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Journal articles on the topic 'Solidification defects'

Author: Grafiati

Published: 8 June 2024

Last updated: 31 July 2025

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1

Elmquist, Lennart, Kaisu Soivio, and Attila Diószegi. "Cast Iron Solidification Structure and how it is Related to Defect Formation." Materials Science Forum 790-791 (May 2014): 441–46. http://dx.doi.org/10.4028/www.scientific.net/msf.790-791.441.

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In this work, the meaning of the solidification structure and how it is related to defect formation in grey cast iron will be discussed. The work also confirms observations made earlier. In previous work the formation of shrinkage porosity in grey cast iron cylinder heads was investigated. It was found that the defect is located around solidification units resembling primary austenite grains. The solidification of grey cast iron starts with the formation of primary austenite grains, followed by the eutectic solidification. The primary grains nucleate and grow either as columnar or equiaxed gra

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2

Nan, Hong Yan, Li Lin Chen, Guo Fa Mi, and Jiao Ma. "Application of Numerical Simulation and Optimization on Tensioner Pulley Bracket." Advanced Materials Research 529 (June 2012): 186–89. http://dx.doi.org/10.4028/www.scientific.net/amr.529.186.

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This article is about casting process of tensioner pulley bracket, which includes solidification simulation, mould filling simulation and defect forecast, using ViewCast software. The scale and location of the shrinkage defects were shown in simulation results. Solidification results demonstrated that the casting defects were not eliminated by the casting technology. The optimized scheme was obtained by replacing and adding chills. The optimization scheme was calculated and the simulation results shown that the reasonable casting process was obtained and the process has been proofed by the pro

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3

Mooraj, Shahryar, Jiaqi Dong, Kelvin Y. Xie, and Wen Chen. "Formation of printing defects and their effects on mechanical properties of additively manufactured metal alloys." Journal of Applied Physics 132, no. 22 (2022): 225108. http://dx.doi.org/10.1063/5.0132137.

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Printing defects are known to degrade the performance of additively manufactured (AM) alloys. Thus, a thorough understanding of their formation mechanisms and effects on the mechanical properties of AM materials is critically needed. Here, we take CoCrFeNi high-entropy alloy as a model material and print this alloy by laser powder bed fusion over a wide range of printing conditions. We reveal the processing windows for the formation of different printing defects including lack of fusion (LOF), keyhole, and solidification cracking. LOF and keyholes can be well correlated with insufficient and e

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4

Meshram, Suresh, and Madhusudhan Reddy. "Influence of Tool Tilt Angle on Material Flow and Defect Generation in Friction Stir Welding of AA2219." Defence Science Journal 68, no. 5 (2018): 512–18. http://dx.doi.org/10.14429/dsj.68.12027.

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Heat treatable aluminium alloy AA2219 is widely used for aerospace applications, welded through gas tungsten and gas metal arc welding processes. Welds of AA2219 fabricated using a fusion welding process suffers from poor joint properties or welding defects due to melting and re-solidification. Friction stir welding (FSW) is a solid-state welding process and hence free from any solidification related defects. However, FSW also results in defects which are not related to solidification but due to improper process parameter selection. One of the important process parameters, i.e., tool tilt angl

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5

Yu, J. K., Q. Yan, and Pin Yang Fang. "Solidification of Aluminum Infiltrated Composites." Materials Science Forum 475-479 (January 2005): 901–4. http://dx.doi.org/10.4028/www.scientific.net/msf.475-479.901.

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The solidification and defects of Al/SiC and Al/C composites were investigated by directional solidification techniques. The solidification and defects of Al/SiC composites are greatly influenced by temperature gradients, solidification rates, the size of SiC particles and the chemical composition of magnesium, but slightly by the volume fraction of SiC particles and the chemical composition of silicon. The solidification shrinkage feeding of Al/C composites is greatly improved by hybridizing carbon fiber bundles with 3 vol% of SiC particles. A model of the solidification feeding was proposed

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6

Huo, Miao, Chuyue Chen, Hangyue Jian, Wenchao Yang, and Lin Liu. "The Stray Grains from Fragments in the Rejoined Platforms of Ni-Based Single-Crystal Superalloy." Metals 13, no. 8 (2023): 1470. http://dx.doi.org/10.3390/met13081470.

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Nickel-based single crystal superalloy is the most important material for blade preparation. However, some solidification defects inevitably occur during the process of preparing single-crystal blades through directional solidification. In this study, in order to study the origin of misorientation defects during solidification, a model with rejoined platforms was designed according to the geometry of single-crystal guide vanes. Electron Back-Scattering Diffraction (EBSD) was used to quantify the orientation deviation of the dendrites and identify the solidification defects in the rejoined plat

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7

Deyun, Liu, Li Yunyue, Zhao Mingyuan, Sheng Lanbing, and Shen Yuanxun. "Research on typical defects of Cu/Fe dissimilar metals vacuum welding-brazing and improvement measures." Journal of Physics: Conference Series 2959, no. 1 (2025): 012010. https://doi.org/10.1088/1742-6596/2959/1/012010.

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Abstract Cu/Fe dissimilar metals are joined by welding-brazing in a vacuum furnace, and then typical defect formation mechanisms of the post-welded joints are observed and analyzed. As a result, it has been found that the major welding-brazing defects are elemental segregation, solidification cracks and poor fusion. It is worth noting that the causes of element segregation and slag inclusion are related to high welding-brazing temperature, impurity of raw materials, inadequate cleaning of materials before welding-brazing and volatilization of impurity metals in the chamber of the vacuum furnac

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8

Korojy, B., L. Ekbom, and H. Fredriksson. "Microsegregation and Solidification Shrinkage of Copper-Lead Base Alloys." Advances in Materials Science and Engineering 2009 (2009): 1–9. http://dx.doi.org/10.1155/2009/627937.

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Microsegregation and solidification shrinkage were studied on copper-lead base alloys. A series of solidification experiments was performed, using differential thermal analysis (DTA) to evaluate the solidification process. The chemical compositions of the different phases were measured via energy dispersive X-ray spectroscopy (EDS) for the Cu-Sn-Pb and the Cu-Sn-Zn-Pb systems. The results were compared with the calculated data according to Scheil's equation. The volume change during solidification was measured for the Cu-Pb and the Cu-Sn-Pb systems using a dilatometer that was developed to inv

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9

Hassan, Mohamed Abubakr, Mahmoud Hassan, Chi-Guhn Lee, and Ahmad Sadek. "Monitoring Variability in Melt Pool Spatiotemporal Dynamics (VIMPS): Towards Proactive Humping Detection in Additive Manufacturing." Journal of Manufacturing and Materials Processing 8, no. 3 (2024): 114. http://dx.doi.org/10.3390/jmmp8030114.

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Humping is a common defect in direct energy deposition processes that reduces the geometric integrity of printed products. The available literature on humping detection is deemed reactive, as they focus on detecting late-stage melt pool spatial abnormalities. Therefore, this work introduces a novel, proactive indicator designed to detect early-stage spatiotemporal abnormalities. Specifically, the proposed indicator monitors the variability of instantaneous melt pool solidification-front speed (VIMPS). The solidification front dynamics quantify the intensity of cyclic melt pool elongation induc

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10

Zhang Tong, 田帅, 孙旭冉, 李日, and Li Ri. "Machine learning-based study of dynamic shrinkage behavior during solidification of castings." Acta Physica Sinica 74, no. 2 (2025): 0. https://doi.org/10.7498/aps.74.20241581.

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Shrinkage cavities and porosity are the main defects generated during the solidification process of castings. The cause of these defects is the contraction of the alloy during solidification, with the last regions to solidify not receiving effective compensation from liquid metal, resulting in cavitation defects. Shrinkage cavities and porosity significantly reduce the mechanical properties of castings and shorten their service life, thus necessitating appropriate process elimination measures. Utilizing numerical simulation technology can effectively predict the shrinkage of castings during so

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11

Khan, Muhammad Azhar Ali. "Simulation Based Mold Design Optimization of a Spring Flap Casting." Solid State Phenomena 305 (June 2020): 178–84. http://dx.doi.org/10.4028/www.scientific.net/ssp.305.178.

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The complex nature of metal casting process brings about a need to simulate it before undertaken in a foundry. Casting simulations provide insights on flow of molten metal within the mold, solidification sequence, nature and location of defects etc. Moreover, mold design can be optimized to minimize defects without undergoing physical trials-and-errors as previously practiced in traditional metal casting. This study is based on casting an ASTM A216 WCB steel spring flap for automotive suspension system using a simulation based optimized mold design. The initial and optimized mold designs are s

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12

Xu, Qing Yan, Bai Cheng Liu, Zuo Jian Liang, Jia Rong Li, Shi Zhong Liu, and Ha Llong Yuan. "Modeling of Unidirectional Growth in a Single Crystal Turbine Blade Casting." Materials Science Forum 508 (March 2006): 111–16. http://dx.doi.org/10.4028/www.scientific.net/msf.508.111.

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Single crystal superalloy turbine blade are widely used in aero-engineering. However, there are often grain defects occurring during the fabrication of blade by casting. It is important to study the formation of microstructure related defects in turbine blades. Single crystal blade sample castings of a nickel-base superalloy were produced at different withdrawal rates by the directional solidification process and investment casting. There was a difference between the microstructure morphology at the top part of the turbine blade sample castings and the one at the bottom. Higher withdrawal rate

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13

Chen, Wei, Shiping Wu, and Rujia Wang. "Effect of Mechanical Vibration on the Mechanical Properties and Solidification Feeding in Low-Pressure Sand Casting of Al-Cu-Mn-Ti Alloy." Materials 15, no. 22 (2022): 8243. http://dx.doi.org/10.3390/ma15228243.

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The shrinkage defects of Al-Cu-Mn-Ti alloy seriously hinder its application in high-performance engineering. In this study, mechanical vibration was introduced to low-pressure sand casting (LPSC) by a waveguide rod to eliminate shrinkage defects and improve mechanical properties. Four LPSC castings were performed by changing the solidification conditions: 20 kPa solidification pressure without and with 14 Hz vibration and 40 kPa without and with 24 Hz (the natural frequency of a casting system) vibration. The shrinkage defects, microstructures, and mechanical tensile properties at room tempera

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14

Luo, Yiming, Ronghui Ju, Bingbo Li, Junjiong Meng, and Xuanjun Wang. "Thermal Decomposition and Solidification Characteristics of BFFO." Crystals 13, no. 5 (2023): 802. http://dx.doi.org/10.3390/cryst13050802.

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A novel energetic material, Bifurazano [3,4-b: 3′,4′-f] furoxano [3″,4″-d] oxacyclo-heptatriene (BFFO), has been investigated regarding two aspects, namely its thermal decomposition and solidification characteristics. The DSC curves indicate that the peak temperature of BFFO decomposition process is 271.1 °C under the static pressure of 2 MPa and the volatility of BFFO at 120 °C is significantly lower than that of TNT, DNAN and DNTF. The solidification curve indicates that the solidification of BFFO is a basic linear uniform solidification process, which is obviously different from that of TNT

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15

Yuan, Lang. "Solidification Defects in Additive Manufactured Materials." JOM 71, no. 9 (2019): 3221–22. http://dx.doi.org/10.1007/s11837-019-03662-x.

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16

Wable, Girish S., Srinivas Chada, Bryan Neal, and Raymond A. Fournelle. "Solidification shrinkage defects in electronic solders." JOM 57, no. 6 (2005): 38–42. http://dx.doi.org/10.1007/s11837-005-0134-x.

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17

Liao, Qiang, Peng Ge, Guangxuan Lu, et al. "Simulation Study on the Investment Casting Process of a Low-Cost Titanium Alloy Gearbox based on ProCAST." Advances in Materials Science and Engineering 2022 (September 20, 2022): 1–10. http://dx.doi.org/10.1155/2022/4484762.

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A model of investment casting of a titanium alloy gearbox based on the ProCAST software was established in this work, and the simulated result was used to optimize the casting process. The flow and temperature field of casting were simulated based on an actual pouring process. Casting defects and the solidification process were analyzed. The results show that the defects can be predicted by the simulation result exactly, and the simulated temperature field is in accordance with the actual process. Shrinkage and porosity are observably alleviated by remodelling the casting mould. The casting te

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18

Daoud, Fatima, Ahmed Bellaouar, and Omar Kholai. "Thermo Mechanical Modeling of Continuously Cast Stainless Steel." Journal of Advanced Research in Fluid Mechanics and Thermal Sciences 130, no. 2 (2025): 100–114. https://doi.org/10.37934/arfmts.130.2.100114.

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The surface and internal quality of continuous casting products are strongly influenced by the behavior of the slab during solidification within the continuous casting machine. Solidification was modeled using a 2D heat transfer model with the finite volume method, employing the SIMPLER algorithm. A slab slice was defined perpendicular to the casting axis, with the following boundary conditions: symmetry along the principal axes (double symmetry), unilateral contact with friction along the machine surface, and an imposed machine temperature. These conditions help in understanding and explainin

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19

Lou, Bai Yang, Fang Li Liu, and Kang Chun Luo. "Numerical Simulation of Mold Filling and Solidification Process of a Disc Aluminum Alloy in Pressure Die Casting." Applied Mechanics and Materials 121-126 (October 2011): 254–58. http://dx.doi.org/10.4028/www.scientific.net/amm.121-126.254.

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The numerical simulations of mold filling and solidification process for the A380 aluminum alloy were done by the supposed mathematical model. The casting defects in the process of mold filling and solidification were predicted by the result of the casting simulation. The casting defects of simulation are well compared with the practice. Some measures presented were improved for the existing technological process.

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20

Szeliga, D., K. Kubiak, and J. Sieniawski. "Numerical Simulation of Directional Solidification Process of Single Crystal Ni- Based Superalloy Casting." Archives of Foundry Engineering 17, no. 2 (2017): 111–18. http://dx.doi.org/10.1515/afe-2017-0061.

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Abstract The analysis of influence of mould withdrawal rate on the solidification process of CMSX-4 single crystal castings produced by Bridgman method was presented in this paper. The predicted values of temperature gradient, solidification and cooling rate, were determined at the longitudinal section of casting blade withdrawn at rate from 1 to 6mm/min using ProCAST software. It was found that the increase of withdrawal rate of ceramic mould results in the decrease of temperature gradient and the growth of cooling rate, along blade height. Based on results of solidification parameter G/R (te

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21

Ridolfi, Maria Rita. "The Formation of the Solidification Microstructure from Liquid Metal in Industrial Processes." Materials Science Forum 884 (January 2017): 115–31. http://dx.doi.org/10.4028/www.scientific.net/msf.884.115.

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This paper focuses on the role played by the liquid metal management on the solidification microstructure in industrial solidification processes. In particular attention is paid to the elimination of solidification defects by governing the microstructure evolution through fluid-dynamics and heat and mass transport in the liquid. The formation of hot tearing and gas porosities as well as columnar and equiaxed microstructures and micro and macro segregation are analyzed to explain how the liquid management is used to avoid defects. Examples on continuous casting and welding are also included.A v

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22

Yu, Xin Gang, Lan Yun Liu, Yan Bin Zuo, et al. "On the Defects in Injection-Moulded Technical Ceramics." Key Engineering Materials 336-338 (April 2007): 1025–27. http://dx.doi.org/10.4028/www.scientific.net/kem.336-338.1025.

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A heated sprue device for ceramic injection moulding was used to research the defects in injection-moulded technical ceramics. By use of the heated sprue device, the problem of sprue solidification was resolved and the density of the injection moulding specimens was increased while the defects eliminated. The influence of the processing parameters on the defects of the injection molding specimens was investigated in detail by X-ray radiography camera and photograph. It turns that the sprue solidification time has much influence on the defects in injection-moulded technical ceramics. Reasons ca

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23

Liu, Zi Kang, Min Luo, Da Quan Li, Long Fei Li, and Jian Feng. "Effects of Process Parameters on Shrinkage Porosity in 357 Semi-Solid Die Casting Parts." Materials Science Forum 993 (May 2020): 166–71. http://dx.doi.org/10.4028/www.scientific.net/msf.993.166.

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The shrinkage porosity that was caused by the insufficient feeding during solidification, was a common defect in the semi-solid die casting process. This defect decreased significantly the mechanical properties of the casting. In order to avoid the shrinkage porosity in casting, the die design, slug preparation and die casting process were carefully considered. In this study, a designed mold was used to make the sequential solidification of the slug. The process parameters, including intensification pressure, die temperature and biscuit thickness of the casting, were studied to show their infl

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24

Nourian-Avval, Ahmad, and Ali Fatemi. "Characterization and Analysis of Porosities in High Pressure Die Cast Aluminum by Using Metallography, X-Ray Radiography, and Micro-Computed Tomography." Materials 13, no. 14 (2020): 3068. http://dx.doi.org/10.3390/ma13143068.

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Mechanical performance of cast aluminum alloys is strongly affected by the defects formed during solidification. For example, fractography studies of the fatigue specimens have shown that fatigue failure in aluminum castings containing defects is almost always initiated from defects, among which pores are most detrimental. However, elimination of these pores is neither always economically nor technically possible. This work characterizes defects in high pressure die cast aluminum alloy as an illustrative material, but the methods used can be applicable to other types of castings and defects. T

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25

Wang, Fei Fei, Yan Wei Sui, Yao Jian Ren, Xin Zhao, and Zhi Sun. "Defects Analysis and Improvement for Electricmotorcar Aluminum Alloy Wheel by Gravity Casting." Advanced Materials Research 189-193 (February 2011): 3880–85. http://dx.doi.org/10.4028/www.scientific.net/amr.189-193.3880.

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Analysis the electricmotorcar aluminum wheels’ hole defect on macroscopic and microscopic, observed that the main defects、concentrated site and the main alloy phase. Combined with the local casting technological parameters, the filling and solidification process of aluminium alloy hub was simulated by using Anycasting software. The results showed that: castings filling smoothly, at the junction of the spoke and the rim and the hub central are easy to produce casting defects. Using the optimized process parameters that is lower pouring temperature, higher pouring height and set the vent to expe

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26

Parisi, A., and M. Plapp. "Defects and multistability in eutectic solidification patterns." EPL (Europhysics Letters) 90, no. 2 (2010): 26010. http://dx.doi.org/10.1209/0295-5075/90/26010.

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27

Sabau, Adrian S. "Predicting interdendritic cavity defects during casting solidification." JOM 56, no. 3 (2004): 54–56. http://dx.doi.org/10.1007/s11837-004-0035-4.

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28

Lewis, Daniel. "Solidification defects revisited and semi-solid processing." JOM 58, no. 6 (2006): 12. http://dx.doi.org/10.1007/s11837-006-0171-0.

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29

Weiß, K., and Christoph Honsel. "New Algorithm to Calculate Liquid – Solid Shrinkage and Graphite Expansion." Materials Science Forum 508 (March 2006): 509–14. http://dx.doi.org/10.4028/www.scientific.net/msf.508.509.

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Meanwhile the calculation of cooling and solidification is a well introduced tool into the foundry industry for calculating gating and riser systems. However, knowing the areas of last solidification is often no answer to the question if there are any defects in the casting or not. Of course one requirement is an exact description of the heat flow and the heat transfer between melt and mould. But furthermore the liquid/liquid and liquid/solid shrinkage influence the temperature fields due to a convective heat flux. Also auxiliary material influence the liquid/solid behaviour. Auxiliary materia

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30

Sabzi, Hossein Eskandari, and Pedro E. J. Rivera-Díaz-del-Castillo. "Defect Prevention in Selective Laser Melting Components: Compositional and Process Effects." Materials 12, no. 22 (2019): 3791. http://dx.doi.org/10.3390/ma12223791.

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A model to predict the conditions for printability is presented. The model focuses on crack prevention, as well as on avoiding the formation of defects such as keyholes, balls and lack of fusion. Crack prevention is ensured by controlling the solidification temperature range and path, as well as via quantifying its ability to resist thermal stresses upon solidification. Defect formation prevention is ensured by controlling the melt pool geometry and by taking into consideration the melting properties. The model’s core relies on thermodynamics and physical analysis to ensure optimal printabilit

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31

Marcolin, Patrícia, Marielen Longhi, Lucas Pandolphi Zini, et al. "Effects of the Casting Temperature in the Leakage of Zamak 5." Materials Science Forum 899 (July 2017): 458–62. http://dx.doi.org/10.4028/www.scientific.net/msf.899.458.

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Recent studies evidenced that the Zamak 5 corrosion is associated to solidification defects arising from the injection process that occur mainly in areas where the solidification rate is faster. Given this factor, the aim of this research was to evaluate the influence of Zamak 5 casting temperature. For this study, Zamak 5 was casted at different temperatures (430 °C, 450 °C, 500 °C, 550 °C) with respective solidification curves. Zamak 5 was analyzed for chemical composition and microstructure. Moreover, complementary tests of microhardness and electrochemical analyses of open circuit potentia

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32

Yang, Qiang, Xintao Zhu, Fu Wang, Dexin Ma, and Jiantao Wu. "A Study of Sliver in C-Shaped Grain Selectors during Investment Casting of Single-Crystal Superalloy." Metals 13, no. 6 (2023): 1102. http://dx.doi.org/10.3390/met13061102.

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In this study, the formation mechanism of sliver defects in C-shaped 2D grain selectors during investment casting of single-crystal superalloy was investigated by analyzing the effects of the C-shaped 2D grain selectors on the solidification behavior of superalloy. The physical field properties of the sliver formation and solidification characteristics of CM247LC nickel-based superalloy were determined. The temperature and stress fields were simulated using ProCAST. The results showed that the stress fields of solidification played an essential role in the formation of sliver, indicating that

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33

Sarfaraj, M. "Casting Defects in Manufacturing: A Comprehensive Study." Research and Applications of Thermal Engineering 8, no. 1 (2025): 45–47. https://doi.org/10.5281/zenodo.15221990.

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<em>Casting is a widely used manufacturing process, but it is often plagued by defects that affect the quality and mechanical properties of cast components. This research paper explores various casting defects, their causes, effects, and potential solutions. A detailed literature review highlights past studies on defect mitigation, followed by an experimental analysis of real-world casting scenarios. The results and discussion present an evaluation of different defect occurrences, with recommendations for improved casting practices. Finally, the conclusion and future scope outline advancements

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Sarfaraj, M. "Filler Materials in Welding: A Review on Mechanical and Metallurgical Properties." Journal of Advanced Research in Industrial Engineering 7, no. 1 (2025): 21–23. https://doi.org/10.5281/zenodo.15235644.

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<em>Casting is a widely used manufacturing process, but it is often plagued by defects that affect the quality and mechanical properties of cast components. This research paper explores various casting defects, their causes, effects, and potential solutions. A detailed literature review highlights past studies on defect mitigation, followed by an experimental analysis of real-world casting scenarios. The results and discussion present an evaluation of different defect occurrences, with recommendations for improved casting practices. Finally, the conclusion and future scope outline advancements

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35

Futas, Peter, Alena Pribulova, Vladimir Sabik, Jozef Petrik, Peter Blasko, and Marcin Brzeziński. "Elimination of Shrinkage in Ductile Iron Castings Using Computer Simulation of Casting and Solidification." Processes 12, no. 3 (2024): 506. http://dx.doi.org/10.3390/pr12030506.

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The production of high-quality castings without foundry defects at minimal production costs is a constant priority for foundries. Innovation and optimization of production processes are key to achieving this goal. Computer simulation of foundry processes offers a modern alternative to expensive and time-consuming experiments in real foundries and provides a reliable representation and analysis of casting and solidification processes. A detailed analysis of the casting and solidification simulation results allows the prediction of various risks that can cause defects in cast castings, thereby r

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36

Krenckel, Patricia, Yusuke Hayama, Florian Schindler, Theresa Trötschler, Stephan Riepe, and Noritaka Usami. "Propagation of Crystal Defects during Directional Solidification of Silicon via Induction of Functional Defects." Crystals 11, no. 2 (2021): 90. http://dx.doi.org/10.3390/cryst11020090.

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The introduction of directional solidified cast mono silicon promised a combination of the cheaper production via a casting process with monocrystalline material quality, but has been struggling with high concentration of structural defects. The SMART approach uses functional defects to maintain the monocrystalline structure with low dislocation densities. In this work, the feasibility of the SMART approach is shown for larger ingots. A G2 sized crystal with SMART and cast mono silicon parts has been analyzed regarding the structural defects via optical analysis, crystal orientation, and etch

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Sowa, Leszek, Tomasz Skrzypczak, and Paweł Kwiatoń. "Computer evaluation of the influence of liquid metal movements on defects formation in the casting." MATEC Web of Conferences 254 (2019): 02017. http://dx.doi.org/10.1051/matecconf/201925402017.

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This paper concerns the modelling of the solidification process including the phenomena of heat transfer and fluid flow during the initial stage of the metal casting process. During this period, the molten metal motions have an essential influence on solidification kinetics. An analysis of solidification kinetics, by determining the velocity and temperature fields in a system of riser-casting was made. Velocity fields were obtained by solving the momentum equations and the continuity equation, while the thermal fields were obtained by solving the conduction equation containing the convection t

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38

Rao, Lei, Lian Bing Zhu, Xiao Long Li, and Qi Yao Hu. "The Defects Analysis and Numerical Simulation of Automobile Brake Hydro Cylinder in Permanent Casting." Materials Science Forum 704-705 (December 2011): 82–87. http://dx.doi.org/10.4028/www.scientific.net/msf.704-705.82.

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Brake hydro cylinder is the key part of automobile hydraulic braking system, which usually works under high pressure condition. So, high safety factor of it is required to avoid accident. There are many kinds of casting defects such as shrinkage cavity, gas entrapment and slag enclosure are formed in the mold filling and solidification processes, which contribute to final casting performance. Based on the mathematical models of molding filling and solidification processes, the numerical simulation has been done. In the meanwhile, the defects forming reasons have been analyzed. According to the

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39

Adegoke, Olutayo, Joel Andersson, Håkan Brodin, and Robert Pederson. "Review of Laser Powder Bed Fusion of Gamma-Prime-Strengthened Nickel-Based Superalloys." Metals 10, no. 8 (2020): 996. http://dx.doi.org/10.3390/met10080996.

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This paper reviews state of the art laser powder bed fusion (L-PBF) manufacturing of γ′ nickel-based superalloys. L-PBF resembles welding; therefore, weld-cracking mechanisms, such as solidification, liquation, strain age, and ductility-dip cracking, may occur during L-PBF manufacturing. Spherical pores and lack-of-fusion voids are other defects that may occur in γ′-strengthened nickel-based superalloys manufactured with L-PBF. There is a correlation between defect formation and the process parameters used in the L-PBF process. Prerequisites for solidification cracking include nonequilibrium s

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Yu, Daliang, Wen Yang, Wanqing Deng, Songzhu Zhu, Qingwei Dai, and Dingfei Zhang. "Crack Initiation Mechanism in Casting AC4B Aluminum Alloy Parts with Complex Structure." Metals 11, no. 1 (2021): 97. http://dx.doi.org/10.3390/met11010097.

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Hot tears were frequently formed in Aluminum (Al) parts with complex structure. In this study, OM (optical microscope), SEM (scanning electron microscope), EDS (energy dispersive spectrometer), and FDM (finite difference method) were used to reveal the hot tears mechanisms in the casted AC4B Al engine. Shrinkage porosities with the size of 300–500 μm were found in casted specimens near the parts’ surface. Many cracked brittle Fe-bearing phase were also found in crack section. The secondary dendrite arm spacing observation in five typical positions showed that the cooling rate in position 5 was

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Huang, Binting, Jishi Yang, Zhiheng Luo, Yang Wang, and Nan Wang. "Formation of Twin Boundaries in Rapidly Solidified Metals through Deformation Twinning." Materials 16, no. 13 (2023): 4503. http://dx.doi.org/10.3390/ma16134503.

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The rapid solidification process is relevant to many emerging metallurgical technologies. Compared with conventional solidification processes, high-density microstructure defects and residual thermal stress are commonly seen in rapidly solidified metals. Among the various defects, potentially beneficial twin boundaries have been observed in the rapidly solidified nanocrystalline microstructures of many alloy systems. In this work, a pathway for forming twin boundaries in rapid solidification processes is proposed. A detailed derivation of strain inhomogeneities upon thermal shrinkage and the d

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Ma, De Xin, Bin Zhou, and Andreas Bührig-Polaczek. "Development and Application of Heat-Conductor Technique for Single Crystal Components of Superalloys." Advanced Materials Research 278 (July 2011): 306–11. http://dx.doi.org/10.4028/www.scientific.net/amr.278.306.

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During single crystal (SC) solidification in turbine blades of superalloys, grain defects often form in the platform region with abrupt variation in cross-section. In order to reduce grain defects induced by component geometries, a Heat Conductor (HC) technique was developed and applied to the production of SC turbine blades. The corresponding ceramic shell moulds were produced by a modified investment casting procedure. The heat conductors with excellent heat conductivity were inserted close to the inner corners of the platform, to effectively extract the local heat during directional solidif

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Han, Dong Dong, Cheng Jun Wang, Juan Chang, Lei Chen, and Huai Bei Xie. "Numerical Simulation of Filling and Solidification in Sand Casting by Procast." Advanced Materials Research 791-793 (September 2013): 550–53. http://dx.doi.org/10.4028/www.scientific.net/amr.791-793.550.

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At present, pulley produced in China has been able to meet the demand of domestic and international markets. But there are many problem of the pulley industry in our country, such as too many production enterprises and the low level of export products. And as components of drive system are light weight and raw material price of pulley casting are rising, manufacturing requirements of the pulley are also more and more high. Aiming at the casting defects of pulley that enterprise current product, pulley casting blank model of common material HT250 be made by three-dimension software, numerical s

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Li, Xiaoqun, Yaqing Hou, Weidong Cai, et al. "Study on Crack Behavior of GH3230 Superalloy Fabricated via High-Throughput Additive Manufacturing." Materials 17, no. 17 (2024): 4225. http://dx.doi.org/10.3390/ma17174225.

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This study utilized Fe, Co, Ni elemental powders alongside GH3230 pre-alloyed powder as raw materials, employing high-throughput additive manufacturing based on laser powder bed fusion in situ to alloying technology to fabricate the bulk samples library for GH3230 superalloy efficiently. A quantitative identification algorithm for detecting crack and hole defects in additive manufacturing samples was developed. The primary focus was to analyze the composition variations in specimens at varying Fe, Co, and Ni elemental compositions and their impact on crack formation. Experimental results demon

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Feng, Shikang, Enzo Liotti, and Patrick S. Grant. "X-ray Imaging of Alloy Solidification: Crystal Formation, Growth, Instability and Defects." Materials 15, no. 4 (2022): 1319. http://dx.doi.org/10.3390/ma15041319.

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Synchrotron and laboratory-based X-ray imaging techniques have been increasingly used for in situ investigations of alloy solidification and other metal processes. Several reviews have been published in recent years that have focused on the development of in situ X-ray imaging techniques for metal solidification studies. Instead, this work provides a comprehensive review of knowledge provided by in situ X-ray imaging for improved understanding of solidification theories and emerging metal processing technologies. We first review insights related to crystal nucleation and growth mechanisms gain

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Ma, De Xin, Qiang Wu, and Andreas Bührig-Polaczek. "Undercoolability of Superalloys and Solidification Defects in Single Crystal Components." Advanced Materials Research 278 (July 2011): 417–22. http://dx.doi.org/10.4028/www.scientific.net/amr.278.417.

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The undercooling behaviour of the superalloys IN 939 and CMSX-6 during the isothermal heating and cooling processes was investigated. Under the same process conditions, the undercoolability of CMSX-6 was measured to be 50.4 K while that of IN 939 was only 10.1 K. This great difference can be attributed to the amount of alloying elements. During Bridgman directional solidification using the same process parameters, the used alloys exhibited a very different tendency to form structure defects. While the CMSX-6 components were nearly defect-free, the IN 939 samples of the same geometry were very

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Mechighel, Farid, Mahfoud Kadja, Mohammed El Ganaoui, and Bernard Pateyron. "Study of Macrosegregation Defects Formation Caused by Double Diffusive Convective Flow during Solidification of a Binary Alloy." Defect and Diffusion Forum 283-286 (March 2009): 340–45. http://dx.doi.org/10.4028/www.scientific.net/ddf.283-286.340.

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Numerical study of both the solidification of the binary alloy Al-4.1%wtCu and macrosegregation defects formation have been carried out. The mixture continuum model was used in the development of the mathematical model representing the solidification phenomena. This model included the conservative equations (mass, momentum, energy and species); these equations were numerically solved by using a finite volume approach.

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Arpita. "Simulation of vertical centrifugal casting using ANSYS." International Journal of Science and Research Archive 11, no. 1 (2024): 2290–303. http://dx.doi.org/10.30574/ijsra.2024.11.1.0327.

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Axis-symmetric products are often made by means of centrifugal casting, which involves heating and transferring molten metal into a rapidly rotating mould. Centrifugal casting defects are mostly associated with the solidification process. However, when employing experimental techniques for centrifugal casting, determining the process of solidification pace and duration is quite challenging. Simulations may be used to analyze and optimize operational conditions.

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Hellström, Kristina, Péter Svidró, Lucian Vasile Diaconu, and Attila Diószegi. "Density Variations during Solidification of Grey Cast Iron." Materials Science Forum 925 (June 2018): 155–62. http://dx.doi.org/10.4028/www.scientific.net/msf.925.155.

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As part of moving towards a sustainable production of diesel engines for heavy vehicle applications, the ability to predict casting defects has become ever so important. In order to model the solidification process for cast components correctly, it is of essence to know how the material will actually behave. To produce sound castings, often of complex geometry, the industry relies on various simulation software for the prediction and avoidance of defects. Thermophysical properties, such as density, play an important part in these simulations.Previous measurements of how the volume of liquid gr

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Sun, Chi, Zhanyi Cao, Yanzhu Jin, et al. "Numerical Simulation of Lost-Foam Casting for Key Components of A356 Aluminum Alloy in New Energy Vehicles." Materials 17, no. 10 (2024): 2363. http://dx.doi.org/10.3390/ma17102363.

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The intricate geometry and thin walls of the motor housing in new energy vehicles render it susceptible to casting defects during conventional casting processes. However, the lost-foam casting process holds a unique advantage in eliminating casting defects and ensuring the strength and air-tightness of thin-walled castings. In this paper, the lost-foam casting process of thin-walled A356 alloy motor housing was simulated using ProCAST software (2016.0). The results indicate that the filling process is stable and exhibits characteristics of diffusive filling. Solidification occurs gradually fro

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