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Dissertations / Theses on the topic 'Die casting process'

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Published: 4 June 2021
Last updated: 1 February 2022

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1

Ziolkowski, Joseph Edmund. "Modeling of an aerospace sand casting process." Link to electronic thesis, 2002. http://www.wpi.edu/Pubs/ETD/Available/etd-1223102-102625.

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2

Hock, Kuah Teng. "Numerical simulation of sand casting process." Ohio : Ohio University, 1987. http://www.ohiolink.edu/etd/view.cgi?ohiou1183046313.

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3

Yin, Jun. "Numerical modelling of centrifugal casting process." Thesis, KTH, Materialvetenskap, 2016. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-195650.

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The centrifugal casting process is a common method for manufacturing the tubes, etc. Due to its high temperature and invisible mold, it is really difficult to know the mechanism of molten steel inside the mold. It is important to know the mechanism of the molten steel inside mold, since it will help the manufacturer to know more accuracy of the flow of the molten steel so that it can work for improving the productivity and quality of the products. Casting funnel design is the designed by Åkers for their funnel which will result in different flow behavior. In thesis work, casting funnel design will be investigated so that it can make sure that the casting funnel design can affect the flow behavior of molten steel or not. Another method of changing the diameter of nozzle was also carried out and investigated with both simulation and experiment to changing flow behavior of molten steel. It will give Åkers alternative method for changing the flow behavior to liquid steel. The mechanism of solidification in centrifugal casting is also really important since it can give manufacturer the general view of solidification process. So solidification of centrifugal casting is also investigated in the thesis work.
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4

Osborne, Mark Albert. "Analysis of the effects of die casting process control on casting dimensional variability /." The Ohio State University, 1995. http://rave.ohiolink.edu/etdc/view?acc_num=osu1487862399449976.

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5

Marcos, Rebal, and Endrias Teklu. "ANALYSIS OF CASTING PROCESS FORCOMPLEX ELECTRONIC UNIT." Thesis, Jönköping University, JTH, Mechanical Engineering, 2009. http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-11545.

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Most aircraft component are currently being manufactured by machining, forging, welding and also assembling such parts. However, the possibilities of cutting cost from a single component has brought about a growing trend towards looking into casting as a possible option for manufacturing aircraft parts.

This thesis was done at the request of Saab Avitronics. It evaluates the possibilities of one aircraft part, a chassis for an electronic unit that was first designed to be machined from a blank, to be cast. The thesis goes through the multifaceted tasks of product development. Casting process selection, cast alloy selection as well as geometry modification were some of these tasks that were performed in this thesis. It also evaluates the performances of chosen casting processes, the design of gating systems as well as various process parameters set, by simulating the casting processes.

The alloy chosen was A356.0 with a T6 temper and the casting processes chosen were plaster mold casting and rheocasting. The geometry of the original chassis, which had very thin sections and undercuts which were complex to cast, was modified and made easier to cast with an acceptable slight increase of mass and size. The modification done on the geometry as well as the gating systems used had proven to be worthwhile, as the simulation of both process showed that such a part can be casted with no crucial defects foreseen. However, probable cavities might occur at the very tip of the chassis’s thin-fins – that it has for carrying away heat. Minor subsurface porosities might also be formed, which would not impair the function of the chassis. The modified chassis was made as close to as finished piece as possible, for the purpose of reducing machining costs. The cost of producing such a part by casting was also seen to be much less than machining it from blank. This could be taken as rationale for casting the chassis with thicker sections, to avoid problems that may arise in casting, and to subsequently machine these faces later, as it would still be cheaper than machining the chassis from a blank.

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6

Capps, Johnathon. "Advancements in vacuum process molding and casting." Auburn, Ala., 2005. http://repo.lib.auburn.edu/2005%20Summer/master's/CAPPS_JOHNATHON_6.pdf.

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7

Ali, Amer F. "Computer aided analysis of the casting process." Ohio : Ohio University, 1993. http://www.ohiolink.edu/etd/view.cgi?ohiou1174931475.

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8

Laurie, Joyce. "Freeze casting : a modified sol-gel process." Thesis, University of Bath, 1994. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.260248.

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9

CIPRIANO, LUIZ CARLOS. "NUMERICAL SIMULATION OF THE CONTINUOUS CASTING PROCESS." PONTIFÍCIA UNIVERSIDADE CATÓLICA DO RIO DE JANEIRO, 1988. http://www.maxwell.vrac.puc-rio.br/Busca_etds.php?strSecao=resultado&nrSeq=33279@1.

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O processo de lingotamento contínua de metais é simulado numericamente. Placas ou tarugos metálicos são produzidos continuamente, mantendo-se o escoamento do material através do molde. A frente de solidificação depende da velocidade de retirada de material e da refrigeração imposta na superfície do lingote. A posição da interface líquido-sólido e o campo de temperaturas na região sólida são determinados, e consideram-se os efeitos da velocidade na curvatura da interface. É analisado um modelo retangular bi-dimensional e a equação da energia é resolvida utilizando-se o método numérica de diferenças finitas das volumes de controle. Os resultados são comparados com soluções analíticas simplificadas onde a termo de transporte não foi considerado e mostram que o calar transportado pelo movimento de lingote tem influência significativa na forma da interface e em sua localização dentro do molde durante o processo.
This work deals with a numerical simulation of the continuous casting process. This process is employed in the fabrication of metallic inguts. The position of the solid-liquid interface is determined together with the temperature field in the solid region. The research is facused on studying the effect of the withdrawal velocity on the interface position, aiming at accidental leakage preventien during the process. In this analysis, the sensible heat is taken into acceunt, in contrast to previous marks reported in the open literature. The present work employed a two-dimensional model. The energy equation was integrated in the rectangular domain by means of the finite-volume method. The liquid regions was at the fusion temperatures, whereas one of the side boundaries was strogly cooled to promote solidification. An algorithm was developed to determine the interface pesition and the domain length. Comparisons of this results obtained with the available solutions obtained excluding sensible heat showed that, depending upon the value of the withdrawal velocity, the sensible heat may or may not be negleted. The simulations was performed with the aid of a microcomputer of the IBM-PC/XT type, employing the Fortran language.
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10

Karni, Yiftah. "Selection of process variables for die casting /." The Ohio State University, 1991. http://rave.ohiolink.edu/etdc/view?acc_num=osu1487688507504379.

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11

Li, Guoming. "FEM modeling of the die casting filling process." Thesis, National Library of Canada = Bibliothèque nationale du Canada, 2000. http://www.collectionscanada.ca/obj/s4/f2/dsk1/tape4/PQDD_0018/MQ57730.pdf.

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12

Li, Guoming Carleton University Dissertation Engineering Mechanical and Aerospace. "FEM modeling of the die casting filling process." Ottawa, 2000.

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13

Gupta, Manish. "Simulation and Analysis of Thin Strip Casting Process." The Ohio State University, 1999. http://rave.ohiolink.edu/etdc/view?acc_num=osu1391676878.

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14

Tantipaibulvut, Chairath. "An evaluation of the production of magnesium base alloy castings by the expendable pattern casting process." Thesis, Loughborough University, 1997. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.250959.

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15

Mao, Haijing. "A numerical study of externally solidified products in the cold chamber die casting process." Connect to this title online, 2004. http://rave.ohiolink.edu/etdc/view?acc%5Fnum=osu1095790853.

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Thesis (Ph. D.)--Ohio State University, 2004.
Title from first page of PDF file. Document formatted into pages; contains xvi, 162 p.; also includes graphics. Includes bibliographical references (p. 158-162).
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16

Kim, Jinsoo 1971. "Interfacial heat transfer of a single belt casting process." Thesis, McGill University, 2000. http://digitool.Library.McGill.CA:80/R/?func=dbin-jump-full&object_id=30254.

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Aluminum-magnesium alloys, used in sheet form, provide substantial strengthening with good ductility as a result of cold work, in addition to excellent corrosion resistance and weldability. In this thesis, the microstructures of Al-Mg alloy strips formed on a small scale simulator of a single belt caster was investigated. Heat transfer characteristics heat fluxes and heat transfer coefficients were also evaluated using thermocouple inserts and the IHCP (Inverse Heat Conduction Problem) method to deduce these values. This single belt casting is being developed as a new promising technology high productivity, in which liquid metal is cast from a dispenser system onto a moving belt that is cooled from below with water jets. In this process, the rate of heat transfer from the solidifying strip to the belt is one of the most important factors because the thermal history of the strip has a great influence on strip quality.
By measuring two temperature points under the moving substrate of different thermophysical properties, the values of heat flux and heat transfer coefficient were evaluated and microstructures were characterized quantitatively using the IHCP technique. With different substrate chemistry, correlations among liquid metal superheat, substrate velocity, substrate roughness, maximum heat flux, and grain size distributions were investigated.
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Kim, Jinsoo. "Interfacial heat transfer of a single belt casting process." Thesis, National Library of Canada = Bibliothèque nationale du Canada, 2000. http://www.collectionscanada.ca/obj/s4/f2/dsk1/tape4/PQDD_0035/MQ64230.pdf.

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18

Bradbury, Philip. "A mathematical model for the twin roll casting process." Thesis, University of Oxford, 1994. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.296919.

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19

Swain, Luke James. "Modelling ceramic mould deformation in the investment casting process." Thesis, University of Birmingham, 2017. http://etheses.bham.ac.uk//id/eprint/8015/.

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Core and shell deformation during the firing stage of the investment casting process was investigated. Relevant thermo-mechanical and thermal properties were characterised for a commercial core and shell system. A finite-element model was created using the experimentally obtained data. Four major mechanisms were shown to contribute to ceramic mould deformation; general thermal expansion, sintering, phase transformations and creep. The shell system experienced little deformation form phase transformation, the core system exhibited minor deformation from sintering. The sintering behaviour of shell material was observed to be highly dependent on the temperature-time profile of the firing cycle, with lower heating rates resulting in more sintering. The crystallisation of amorphous silica to β-cristobalite in core materials was also seen to follow this trend. A rule of mixtures approach showed that inter-layer interaction in shell materials was minimal. An Avrami-based kinetic modelling approach was applied to pressed silica pellets, showing very good prediction of similar heating rates, but an interaction effect between crystallisation and sintering behaviour needs to be established to predict a wider range of heating cycles. A master sintering curve approach was adapted to incorporate crystallisation to predict the displacement of pellets mimicking core materials. Due to silica crystallisation inhibiting sintering, lower heating rates produced less displacement. In order to validate the finite-element model, an experimental test was developed capturing the deformation of a shell test bar in a three-point bend rig at high temperature using photography. Images were then analysed in ImageJ® to measure the bending of the shell material, this was validated using a transducer attached to a three-point bend knife. Comparison of the finite-element model with the validation test showing good agreement. The creep exponents which were the main proponent of shell bending were optimized to be used in future models.
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20

Labatt, Sheila. "Glass as ink : seeking spontaneity from the casting process." Thesis, Royal College of Art, 2018. http://researchonline.rca.ac.uk/3464/.

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This practice-based research addresses internal form in cast glass. That is, ink- like imagery, which is wholly contained within clear, colourless glass. For the purposes of this project, ‘ink’ refers to liquid ink as is used in Chinese brush painting and calligraphy rather than to ink applications such as those used in print media. The aim is not to use ink itself. Rather, it is to emulate ink, rendered inside glass, while exploring the material similarities between the two media, including their liquid properties and their ability to be worked opaque or translucent. The project examines the interface between control and chance; where the artistic process ends and the unique properties of glass take over and are governed by heat, time and gravity. It also addresses the transformation of two- dimensional line drawing and ink wash into the third dimension. My research question is how the kiln and furnace casting processes can best be exploited to render the fluid, gestural and expressionistic immediacy of brush and ink painting, three-dimensionally, in solid glass. Following 14 years of studying and making art in Korea (1997‒2003) and China (2003‒2010), I have developed an affinity for brush and ink painting and, more specifically, for Chinese Grass script calligraphy and traditional landscape. This project aims to explore various methods of capturing apparent gesture and spontaneity in cast glass, in the form of ‘ink’ abstractions that evoke these styles of Chinese painting. My methodology includes identifying and isolating the elements that characterise Chinese brushwork in calligraphy and landscape painting, which are intimately linked fine art forms in China. Studio tests include manipulating different types of glass to create a dynamic, rhythmic, assured and graceful ink aesthetic, interpreted in the third dimension. I use flameworked inclusions to explore ink-like line and experiment with glass powders to evoke different intensities of ink wash. All tests are recorded in detail and are used to anticipate and loosely control glass movement. My research into Chinese brushwork characteristics is used to identify a framework within which the studio work sits. The variety, order and combination of techniques used to create the work constitute original knowledge in the field of cast glass. My method for reinterpreting the characteristics of Chinese painting, including line quality, ink wash, composition and balance, embedded three-dimensionally within the framework of cast glass, also contributes new knowledge. Based on systematic research and analysis, the terms ‘casting’, ‘moulds’, ‘spontaneity’ and the ‘third dimension’ are examined and defined anew.
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21

Sood, Minkesh Paul. "A novel geometry based approach for casting process optimisation." Thesis, Swansea University, 2006. https://cronfa.swan.ac.uk/Record/cronfa42352.

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The work presented in this thesis constitutes the main body of research carried out to develop a new technique for solidification simulation by using the Medial Axis Transformation (MAT) technique in combination with other geometric reasoning and numerical methods. The aspects of casting solidification researched include a review of existing geometric reasoning techniques and employability of MAT in combination with other methods. In the first phase of research, MAT was used to present a one-dimensional interpolation scheme that provided quick results compared to the numerical methods and evolving temperature solutions in time when compared to modulus method. The scheme successfully predicted the location of hotspots and provided an acceptable temperature distribution. Learning from, and owing to limitations posed by the interpolation scheme, a new innovative and hybrid technique was then proposed that for the first time unifies geometric and numerical methods, thereby inheriting their advantages and overcoming their respective limitations. The inscribed radius and other relevant geometric information were extracted from MAT. This was then combined with the Heuvers' Circle method. A new equation, based on Chvorinov's classic rule and modulus method, was derived that enabled the proposed technique to utilise the radius information of the casting to obtain effective interface boundary conditions for an optimal solution. The proposed method was then tested on a range of casting geometries, including those from the foundries. The problems arising from complexity of the medial axes were resolved by developing a sorting technique to select the most effective Heuvers' radii and a scaling framework was also developed to obtain realistic values. Finally the application of this technique to 3D castings was conceptualised and demonstrated through a case study. Thus an effective technique has been developed that not only retains the simplicity, ease of use, speed of the conventional geometric reasoning techniques but also the accuracy and sensitivity to material properties and boundary conditions offered by the numerical methods. The proposed method is capable of providing optimal solutions in two FE simulations.
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Sadeghi, Mohammad. "Optimization product parts in high pressure die casting process." Licentiate thesis, Mälardalens högskola, Framtidens energi, 2015. http://urn.kb.se/resolve?urn=urn:nbn:se:mdh:diva-27733.

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This thesis describes optimization of die temperature in high pressure die-casting (HPDC) of A380 alloy by experimental observation and numerical simulation with the use of statistical tools. The goal of this research is to determine the optimum die temperature to minimize incidence of these defects and thus maximize production of parts without defects.   In HPDC, molten metal is injected into the die at high speed (40-60 m/s for aluminum alloys). Die temperature plays an important role on the rate of rejected parts. Therefore, flow patterns of molten metal in HPDC of an automotive component with very complex geometry (the ladder frame from the EF7 motor) were examined to determine the optimal die temperature. Defects in the production process fall into three categories, including surface, internal and dimensional defects. Samples produced in the experiments were classified according to any present defects. Another important parameter that influences casting defects is the cooling rate. Die temperatures were measured at the initial step and final filling positions. Experiments were performed with die temperatures ranging from 150 °C to 250 °C. The results show that the melt temperature difference in the die between the initial step and the final filling position was between 20 and 25 °C. Statistical tools such as regressions, relationships, max, min, correlations, ANOVA, T-test, Principal Component Analysis (PCA) and descriptive statistics were used to facilitate interpretation of data from the die-cast experiments. Perform some case studies in order to study the process behavior, take a better knowledge of effective parameters, and measure the required parameters. The collected data are utilized to: Set the model Validate/ verify the model ProCast software was used to simulate the fluid flow and solidification step, and the results were verified by experimental measurements. The optimal die temperature for this alloy was found to be above 200 oC. Statistical analysis of the experimental results found that defects were minimized and confirmed parts were maximized in HPDC of the ladder frame within a die temperature range of 210° C to 215° C.
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Huan, Z., and G. D. Jordaan. "Thermal process and novel control methods for spin-casting." Journal for New Generation Sciences, Vol 4, Issue 1: Central University of Technology, Free State, Bloemfontein, 2006. http://hdl.handle.net/11462/490.

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Published Article
The quality of spin casting products and mould life are critically dependent on thermal conditions they undergo. In order to improve the performance of production and to optimise the spin-casting process, characteristics of the thermal process was firstly identified by means of the measurement and simulation. Furthermore the investigation of the developed control methods, including the thermal property substitute method and mixture method of the metal powder, was kept on the effect of air-cooling induced automatically from the spinning of the mould on the thermal process.
The air cooling system was developed to optimise the thermal process during casting, utilising a theoretical analysis of the air-flow characteristics in a cooling tube submerged in a silicon mould and the characteristics of convection heat transfer associated with the mould and cast part. A numerical simulation of the casting process was also adopted in the analysis. The effect of the developed system on the thermal process was determined experimentally and it was found that a system of aircooling, automatically induced from the spinning of the mould, is feasible in optimisation of the thermal process.
The developed control methods can be applied to the practice of spin casting individually or collectively according to the specific situations and requirements.
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24

Charmeux, Jean-Francois. "Capabilities of the Investment Casting process for producing meso/micro metal castings using Rapid Prototyping manufacturing routes." Thesis, Cardiff University, 2007. http://orca.cf.ac.uk/54701/.

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This thesis examines the capabilities of different Rapid Prototyping (RP) manufacturing processes for producing sound metallic parts incorporating features in the micrometre range using the Investment Casting (IC) process. RP has been growing in the past twenty years and is nowadays widely employed in the area of precision investment casting since the technology offers the possibility of manufacturing wax patterns which can be directly implemented into investment casting. Owing to the steady improvements of the technology, some of the recently developed RP building machines offer the possibility of manufacturing small parts incorporating micro-features. In this work, a detailed description of the accuracy and capabilities of the IC process regarding its potential for producing sound meso/micro components is given using two types of conventional RP machines. The results of this analysis are then compared through a benchmarking study with a recently developed RP process suitable for the direct manufacture of ceramic moulds. The different technological chains are compared regarding their overall accuracy, surface finish, the amount of structural defects present in the castings and their relative production costs and lead-time. Finally, the potential of the investment casting process for manufacturing sound micro-castings with high aspect ratio is approached from a structural point of view. Through a metallographic analysis study, the research investigates the size-scale effect of cast micro-components upon their microstructure and the subsequent changes in their mechanical properties.
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25

Su, Xiuling. "Computer Aided Optimization of an Investment Bi-Metal Casting Process." University of Cincinnati / OhioLINK, 2001. http://rave.ohiolink.edu/etdc/view?acc_num=ucin998405696.

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26

Quariguasi, Netto Pedro Gutemberg. "Mathematical and physical modelling of a single-belt casting process." Thesis, National Library of Canada = Bibliothèque nationale du Canada, 1998. http://www.collectionscanada.ca/obj/s4/f2/dsk1/tape11/PQDD_0016/NQ44560.pdf.

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27

Aniunoh, Kenneth Kanayo. "An experimental and numerical study of the film casting process." Connect to this title online, 2007. http://etd.lib.clemson.edu/documents/1202498963/.

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28

Miao, Xincheng. "Numerical study of a continuous casting process with electromagnetic brake." Doctoral thesis, Technische Universitaet Bergakademie Freiberg Universitaetsbibliothek "Georgius Agricola", 2014. http://nbn-resolving.de/urn:nbn:de:bsz:105-qucosa-144798.

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This dissertation investigates the effect of electromagnetic braking and gas injection on the fluid flow in a continuous casting slab mold numerically and makes verifications on basis of a small Liquid Metal Model for Continuous Casting of steel (mini-LIMMCAST). Numerical calculations were performed by means of the software package CFX with an implemented RANS-SST turbulence model. The non-isotropic nature of the MHD turbulence was taken into account by specific modifications of the turbulence model. The numerical results were validated by flow measurements at the mini-LIMMCAST facility. Numerical simulations disclose the damping effect on the flow closely depending on the wall conductance ratio. In addition, specific modifications of the turbulence model play a crucial role in reconstructing the peculiar phenomenon of an excitation of nonsteady, nonisotropic, large-scale flow perturbations caused by the application of the DC magnetic field.
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29

Karantzalis, Alexander E. "Characterisation of AI MMCs manufactured by a flux casting process." Thesis, University of Nottingham, 1997. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.243346.

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Lee, Kevin. "Understanding shell cracking during de-wax process in investment casting." Thesis, University of Birmingham, 2016. http://etheses.bham.ac.uk//id/eprint/6783/.

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In investment casting, the removal of wax from the shell is a critical step which may cause shell failure. It would be advantageous to predict the stress development during de-waxing process with computer simulation. The process was simulated with the consideration of two aspects: (i) The thermo-physical data required to model the shell and wax behaviour in the autoclave environment and (ii) A simulation capable of capturing the interaction between shell, wax and the autoclave environment. Data on mechanical properties, thermal properties, permeability, rheology, thermal expansion and density was gathered for wax and shell as appropriate. Flow-3D was used to simulate the de-wax process such that the shell and wax can be simultaneously modelled. It was shown that the Von misses stress exceeded the expected critical failure stress at certain nodes after steam was introduced to the system. Waxes with higher viscosity were predicted to reach the critical stress sooner. The simulation showed that for the selected drainage orifice sizes that was no or little difference in the time taken to reach the critical stress. Wax compressibility which was considered to represent shell permeability was predicted to have a large effect on shell cracking prediction. In general, the statistics of failure in validation test limited the conclusions that could be drawn. Waxes predicted to show differences in cracking and drainage with increasing orifice size did so in the experiment. The simulated drainage times were greater than determined experimentally by around 380s and this requires further investigation.
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Neumann, Matthew Craig. "Ancient Mexican bells : an empirical rediscovery of the casting process." Thesis, Massachusetts Institute of Technology, 1997. http://hdl.handle.net/1721.1/10225.

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Saxena, Amit. "Mathematical modeling of horizontal twin roll thin strip casting process." The Ohio State University, 2001. http://rave.ohiolink.edu/etdc/view?acc_num=osu1392309532.

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Mortara, L. "Analysis and development of an aqueous tape casting ceramic process." Thesis, Cranfield University, 2005. http://dspace.lib.cranfield.ac.uk/handle/1826/1960.

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The laboratory scale process developed by Navarro [Navarro, 2001 ] for the production of pyroelectric ceramics was used as a case study for the design of a high-level methodology for the scale-up of ceramic processes. A twofold approach was adopted as the basis of the methodology to perform the process scale-up. A "process focussed" approach was used that considered the sequence of processing operations, their feasibility on a larger scale and the potential problems foreseeable for a scaled-up process. Secondly, a "product focussed" approach analysed the quality of the product in respect to the customer requirements (the specifications).This approach also concerned the analysis of the process potential to perform within an essential tolerance interval. This aim was pursued through the use of a statistical technique, the Statistical Process Control. With the product focussed approach, the mechanical and electrical characteristics of the wafers obtained with the laboratory scale process were compared with the industrial requirements. The ceramic wafers possessed satisfactory characteristics except for their strength. The processing parameters were investigated in order to optimise the sintered ceramic microstructure and to understand their relative influence on the achievement of adequate characteristics for allowing handling and machining. Sintered density and grain size were studied as functions of green density and firing temperature. Increasing the green density from the original 37% to approximately 65% of the theoretical density by means of warm pressing allowed the wafers to achieve a more homogeneous microstructure and a higher sintered density up to approximately 97% of the theoretical. Thanks to the increase in green density, the sintering temperature could be reduced by 100°C and the total sintering time was shortened by 190 minutes. The samples produced with warm pressing were more resistant as 75% of them survived during the poling and machining test, in contrast with the 5% of the original samples. The suitability of the warm pressing technique to increase the green density up to 5 g.cm 3 (61 % of the theoretical density) was investigated by means of the statistical process control tool. A correct design of the press equipment was judged the most relevant factor for determining the control and the capability of the process. A rheological study was directed to understand how the slurry ingredients influenced the ceramic suspension, the green tape density and morphology. Two preparation routes were compared in order to discriminate among the effects induced by the electrosteric dispersant and the polyvinyl alcohol binder on the PZT particles suspension. It was shown how the dispersant influenced both the suspension characteristics and the comminution efficiency of the milling. The binder was shown to adsorb onto the ceramic particles. A model was proposed describing the interaction among ingredients which suggested that the adsorbing polymer induced particles flocculation by bridging mechanism, especially when added to stabilised slurries. As a result, PVA was judged inappropriate for tape casting of this PZT powder as it yielded low green density tapes.
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Symeonidis, Kimon. "The Controlled Diffusion Solidification Process: Fundamentals and Principles." Worcester, Mass. : Worcester Polytechnic Institute, 2009. http://www.wpi.edu/Pubs/ETD/Available/etd-042909-102711/.

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35

Siavashi, Kiavash. "The effect of casting parameters on the fluidity and porosity of aluminium alloys in the aost foam casting process." Thesis, University of Birmingham, 2012. http://etheses.bham.ac.uk//id/eprint/3525/.

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The Lost Foam Casting process has been firmly established for Aluminium and ferrous alloys. This process offers many advantages over conventional casting processes but its full potential has yet to be reached due to the many defects introduced to the casting associated with decomposition of the foam pattern during mould filling. The foam pattern commonly used in this process is Expanded Polystyrene (EPS) which degrades to liquid and vapour byproducts. The liquid decomposition byproducts travel to the metal/mould interface, where the globules of liquid foam can become trapped against the coating and their molecular weight is reduced due to the heat from the molten metal. At the same time, they release bubbles of gas into the castings. These globules can wick into the refractory coating only if their molecular weight is sufficiently reduced to below a critical molecular weight. In this study, to improve the quality of Aluminium alloys made by Lost Foam Casting, easier removal of the decomposition byproducts was obtained by using low molecular weight foam patterns. The molecular weight of expanded Polystyrene was not reduced when it was exposed to γ-rays because of cross-linking while the molecular weight of Poly Methyl Methacrylate (PMMA) was significantly due to chain session. Therefore, plates of Probead-70™ (a copolymer of Polystyrene 30 wt %-Poly Methyl Methacrylate 70 wt %) were exposed to γ-rays and reduced their molecular weight by up to about 85% below the critical molecular weight value. With low molecular weight foam patterns the decomposition byproducts require less reduction to reach the critical molecular weight to become absorbed by the coating, and consequently less defects are introduced into the casting. γ-radiation was employed to reduce the molecular weight of the foam. The porosity content of the castings was significantly reduced leading to an improvement of their mechanical properties such as their fatigue life which was increased by 100%. Lost Foam Casting has also been reported to experience complexities with fluidity. Misrun is likely to occur in Lost Foam Casting due to the formation of a large amount of gas at the metal/foam interface, increasing the back pressure, compared to the conventional castings. This reduces the velocity of the molten metal which might lead to solidification of the molten metal before filling the mould entirely. In the current work, a reproducible fluidity test was designed and the effects of different casting parameters on fluidity were examined. In some of the castings inserted thermocouples were employed to study the filling behaviour to determine the velocity of molten metal, thickness of the metal/foam interface and the time of freezing. It was concluded that it is not recommended to alter the coating thickness in order to improve fluidity, because the effect of coating thickness depends on the pouring temperature of the castings and permeability of the coating. The metallostatic pressure was found to affect the fluidity insignificantly (within the values in the current work, 2600-2700 Pa). Instead, increasing coating permeability, decreasing the density of the foam pattern and increasing the pouring temperature were found to increase the fluidity in Lost Foam Casting. However the effect of increasing pouring temperature and decreasing foam density may be detrimental to the quality of castings. The molecular weight of the foam pattern and the use of brominated foam patterns did not have a considerable effect on fluidity in Lost Foam Casting. It was also found that solidification in the Lost Foam Casting occurs at the metal/foam interface. A heat balance between the molten metal and the mould, and the foam pattern, was developed to give a fluidity equation to aid interpretation of the fluidity results. In summary, this research has provided a better understanding of the effect of casting parameters on the fluidity of Lost Foam Casting and the heat transfer from the molten metal to the foam pattern and to the mould. In addition, the quality of AL alloys castings was improved by reducing the molecular weight of the foam pattern used in the Lost Foam Casting process.
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36

Moisan, Jean-Francois. "Ultrasonic monitoring of die-casting process using clad buffer rod sensor." Thesis, McGill University, 2001. http://digitool.Library.McGill.CA:80/R/?func=dbin-jump-full&object_id=32968.

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In-line monitoring of die-casting of aluminum (A356, A357, 86S), magnesium (AZ91) and a metal matrix composite (Gra-NiRTM 6S:3G) will be monitored using the reflection coefficient obtained by using an ultrasonic technique, the pulse/echo. For each of the materials enumerated above, the average temperature of the mold through its thickness, the end of filling of the part, the solidification of the part in the cavity of the mold, the gap and/or the detachment of the part, the sound velocity and the attenuation of the material will be measured by this ultrasonic technique during the process.
For the materials the melt temperature will not exceed 600°C because the casting is made at the semi-solid state, between the solidus and liquidus, of the materials. A novel high performance buffer rod with a cooling system is integrated into the die. Therefore, ultrasonic measurements can be carried out with high signal-to-noise ratio at elevated temperatures.
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37

Corvatta, Sarah. "Propellant casting process simulation in a small-scale solid rocket booster." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2020.

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Small-scale solid rocket motors have been extremely successful among propulsion industries in the last decades for improving the accuracy of thrust-time prediction in new motors in order to reduce the amount of experimental tests needed for the characterization of their internal ballistics behaviour. It is of common knowledge the fact that the ballistic response of solid rocket motors depends on several factors, among which the manufacturing process stands out. It is the grain that defines the quality of the propellant. Therefore, the thrust performance can be affected by heterogeneity of grain caused by inclusions (like bubbles, air gaps or cavities) and by the different concentration and orientation of the solid particles during the casting process. The main objectives of the present work are, firstly, the implementation of numerical simulations of small-scale solid motors casting process that helps to characterize the propellant and to study its rheological behaviour and, secondly, the acquisition of an insight of the burning rate anomaly phenomenon, also known as "Hump Effect", through the analysis of particle concentration. This work is divided into two parts: the former is focused on the challenge of bi-dimensional, multi-batch and 3D fluid dynamic simulations of the casting process and the other one focused on the tracking of the particles present inside the propellant. The software that has been used for this work is ANSYS Fluent. Post-processing codes have been implemented with MATLAB in order to obtain the concentration of the particles inside the rocket motor.
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38

Yun, Ming. "A numerical and experimental study of the twin-roll casting process." Thesis, University of Oxford, 1992. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.315792.

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39

Wang, Dongtao. "Equilibrium temperature analysis and fill pattern reasoning for die casting process." Connect to this title online, 2004. http://rave.ohiolink.edu/etdc/view?acc%5Fnum=osu1095171663.

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Thesis (Ph. D.)--Ohio State University, 2004.
Title from first page of PDF file. Document formatted into pages; contains xx, 199 p.; also includes graphics. Includes bibliographical references (p. 196-199).
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40

EBERHARD, PARKER BROWNE. "TRACES OF MATERIAL AND PROCESS." University of Cincinnati / OhioLINK, 2003. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1053445721.

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41

Bouhouche, Salah. "Contribution to quality and process optimisation in continuous casting using mathematical modelling." Doctoral thesis, Technische Universitaet Bergakademie Freiberg Universitaetsbibliothek "Georgius Agricola&quot, 2009. http://nbn-resolving.de/urn:nbn:de:swb:105-6900128.

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Mathematical modelling using advanced approach based on the neural networks has been applied to the control and the quality optimisation in the main processes of steelwork such as the ladle metallurgical treatment and continuous casting. Particular importance has been given to the improvement of breakout prediction system and the reduction in the rate of false alarm generated by the conventional breakout detection system. Prediction of the chemical composition and temperature of liquid steel in the ladle has been achieved by neural networks and linear model. This prediction can be considered as a soft sensor. Slab surface temperature stabilisation on the basis of the casting events has been controlled by a neural networks algorithm, that gives an improvement in the surface temperature fluctuation in comparison to the conventional control system which is based on the PID controller. Quality monitoring and classification is also achieved by a neural network which is related to the breakout detection system. This technique achieves a classification of different defects based on the different alarm signal given by the breakout prediction system. Fault detection and process monitoring is developed using neural networks modelling. All models are developed on basis of practical operating database obtained from the iron and steel industry.
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42

Bouhouche, Salah. "Contribution to quality and process optimisation in continuous casting using mathematical modelling." Doctoral thesis, [S.l. : s.n.], 2002. http://deposit.ddb.de/cgi-bin/dokserv?idn=966041208.

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43

Bayandorian, Iman. "Magnesium alloy strip produced by a melt-conditioned twin roll casting process." Thesis, Brunel University, 2010. http://bura.brunel.ac.uk/handle/2438/4506.

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Twin roll casting (TRC) offers a promising route for the economic production of Mg sheet, but unfortunately, it produces strip with coarse and non-uniform microstructures and severe centre line segregation. Recently, a novel magnesium strip casting process termed melt conditioned twin roll casting (MC-TRC) was developed that, compared with the conventional TRC process, emphasizes solidification control at the casting stage rather than hot rolling. This was achieved by melt conditioning under intensive forced convection prior to twin roll casting resulting in enhanced heterogeneous nucleation followed by equiaxed growth. In this study the development of TRC and MC-TRC processes and a microstructural comparison of the MC-TRC Mg-alloy strip with that of conventional TRC strip, have been investigated. Emphasis has been focused on the solidification behaviour of the intensively sheared liquid metal, and on the mechanisms for microstructural refinement and compositional uniformity in the MCTRC process. The results of the process development indicate that the MC-TRC process reduces considerably or eliminates defects such as the centre line segregation, voids and cracks at or near the strip surface that are always present in conventional TRC strip. The newly-designed homogenization treatment investigated for TRC and MC-TRC magnesium alloy strips was based on microstructural evolution obtained during heat treatment. The results of the MC-TRC strips showed a much faster recrystallization rate with finer recrystallized grains, which are due to more homogeneous and a finer grain size of the as-cast MC-TRC strips compared with the as-cast TRC strips. During down-stream processing, the effects of MC-TRC process on microstructural evolution of hot-rolled magnesium strips have been understood thoroughly by accurate control of the hot-rolling procedure during each step of strip thickness reduction. This study indicates that the MC-TRC strip requires fewer rolling steps when compared to TRC strip, thus offering reduced processing cost and carbon footprint. Mechanical properties at room temperature of MC-TRC as-cast and rolled sheets are much improved when compared with the conventional TRC as-cast and rolled sheets which can result in a higher quality of final components. The mechanical properties at elevated temperature shows for the first time that the higher elongation and lower yield strength of MC-TRC as-cast strips at a temperature close to its optimised hot-rolling temperature results in better ability for rolling and higher ductility of MC-TRC Mg strip compared with the TRC Mg strip.
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44

Liu, Gang. "Fabrication of porous ceramics and composites by a novel freeze casting process." Thesis, University of Birmingham, 2011. http://etheses.bham.ac.uk//id/eprint/1532/.

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Porous ceramics have been widely used in many fields. Among the fabrication techniques for porous ceramic, freeze casting has recently attracted much attention as being a versatile, low cost and environmental friendly process. In this study, alumina and Al\(_2\)O\(_3\)-ZrO\(_2\) were utilized as model materials to investigate the preparation technique of freeze casting. Basic factors such as initial solids loading, cooling rate, and sintering temperature that would affect the final morphologies and the effect of additives have been studied. Porous alumina ceramics with lamellar microstructure exhibited compressive strengths up to 123 MPa for 33% porosity and 55 MPa for 42% porosity, making them suitable to be considered for potential load-bearing applications. In a two-phase system (Al\(_2\)O\(_3\)-ZrO\(_2\)), the choice of particle size of the ceramic powder was of great significance, which can lead to engulfment and phase segregation. BaTiO\(_3\) and Lead zirconate titanate (PZT) were employed to demonstrate the application of the freeze casting technique. BaTiO\(_3\)-epoxy composites exhibited modest piezoelectric constant but the dielectric constant was 1 order of magnitude higher than conventional composites with randomly distributed ceramic particles. For the 2-2 PZT-epoxy composites, with an increase of initial solids loading from 11 vol.% to 25 vol.%, the volume of ceramic phase in the composite gradually increased from about 30 vol.% to 50 vol.%, the piezoelectric constant \(d_{33}\) increased from about 103 pC/N to 203 pC/N, demonstrating the potential applications of this technique for the fabrication of 2-2 piezocomposites.
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45

Wei, Xiaodan. "Thermal mechanical analysis of interfacial behavior in aluminum alloy wheel casting process." Thesis, University of British Columbia, 2014. http://hdl.handle.net/2429/46024.

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The focus of this project is to improve the understanding of the interfacial heat transfer behavior within the Low-Pressure Die Casting (LPDC) process, which is the main manufacturing process for A356 aluminum alloy wheels, and to develop an improved methodology/expression for calculating the heat transfer across the wheel/die interface. To formulate and assess expressions for the interfacial behavior, a 2D-axisymmetric coupled thermo-mechanical model has been developed in the commercial finite element package, ABAQUS. The model was capable of predicting the thermal history, deformation and the variation of the air gap and pressure along the wheel/die interface. The temperature predictions of the coupled thermo-mechanical model were compared with temperature measurements obtained at Canadian Auto Parts Toyota Inc obtained on a production die. A displacement measurement setup using a high temperature eddy current displacement sensor was designed and tested in a lab setting but not employed in a plant trial due timing issues. Initially, the coupled thermo-mechanical model was run with a temperature dependent interfacial heat transfer coefficient to obtain preliminary air gap and pressure behavior at various locations. Comparisons with the thermocouple measurements suggest that the model is able to generally qualitatively, and at some locations quantitatively, predict the temperature changes from the main physical phenomena occurring during the casting process. The preliminary air gap and pressure predictions were used to develop a temperature, gap size and pressure dependent interfacial heat transfer coefficient based on literature review. The interfacial heat transfer coefficient was implemented in the model, and was found to improve the agreement between the model predictions and measured temperatures, but was prone to numerical convergence issues. A new methodology of incrementally changing the interfacial heat transfer coefficient has been proposed to solve the issues. The methodology was implemented in an EXCEL spreadsheet to test it and the calculated interfacial heat transfer coefficients were found to be continuous, reflecting the effects of air gap and pressure evolution. The methodology and corresponding algorithm should be further developed for use in an ABAQUS model in the future.
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46

Pimenta, Paulo Vicente de Cassia Lima. "Thermomechanical simulation of continuous casting process using element based finite-volume method." Universidade Federal do CearÃ, 2014. http://www.teses.ufc.br/tde_busca/arquivo.php?codArquivo=13684.

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CoordenaÃÃo de AperfeÃoamento de Pessoal de NÃvel Superior
The continuous casting technique in the last four decades has been large used for to production of semi-finished steel. The heat transfer is major mechanism and it occurs in various steps during the continuous casting. The quality of steel is directly related to the way the heat transfer occur because the thermal variations produce mechanical loads as well as contact forces which are generated through the rollers and shake of the mold. Such factors may cause defects such as fractures or cracks in the final product if the resulting stresses and strains exceed critical values. The technique must be improved in order to reduce the appearance of defects and the production time. For this a good understanding of physical phenomena involved during the solidification process is critical. The focus of this work is to apply the EbFVM (Element based Finite-Volume Method) approach to study the effects of linear tensions unidirectionally coupled with the temperature applied to continuous casting of the steel 1013D (0,3% of carbon) In the simulations we adopted some simplifications such as the Plane Strain and isotropic material. We also neglected the body forces contact with the rollers the liquid pressure on the walls of the steel ingot (ferrostatic pressure) and the convective effect. However despite of the simplifications adopted this work provides quantitative informations on the linear tensions accumulation that point out to areas of possible of cracks formations
A tÃcnica de lingotamento contÃnuo nas Ãltimas quatro dÃcadas à cada vez mais utilizada na produÃÃo de aÃo semiacabado. A transferÃncia de calor à o principal mecanismo dominante e ocorre em todas as etapas do processo. A qualidade do aÃo no lingotamento està diretamente relacionada à forma que ocorrem as trocas de calor pois as variaÃÃes tÃrmicas produzem carregamentos mecÃnicos assim como as forÃas de contato as quais sÃo geradas por intermÃdio dos rolos e da oscilaÃÃo do molde. Tais fatores podem causar defeitos como fraturas ou trincas no produto final caso as tensÃes e deformaÃÃes resultantes excedam valores crÃticos. O aprimoramento da tÃcnica tem a finalidade de evitar o surgimento de defeitos e reduzir o tempo de produÃÃo. Para isso à fundamental uma boa compreensÃo dos fenÃmenos fÃsicos envolvidos ao longo do processo de solidificaÃÃo. O foco deste trabalho à aplicar a abordagem do EbFVM (Element based Finite-Volume Method) no estudo dos efeitos das tensÃes lineares acopladas unidirecionalmente com a temperatura aplicado ao lingotamento contÃnuo do aÃo 1013D (0,3% de carbono) Nas simulaÃÃes adotou-se algumas simplificaÃÃes com o estado plano de tensÃes e isotropia do material. Descartando-se as forÃas de corpo o contato com os rolos a pressÃo do aÃo lÃquido nas paredes do lingote (pressÃo ferrostÃtica) e o efeito convectivo. Contudo apesar das simplificaÃÃes adotadas este trabalho traz informaÃÃes quantitativas quanto a formaÃÃo do acÃmulo das tensÃes lineares que apontam para regiÃes de possÃveis formaÃÃes de trincas
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47

Begg, John. "Process optimisation in the squeeze casting of zinc-aluminium alloys and composites." Thesis, Loughborough University, 1992. https://dspace.lboro.ac.uk/2134/27495.

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Squeeze casting is a process which has the potential to produce castings with exceptional mechanical properties. It also appears to be the most suitable route to produce sound cast metal matrix composites. An investigation was carried out into the squeeze casting of four zinc–aluminium alloys: commercial ZAS (simple eutectic alloy); commercial ZA12 (simple eutectic alloy); commercial ZA27 (peritectic alloy); binary Zn-37Al (solid solution alloy). Although the three commercial alloys can be cast by a variety of conventional gravity and pressure processes it was considered that squeeze casting would produce castings with more homogeneous microstructures and enhanced room temperature properties. The binary Zn-37Al was considered to be a suitable alloy for squeeze casting.
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48

Reddy, Mahender Palvai. "Finite element simulation of three-dimensional casting, extrusion and forming processes." Diss., This resource online, 1990. http://scholar.lib.vt.edu/theses/available/etd-07282008-135311/.

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49

張自恭. "Analysis of twin-roll casting process." Thesis, 1997. http://ndltd.ncl.edu.tw/handle/27835049411060883287.

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50

Costa, Ana Paula de Oliveira. "Multiscale technics in a casting process." Dissertação, 2020. https://hdl.handle.net/10216/129262.

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