser variations in recycled aluminum sand casting on hardness values." INVOTEK: Jurnal Inovasi Vokasional dan Teknologi 21, no. 3 (October 13, 2021): 213–20. http://dx.doi.org/10.24036/invotek.v21i3.940.
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Abstract In this study, we will discuss the process of casting used aluminum metal. Used aluminum is one of the industrial wastes that can be converted into products using the casting method. This study aims to obtain a good casting material with good hardness values and minimal defects. The research will focus on the results of castings by analyzing the visuals and hardness values of the specimens. The research design is a pre-experimental type of One-Shot Case Study by conducting treatments whose results will be directly observed and analyzed descriptively. The treatment given is to increase the number of risers in recycled aluminum castings. Variations in the number of risers are 1 riser, 2 riser, and 3 riser. Each variation has 3 specimens, so there are 9 specimens in the study. The data from the test results contained a fairly large porosity value for each riser variation. The hardness value that has been tested using the Rockwell hardness tester obtained the highest hardness value occurs in the 2 riser variation, namely 27.69 HRA and the lowest hardness value occurs in the 3 riser variation, namely 21.56 HRA. Thus, for casting used aluminum with a casting pattern as in this study, it is best to use 2 risers.
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Izman, S., Amirreza Shayganpour, M. H. Idris, and Hassan Jafari. "DOE Analysis of the Influence of Sand Size and Pouring Temperature on Porosity in LFC." Applied Mechanics and Materials 121-126 (October 2011): 2661–65. http://dx.doi.org/10.4028/www.scientific.net/amm.121-126.2661.
Full textAbstract:
Lost foam casting is a relatively new process in commercial terms and is widely used to produce defect free castings owing to its advantages like producing complex shape and acceptable surface finish. In the present research, experimental investigations in lost foam casting of aluminium-silicon cast alloy, LM6, were conducted. The main objective of the study was to evaluate the effect of different sand sizes and pouring temperatures on the porosity of thin-wall castings. A stepped pattern was used in the study and the focus of the investigations was at the thinnest 3 mm section. A full 2-level factorial design experimental technique was employed to plan the experiment and subsequently identify the significant factors which affect the casting porosity. The result shows that increasing in the pouring temperature decreases the porosity in the thin-wall section of casting. Finer sand size is more favourable than coarse size for LFC mould making process.
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Asmoro, Anan Tri. "Perbandingan Kualitas Hasil Pengecoran Metode Sand Casting Dan Metode Pengembangan Lost Foam Invesment Casting Dengan Variasi Bahan Pengikat Berdasarkan Analisis Hasil Pengecoran." Jurnal Teknik Mesin dan Pembelajaran 2, no. 1 (November 3, 2019): 117. http://dx.doi.org/10.17977/um054v2i1p117-123.
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Penelitian ini merupakan penelitian komparasi antara metode sand casting dan pengembangan metode lost foam investment casting dengan variasi bahan pengikat bentonit pada sand casting dan semen merah pada lost foam investment casting. Metode yang digunakan pada penelitian ini menggunakan metode pre experimental design dengan model intact group comparision dengan analisis deskriptif. Pengujian yang digunakan meliputi uji visual, uji kekersan vikers, dan struktur mikro. Adapun hasil dari penelitian ini menunjukkan pada uji visual didapatkan metode pengembangan lost foam investment casting memiliki kehalusan yang lebih baik dari sand casting. Berdasarkan nilai kekerasan vikers lost foam investment casting memiliki nilai kekerasan 61.07 HV lebih tinggi dari sand casting dengan nilai kekerasan rata-rata 55.85 HV. Berdasarkan nilai uji struktur mikro didapatkan lost foam invesment casting memiliki struktur butir yang lebih homogeny dibandingkan dengan sand casting.
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Ayer, O., and O. Kaya. "Mould design optimisation by FEM." Journal of Physics: Conference Series 2130, no. 1 (December 1, 2021): 012021. http://dx.doi.org/10.1088/1742-6596/2130/1/012021.
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Abstract Production can be briefly defined as creating something new as a result of effort. There are many different production methods. With the industrial revolutions, the number of these methods has increased, and these methods have developed. Over time, heavy and laborious work that people had to do began to be done by machines. The casting method, which is one of the most common production methods in the world, is to pour the molten metal or its alloy into a mould cavity suitable for the shape of the desired product and remove it from the mould after it solidifies. In this study, firstly, the manufacturing method by casting was mentioned, and the difficulties of mould design in the casting method were explained. Secondly, the benefits of computer-aided simulation programs for casting are explained. As an example, a model was designed and different runners were added to this model. These models, which were prepared afterwards, were cast in a virtual environment with the FLOW-3D CAST program, which is a simulation program. Casting results and casting defects after these castings were compared and interpreted. The results show that it is important for the casting quality to keep the runner diameters as small as possible in runner designs. Two or three times more air voids are formed in the sand mould casting method compared to the permanent mould casting. Additionally, it was observed that the casting material had less shrinkage in the sand mould casting method. It is concluded that sand mould casting is disadvantageous in terms of the parameter of time.
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Trytek, A., A. W. Orłowicz, M. Tupaj, M. Mróz, O. Markowska, G. Bąk, and T. Abram. "The Effect of a Thin-Wall Casting Mould Cavity Filling Conditions on the Casting Surface Quality." Archives of Foundry Engineering 16, no. 4 (December 1, 2016): 222–26. http://dx.doi.org/10.1515/afe-2016-0113.
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Abstract The paper presents results of metallographic examination of faults occurring in the course of founding thin-walled cast-iron castings in furan resin sand molds. A non-conformance of the scab type was Observed on surface of the casting as well as sand buckles and cold shots. Studied the chemical composition by means of a scanning electron microscope in a region of casting defects: microanalysis point and microanalysis surface. Around the observed defects discloses high concentration of oxides of iron, manganese and silicon. A computer simulation of the casting process has been carried out with the objective to establish the cause of occurrence of cold shots on casting surface. The simulation was carried out with the use of NovaFlow & Solid program. We analyzed the flowing metal in the mold cavity. The main reason for the occurrence of casting defects on the surface of the casting was gating system, which caused turbulent flow of metal with a distinctive splash stream of liquid alloy.
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Kordas, P. "Influence of the conditions of casting and heat treatment on the structure and mechanical properties of the AlMg10 alloy." Journal of Achievements in Materials and Manufacturing Engineering 1, no. 83 (July 1, 2017): 26–32. http://dx.doi.org/10.5604/01.3001.0010.5137.
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Purpose: Assessment of the possibilities of shaping the structure and improvement of mechanical properties of casting from AlMg10 alloy through a selection of casting technology and precipitation hardening. Design/methodology/approach: the work evaluated the impact of casting and heat treatment technology on the mechanical properties and structure of AlMg10 alloy castings. The tests were performed on 200 mm × 100 mm × 25 mm plate castings produced by gravity casting methods for sand and metal moulds and by a liquid state press moulding technology. Castings made with these technologies solidify in substantially different heat- evaporation conditions and exhibit varying degrees of primary structure fragmentation. Metallographic and strength tests were performed on raw castings and after heat treatment. Findings: The changes in the morphology and size of primary crystals and the dispersion of the reinforcing phase according to the casting solidification rate and the precipitation hardening treatment were analyzed. Solidifying castings in the form of sand show a globular structure, whereas in die and press castings, a typically dendritic structure occurs, with the dendritic crystals in pressed castings being much smaller in size than the die castings. In castings which were not heat-treated, the reinforcing phase of Al3Mg2 occurs in interdendritic spaces, and its dispersion increases with the rate of cooling. After supersaturation and ageing treatments, the phase α has a grain structure in all samples. The largest dispersion of reinforcing molecules is characterized by press castings. In a raw state, the highest mechanical properties are shown by castings made in the form of sand and the method of pressing in a liquid state. Heat treatment of AlMg10 alloy castings significantly influences the increase of mechanical indexes in all castings investigated. The highest features of Rm are approx. 330 MPa and A5 above 10% is obtained in castings made by the press method. Research limitations/implications: Particular attention should be paid to the avoidance of the effects of slag inclusion, shrinkage and magnesium oxidation during casting of AlMg10 alloys. In die castings of a plate type, due to own stresses, a significant decrease in mechanical properties occurs. Practical implications: The most advantageous mechanical properties of AlMg10 alloy castings are obtained by using liquid-state pressing technology. In addition, this technology makes it possible to produce thin-walled castings of high dimensional accuracy, high air- tightness, fine grain structure, lack of surface defects and low roughness. Originality/value: The paper presents the possibility of improving the mechanical properties of AlMg10 castings by applying heat treatment. It has been proven that the casting method has a significant effect on the mechanical properties of the castings.
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Doroshenko, V. S., and P. B. Kaliuzhnyi. "Prevention of surface defects on the internal cavities of casing iron castings." Fundamental and applied problems of ferrous metallurgy 36 (2022): 487–98. http://dx.doi.org/10.52150/2522-9117-2022-36-487-498.
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The insufficiently high quality of the surface of metal castings, which are made in sand molds, is due to the formation of various surface defects, of which galling is the most common. Cleaning castings from scorch leads to additional costs of material and labor resources, which can reach 40-60% of the total labor intensity of production. The process of increasing the strength of the non-stick coating of casting molds and rods can be implemented by optimizing its composition. According to the result of the analysis of thermochemical reactions at the contact interface "melt - mold" in the process of heat exchange between the casting and the casting mold and related physical processes, as well as hydrodynamic processes of interaction in the contact zone, in particular, specific for graphitized cast iron, in order to prevent surface defects on the internal cavities of body cast iron castings, after experimental and industrial work, non-stick coatings of increased resistance were developed and applied in foundry production for sand molds and rods. Coating compositions were completed according to the concept of partially directing the energy of the high-temperature exposure of the metal to chemical transformations in the non-stick coating and the contact zone of the sand mold with the formation of compounds that would contribute to the sintering of the particles of the surface layer of the mold at the temperature of its heating from the contacting metal. This served as a means of preventing cracks in such a layer and avoiding cracks and mechanical burning on the surface of castings. A method of reducing the metal pressure from the pre-shrinkage expansion of graphitized cast irons during its action on the surface of the walls of the casting cavities by the timely partial weakening of the vacuumed casting mold without disturbing the given geometry of the casting when applying the method of casting according to gasifying patterns has also been developed.
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Liu, Feng, Zhong De Shan, Chao Yi Wang, and Lei Ming Chen. "Research on Rapid Manufacturing Technology of Complicated Casting Mold without Pattern." Advanced Materials Research 774-776 (September 2013): 1418–22. http://dx.doi.org/10.4028/www.scientific.net/amr.774-776.1418.
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In 21th century, the product upgrading becomes faster and faster. The development of varieties of production needs rapid manufacturing technology. The rapid fabrication of sand mold & core is the key of rapid casting. In this paper, the rapid manufacturing technology without pattern was applied to produce the complicated sand molds & cores of pump case. The digital precision forming technology without pattern casting was selected to mill the outer sand mold. And the Selective Laser Sintering (SLS) technology was used to print the sand core. So the complicated sand molds and cores were fabricated rapidly without pattern. As a typical digital manufacturing technology, the rapid manufacturing technology without pattern has a variety of benefits such as short cycle, low cost, flexibility and so on. The technology that combines the sand milling and SLS provides a high-efficiency method for the Single and small batch castings.