Journal articles: 'Die casting process'

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Chen, Yi, Gang Yang, Yi Yang, Kang Sheng Wang, and Chen Guang Lu. "Casting Process and Simulation of K19 Cylinder Block." Applied Mechanics and Materials 602-605 (August 2014): 311–15. http://dx.doi.org/10.4028/www.scientific.net/amm.602-605.311.

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Cylinder blocks are the most important parts of engine, and their qualities will fundamentally determine the efficiency of engine. In this work, the casting process of K19 engine cylinder block was studied. A casting process was designed and assessed by the numerical software MAGMA to produce cylinder block castings. An actual experiment of casting was carried out and the mechanical properties of the casting were examined. The simulation results show the liquid metal smoothly fills the casting mold and no shrinkage cavity and porosity are formed in the castings. The cylinder block produced by the actual experiment exhibits superior mechanical properties to common ones, which proves the casting process designed is suitable for producing high quality cylinder block castings. The research shows that numerical simulation can provide very useful guidance for the production of castings

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Chang, Qing Ming, Yin Kai Yang, Jing Yuan, and Xia Chen. "Numerical Simulation of Mold Filling and Solidification Behavior in Permanente Casting Process." Applied Mechanics and Materials 313-314 (March 2013): 179–83. http://dx.doi.org/10.4028/www.scientific.net/amm.313-314.179.

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Melt flow and casting solidification are essential parts of the permanent mold casting process and affect significantly the quality of castings．For this reason, accurate prediction of mold filling pattern and temperature field in permanent mold castings plays on an important role in producing sound castings. In this paper, the model filling and solidification of a box casting produced from an aluminum alloy is studied. Different casting processes are employed, simulated and optimized to obtain sound castings. Simulation results reveal that with appropriate gating system, pouring rate, cooling line, a smooth mold filling, reduced shrinkages and other defects are available and desired sound castings can be produced.

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Kabdullinov, A. M., B. R. Nussupbekov, A. K. Khassennov, M. Stoev, and M. B. Karagaeva. "Automated control system for casting process." Bulletin of the Karaganda University. "Physics" Series 87, no. 3 (September 29, 2017): 65–70. http://dx.doi.org/10.31489/2017phys3/65-70.

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Suranuntchai, Surasak, and Ekkachai Kittikhewtraweeserd. "Analysis of Horizontal Squeeze Casting Process for Pipe Oil Part." Advanced Materials Research 482-484 (February 2012): 154–58. http://dx.doi.org/10.4028/www.scientific.net/amr.482-484.154.

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To achieve the laminar flow filling pattern in squeeze casting processes, many literatures [1-4] have reported that ideal velocity of liquid metal passing through the ingate should be between 0.1 – 0.5 m/sec. John Campbell [1] reported that liquid metal front speed velocity should be 0.4 m/sec in order to eliminate the gas porosity inside the casting. However, such slow speed requires the higher temperature of liquid metal and die. This results in not only the longer cycle time but also a coarser microstructure of the casting. In addition, the sample castings used in the literature are simple form castings which do not reflect the real castings used in daily life. In this study, the indirect squeeze casting processes is adopted to cast a motorcycle’s component originally produced by a high pressure die casting process. Based on shape and dimensions of the casting to get the real casting out for the mass production, melt’s speed must be higher than the level reported by the literatures (around 1 m/sec). As a result, a fully laminar flow may not be achievable. This is confirmed by the primary study of the process parameters and tooling design using the casting process simulation. However, by clinging on the two principles of the squeeze casting processes; (1) minimizing the amount of entrapped air by slowly fill the cavity and (2) reducing the amount of solidification shrinkage by pressurized solidification; the casting from two processes will be casted in order to compared the micro-structure and mechanical properties.

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Yu, Hai Liang, Jin Wu Kang, Shi Xiong Huang, and Tian You Huang. "Integrated Simulation of Castings Deformation during Casting and Heat Treatment Processes." Advanced Materials Research 148-149 (October 2010): 103–7. http://dx.doi.org/10.4028/www.scientific.net/amr.148-149.103.

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Deformation often appears in castings during casting and heat treatment processes, which determines the machining allowance setting and the machining size distribution of product. The paper presents a novel method for integrated simulation of the deformation behavior of castings during casting and heat treatment processes with a unified finite element model. Firstly, analyze the deformation of castings during casting process with the model containing mold and casting, and update the geometry of casting after casting process, then analyze the deformation of castings during heat treatment process and the final geometry shape of casting before machining could be obtained. By the method, investigation on the deformation behavior of a hydro turbine blade casting during casting and heat treatment processes was carried out, and the residual stress distribution and geometry shape of the casting were obtained.

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Gai, Deng Yu, Yu Zhao Chu, Qing Fen Li, and Qun Xia Li. "Process Optimization of Large Turbine Blade Casting Base on Numerical Simulation." Applied Mechanics and Materials 16-19 (October 2009): 535–39. http://dx.doi.org/10.4028/www.scientific.net/amm.16-19.535.

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3-D velocity and temperature fields of mold filling and solidification processes of large turbine blade casting were simulated. It indicated that the velocity field of upright casting is faster and steadier than lying casting. The deformation was predicted and the rule of deformation was reflected by analyzing stress field during solidification of upright casting. The casting processes were optimized, and then applied to produce castings.

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Semanco, Pavol, Marcel Fedák, Miroslav Rimár, Peter Skok, and Emil Ragan. "Equation Model of the Cooling Process in High Pressure Die-Casting Technology." Advanced Materials Research 505 (April 2012): 165–69. http://dx.doi.org/10.4028/www.scientific.net/amr.505.165.

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In the die-casting technology there is very necessary to determine cooling process of castings in metallic mold especially in the case of castings with great weight to achieve quality surface and properties of the casting without any defects. To regulate cooling in the time course, it is desirable to develop equation of regulation system that determining mold temperature dependence on casting temperature. In the paper we proposed model of regulatory system in the cooling process of casting in a mold that is based on an analysis of amplitude, phase and transition characteristics. The result is presented as proposal for regulatory circuit to control cooling process of casting in the mold.

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Chang, Qing Ming, Jing Yuan, Yin Kai Yang, and Xia Chen. "Modeling Analysis and Optimization of Sand Casting Process." Advanced Materials Research 479-481 (February 2012): 226–29. http://dx.doi.org/10.4028/www.scientific.net/amr.479-481.226.

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In this research paper, the sand casting process of a cover-type part for wind turbine was investigated with ProCAST software . The cover-type casting part is big in two dimensions and it is heavy in some local positions where shrinkage cavity and porosity are very likely to from. A non-uniform mesh is used corresponding to the non-uniform wall thickness. Different casting processes are employed, simulated and optimized to obtain sound castings. Simulation results reveal that with appropriate pouring temperature, correct number, size and location of chills and risers, a smooth mold filling, reduced shrinkage and other defects are available and desired sound castings can be produced

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Chirita, G., I. Stefanescu, Delfim Soares, and F. S. Silva. "Effect of Gravity/ Vibration/ Centrifugal Process on Mechanical Properties of an Al-Si Alloy." Materials Science Forum 587-588 (June 2008): 395–99. http://dx.doi.org/10.4028/www.scientific.net/msf.587-588.395.

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On this paper, a study that evaluates the influence of some variables on the mechanical properties of the vertical centrifugal casting is made. It is emphasized the fact that the centrifugal effect from vertical centrifugal casting brings special features on mechanical properties. It has been observed that the centrifugal effect may substantially increase, in some alloys, the rupture strength, rupture strain, and Young modulus, as compared to the gravity casting technique. When compared to gravity casting, the centrifugal casting process, besides the centrifugal force (pressure effect), always has an inherent associated vibration during the casting. In this study, as an attempt to isolate the vibration effect from the overall centrifugal effect, tests on castings obtained by vibrating gravity casting process are made. A comparison between castings obtained by centrifugal casting technique, vibrating casting technique and gravity casting technique is made in order to fully understand the features that allow the improvement on mechanical properties during the vertical centrifugal casting technique. An analysis of the most important effects, on both mechanical properties and on some metallurgical features is made.

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MIZUNO, Shinya. "New technologies of aluminum castings. New casting process." Journal of Japan Institute of Light Metals 47, no. 11 (1997): 580–86. http://dx.doi.org/10.2464/jilm.47.580.

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Kimura, Hiroyosi. "Machinery Castings Produced by Full Mold Casting Process." Proceedings of the Materials and processing conference 2000.8 (2000): 25–26. http://dx.doi.org/10.1299/jsmemp.2000.8.25.

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Shao, Heng, Yan Li, Peng Zhao, Hai Nan, and Qing Yan Xu. "Numerical Simulation of Centrifugal Casting Process of Large Thin-Wall Ti Alloy Casting." Materials Science Forum 850 (March 2016): 469–81. http://dx.doi.org/10.4028/www.scientific.net/msf.850.469.

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Centrifugal pouring is often used in investment casting of large thin-wall Ti castings to promote filling. Shrinkage defects often appear in a Ti casting produced by centrifugal casting. Numerical simulation indicate that shrinkage is caused by these reasons: improper pouring system and thin-wall structure limited feeding of liquid metal from pouring system, and centrifugal force enlarged the shrinkage defects by strengthen feeding of liquid within the casting. Thus centrifugal casting is replaced by gravity casting and a new pouring system is adopted. Obvious shrinkage defects disappear in the new casting process.

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Yang, Xiang Jie, Yi He, Yong Bo Zhu, Chuan Lin Hu, Hong Min Guo, Yun Hai Jing, and Guang Bin Yi. "The Study of A356 Alloy Rheo-Squeeze Casting Process." Solid State Phenomena 256 (September 2016): 270–75. http://dx.doi.org/10.4028/www.scientific.net/ssp.256.270.

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In this paper, the castings of A356 alloy were made by the rheo-squeeze casting with slurry-making from the process of LSPSF. Experiments were designed to study the influence of three parameters in rheo-squeeze casting process, such as injection speed, mould preheating temperature and injection pressure, on castings performance. The results show that high-quality castings were produced with the injection speed of 0.5m/s ,the mould preheating temperature of 240°C, the injection pressure of 50MPa. The mechanical properties, such as the yield strength, tensile strength and elongation of the castings with T6 heat treatment are 241 MPa, 328MPa and 11.6%, respectively.

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Huang, Yao, Yue Dong, and Yong Huang. "Shell Die-Casting and its Process Based on Numerical Simulation." Advanced Materials Research 233-235 (May 2011): 1167–70. http://dx.doi.org/10.4028/www.scientific.net/amr.233-235.1167.

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In this paper, the distribution and variation trend of temperature and velocity fields were obtained by numerical simulation of the casting process of shell die casting. According to the results of the numerical simulation, the die casting technology was optimized. The sound castings were produced. It was verified that shrinkage cavity and porosity could be reduced by increasing injected pressure and decreasing pouring and mould temperatures. The reliability of numerical simulation of die casting process was proved. In addition, the qualified products were obtained on the basis of the optimized die-casting parameters from the simulation results.

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Xu, Yong Tao, Tian Yang Guan, Zhi Feng Zhang, Yue Long Bai, and Wei Min Mao. "Semi-Solid Rheological Squeeze Casting Process of ZL114A Aluminum Alloy Thin-Wall Complex Casting." Materials Science Forum 993 (May 2020): 248–53. http://dx.doi.org/10.4028/www.scientific.net/msf.993.248.

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High-strength aluminum alloy with large-scale and thin-walled complex castings have broad application prospects in aerospace, weapons, electronics, defense and military industries. However, due to the uneven thickness of the plate, the casting defects are inevitable by the ordinary casting method, and it is impossible to accurately control the shape and performance of the casting in the casting process. Previous studies have found that the semi-solid rheological extrusion casting technology with short process and near-end type can help solve this technical problem. Therefore, this paper studies the semi-solid rheological extrusion casting process of thin-walled complex casting of ZL114A aluminum alloy. The combination of numerical simulation and experimental research is used to simulate and optimize the filling and solidification process of thin-walled specimens. Based on this, a semi-solid rheological extrusion casting test was conducted. The result showed that, (1) The optimized model can well reflect the filling and solidification process under different rheological extrusion casting parameters, and obtain defect-free castings through process optimization. (2) The thin-walled parts of the thin plate casting produced by semi-solid rheology extrusion have excellent mechanical property and ductility.

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Sadayappan, K., W. Kasprzak, Zach Brown, L. Quimet, and Alan A. Luo. "Characterization of Magnesium Automotive Components Produced by Super-Vacuum Die Casting Process." Materials Science Forum 618-619 (April 2009): 381–86. http://dx.doi.org/10.4028/www.scientific.net/msf.618-619.381.

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Magnesium automotive components are currently produced by high pressure die casting. These castings cannot be heat-treated to improve the strength and ductility mainly due to the casting imperfections such as porosity and inclusions created by the air entrainment during the turbulent mold filing. These imperfections also prevent magnesium components to be used for highly stressed body components. Efforts were made to produce high integrity magnesium castings through a Super-Vacuum Die Casting process. The AZ91D castings were found to have very low porosity and can be heat-treated without blisters. The tensile properties of the castings were satisfactory. The mechanical properties and thermal analysis indicate that the conventional heat treatment procedure needs to be optimized for such thin sectioned and rapidly solidified castings which have very fine microstructures.

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Xu, Shao Yong, Si Yuan Long, and Fen Ge Li. "A Novel Squeeze Casting Process for Producing Magnesium Wheels." Materials Science Forum 546-549 (May 2007): 113–18. http://dx.doi.org/10.4028/www.scientific.net/msf.546-549.113.

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This paper analyzes the casting process characteristics of Mg alloys compared with Al alloys in the production of high quality (i.e. structural) structural vehicle components. The disadvantages of traditional squeeze casting for high quality Mg components has led the authors to develop a novel squeeze casting process which overcomes the drawbacks of the current methods. The details of the new process are presented here and show the increased productivity and quality of castings that can result from changing the way molten metal is handled and processed. The feasibility of this new squeeze casting process was applied to Mg wheels for LX150 motorbikes.

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Gaspar, Stefan, and Ján Pasko. "Analysis of Fracture Process and Common Defects in Casting Alloys EN43100 Manufactured by Die Casting Technology." Advanced Materials Research 1077 (December 2014): 39–43. http://dx.doi.org/10.4028/www.scientific.net/amr.1077.39.

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Recent research in the process of die casting production of aluminium alloys which are nowadays deeply implemented in the rapidly developing automobile, shipping and airline industry aims to increase the manufacture and quality properties of the casting in order to obtain its high mechanical properties at acceptable economic costs. In terms of ensuring the quality indicators in the production of aluminium castings it is necessary to pay close attention to internal structural quality of the castings characterized by type and extent of foundry defects (cavities, Al2O3 particles, internal cold laps). The presenting contribution deals with the analysis of the fracture process, the microorganism disturbance of test samples, the impact of casting speed on the occurrence and extent of the castings porosity and reasons for the internal foundry defects of casting alloys EN 43100 manufactured by die casting technology.

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Gaspar, Stefan, and Jan Pasko. "Increase Pressure and Homogeneity of Die Castings from EN AC 47100 Alloy." Applied Mechanics and Materials 729 (January 2015): 108–13. http://dx.doi.org/10.4028/www.scientific.net/amm.729.108.

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In the pressure die casting process, a great attention is paid to a die castings quality improvement. This quality has to be ensured with a great reliability and, at the same time, it is necessary to apply control methods to a technological process which provide a complete picture of a die casting process as well as internal quality of the produced die castings. It requires control of the present technological factors of a pressure die casting process. The contribution deals with the effect of die casting plunger velocity inside a filling chamber on mechanical properties of a die casting product from EN AC 47100 alloy.

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Fu, Li Bin, and Jun Yang. "Design and Optimization of Bolster Casting Process." Advanced Materials Research 482-484 (February 2012): 692–96. http://dx.doi.org/10.4028/www.scientific.net/amr.482-484.692.

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The low-pressure casting method has been used to the foundry process of bolster. According to the structural characteristics of the cast and the design process of low-pressure casting, the process programs had been accomplished. Through comparing the advantages and disadvantages of several group programs by computer simulation, after determining the initial process program, we optimized the casting process according observing the processes of cast filling and solidification by the computer simulation process of running castings. The risers and chills are very important. The contraction area of cast appears on the large flat, and the risers had been set on the large flat. This can not only play the role of feeding but also have the function of scavenging action.

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Midson, Stephen. "Industrial Applications for Aluminum Semi-Solid Castings." Solid State Phenomena 217-218 (September 2014): 487–95. http://dx.doi.org/10.4028/www.scientific.net/ssp.217-218.487.

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The goal of this paper is to examine industrial applications for semi-solid castings, and to develop strategies necessary for the wider commercialization of the semi-solid casting process. The performance and production techniques of semi-solid castings are reviewed, with the goal of identifying commercial niches where semi-solid castings can provide clear benefits over other casting process. A comparison of mechanical properties between semi-solid castings and other casting processes is presented. In addition, this paper provides an evaluation of the features of the optimal semi-solid casting processes, examines the characteristics of components that would benefit for production by semi-solid casting and describe the types of quality systems that casters need to have in place to make these types of castings. Cost analyses are presented suggesting that rheocasting can complete well with other casting processes.

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Wu, Lan Ying, Xiao Lian Xiang, and Long You. "Research of Casting Process about Cover and Pump Body of Tonghai Pump and Mechanical Properties Test." Advanced Materials Research 631-632 (January 2013): 676–80. http://dx.doi.org/10.4028/www.scientific.net/amr.631-632.676.

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In order to obtain cover and pump body of tin bronze Tonghai pump that is dense and good pressure resistance,the casting mold of the cover of Tonghai pump is metal mold. The casting method of Tonghai pump is vacuum counter-pressure casting.The method of casting pump body of Tonghai pump is vacuum investment casting. This research is about reasonable casting process parameters of vacuum counter-pressure casting and vacuum investment casting.Finally qualified castings of cover and pump body of Tonghai pump can be obtained.

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Zeng, Jian Min, and Yao He Zhou. "A New Sand Casting Process with Accelerated Solidification Rate." Materials Science Forum 686 (June 2011): 765–69. http://dx.doi.org/10.4028/www.scientific.net/msf.686.765.

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In order to solve the problems involved in coarse grains, macro and micro porosities initiated by low solidification rate in sand casting, an innovative counter-gravity sand casting process, Casing under Adjustable Pressure with Accelerated Solidification (CAPAS) was put forward in this paper. The hydrodynamics of mold filling for CAPAS is based on Bernoulli's principle. The mold and crucible were placed separately in the upper and lower chambers, with the feed tube connected between them. High-speed jet flow of air made negative pressure in the upper chamber. In this way, pressure differential was created between the two chambers. Thereby the molten metal in the crucible was forced to flow upward smoothly to fill the mold cavity. After mold filling, cold air was introduced into sand mold through aisles that are set within the mold, which results in strong convective heat exchange at the casting/mold interface. So solidification rate of casting increased dramatically. The microstructures of the aluminum castings were compared between CAP (Low pressure sand casting) and CAPAS by optical microscope. The results showed that the microstructure of CAPAS aluminum casting was much finer than that of CAP casting and tensile strength markedly increased.

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Zeng, Jian Min, Jie Liang, Zhi Liu Hu, Ping Chen, and Li Hua Liang. "Numerical Simulation Software of Casting Process used for Computer Aided Instruction." Advanced Materials Research 399-401 (November 2011): 13–16. http://dx.doi.org/10.4028/www.scientific.net/amr.399-401.13.

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Simulation software is an essential tool for today‘s engineers. Its application enables castings to be designed with predicting the final results prior to they are produced. Thus, the simulation plays significant role in casting production. If a realistic calculation of the mold filling and solidification processes can be made it is possible to predict casting defects caused by casting system and/or casting design. In order to understand the changes occurring during solidification of casting, numerical simulation has been used in our classroom teachings for postgraduates. The software structures, mathematical principles, software utility, functions and output criteria are introduced in this paper to demonstrate that computer aided instruction is of Intuitive, attractive and can be used in classroom before the real experiments as assistant means to help postgraduates to understand what is casting and what is solidification

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Yang, Guang Yu, Wan Qi Jie, Qi Tang Hao, and Jie Hua Li. "Study on Process of Magnesium Alloy Investment Casting." Materials Science Forum 561-565 (October 2007): 1019–22. http://dx.doi.org/10.4028/www.scientific.net/msf.561-565.1019.

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The process of different sorts of magnesium alloys investment casting is studied using a mold materials composed of zircon and colloided silica binder. The investment shell is flushed out employing protective gas mixture of 1% HFC134a and inert gas. The castings with perfect appearance and high metallurgical quality are produced successfully for ZC62 and ME-1magnesium alloy respectively. The mechanical properties of the castings reached the ASTM standard.

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Sołek, K., and L. Trębacz. "Thermo-Mechanical Model of Steel Continuous Casting Process." Archives of Metallurgy and Materials 57, no. 1 (March 1, 2012): 355–61. http://dx.doi.org/10.2478/v10172-012-0034-3.

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Thermo-Mechanical Model of Steel Continuous Casting Process In the paper a numerical model of heat and mass transfer in the mould zone in the steel continuous casting technology was presented. The model has been developed using ProCAST software designed for simulation of casting processes. It allows to determine temperature and stress distribution in continuous castings in order to optimize the most important process parameters. In this work calculations were executed for low carbon steel grades casted in the industry. In the simulations the real rheological properties measured in the experimental work and the boundary conditions determined on the basis of the industrial data were used.

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Georgiev, Georgi Evt, Sasho Popov, Valentin Manolov, Rositsa Dimitrova, and Pavel Kuzmanov. "Heat Transfer Process Computer Simulation and Microstructure Prediction During Crystallization of Metal Alloys." Journal of Theoretical and Applied Mechanics 43, no. 1 (March 1, 2013): 71–78. http://dx.doi.org/10.2478/jtam-2013-0007.

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Abstract Processes of crystallization during casting formation from aluminum alloys, steel and cast iron have been studied using 3-D com- puter simulation. Temperature fields of castings have been obtained and the microstructure distribution of these castings has been predicted. A comparison between numerical results and experimental measurement has been performed. It is proved, that the proposed approach is suitable for investigation and analysis of casting technologies.

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Aneesh Kumar, J., K. Krishnakumar, and S. Savithri. "Computer Simulation of Centrifugal Casting Process Using FLOW-3D." Materials Science Forum 830-831 (September 2015): 53–56. http://dx.doi.org/10.4028/www.scientific.net/msf.830-831.53.

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Centrifugal casting process is one of the potential manufacturing techniques used for producing functionally graded materials viz., composite materials or metallic materials which have high differences of density among constituents. In this process, the fluid flow plays a major role and understanding the complex flow process is a must for the production of defect-free castings. Since the mold spins at a high velocity and the mold wall being opaque, it is impossible to visualise the flow patterns in real time. Hence, in the present work, the commercial CFD code FLOW-3DTM, has been used to simulate the mold filling sequence for a simple hollow cylindrical casting during vertical centrifugal casting process. Effect of various spinning velocities on the fill pattern during vertical centrifugal casting process is being investigated.

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Bharadwaj, Akash. "Casting of Hypoid Gear & Process Cost Reduction." International Journal Of Mechanical Engineering And Information Technology 05, no. 04 (April 25, 2017): 1560–83. http://dx.doi.org/10.18535/ijmeit/v5i4.04.

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Battaglia, Eleonora, Franco Bonollo, Elena Fiorese, and Giorgio Kral. "Overview of the Correlations between Process Parameters, Microstructure and Mechanical Properties of Reference Castings and Industrial Demonstrators." Key Engineering Materials 710 (September 2016): 35–40. http://dx.doi.org/10.4028/www.scientific.net/kem.710.35.

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Among the Aluminum casting processes, High Pressure Die Casting (HPDC) is an efficient, versatile and economic way for producing large number of components. Nevertheless, because of the elevated amount of rejected castings, it is important to know which are the main causes of defect formation and their effects on microstructure and mechanical properties. This paper presents, within the European MUSIC project, an overview of the preliminary correlations obtained studying both castings with defect generator geometry, referred to as Horse-shoe Reference Castings, and industrial demonstrators, referred to as Gear Box Housing. The deduced correlations between static mechanical properties and casting defects highlighted interesting trends in both cases.

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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 influence on shrinkage porosity defects. The experimental results show that the high intensification pressure, high die temperature and long biscuit can be beneficial to obtain castings with no shrinkage porosity.

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Dong, Yi, Xiao Ming Fan, and Bin Liu. "Numerical Simulation and Technology Optimization of Rear Oil Seal Bearing Die Castings Based on ProCAST." Advanced Materials Research 189-193 (February 2011): 4008–13. http://dx.doi.org/10.4028/www.scientific.net/amr.189-193.4008.

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In production,the Φ105 mm hole of rear oil seal bearing die castings often appear porosity, shrinkage and other defects , resulting in the parts to scrap. The existing gating system design of rear oil seal bearing die castings was improved , and the flow and temperature field of the two programs that before and after improvement were analyzed by ProCAST software. The simulation results predicted the casting defects, and the conclusion was consistent with the production. By using the improved process optimization, the rejection rate of die castings can be reduced effectively. Die casting is a chipless forming of casting with high casting dimensional accuracy, high surface quality and high production efficiency [1,2]. Therefore, it has developed rapidly in the automotive, communications and other industries. However, due to shrinkage, porosity and other reasons, leading to high rejection rate of castings. With the emergence of commercial casting simulation software, the casting production has been developed from semi empirical and semi theoretical onto theorization, quantification and controllable track[3-5]. In this paper, the casting defects of rear oil seal bearing is analyzed by using numerical simulation technology[6]. By optimizing the casting process, the casting quality is improved, and the rejection rate is reduced effectively.

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Liao, Dun Ming, Li Liang Chen, Jian Xin Zhou, and Rui Xiang Liu. "CAD/CAE Technology and its Application on Nonferrous Alloy Casting." Advanced Materials Research 139-141 (October 2010): 1113–16. http://dx.doi.org/10.4028/www.scientific.net/amr.139-141.1113.

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The nonferrous alloy castings will be much demanded with the development of aerospace, light-weight weapons and automotive industry. Casting CAD/CAE technology has played an increasingly important role in foundry. It can help technician to design casting process and simulate heat transferring and molten metal flowing before actual production. Firstly, the main contents and basic principles, mathematical models of casting CAD and CAE were introduced. Secondly, the casting CAD/CAE technology route was interpreted, and then several CAD/CAE applications of casting process design and simulating were carried out on nonferrous alloys, such as aluminum, magnesium and copper. The results indicate that CAD/CAE technology can be applied to casting process design and predict casting defects which usually occur during the casting mold filling and solidification process, it can provide references to optimize casting process, so as to improve casting quality, reduce the rejection rate and shorten the development cycle of new products.

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Grassi, John, John Campbell, Martin Hartlieb, and Fred Major. "The Ablation Casting Process." Materials Science Forum 618-619 (April 2009): 591–94. http://dx.doi.org/10.4028/www.scientific.net/msf.618-619.591.

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A new patented casting process is described, based on a precision aggregate mold, bonded with a water-soluble binder. For the first time the twin functions of the mold (i) defining shape and (ii) providing cooling have been successfully separated allowing the production of castings of all sizes and shapes (thin and thick walls) for all Al and Mg alloys. Because solidification and cooling are separately controlled by the application of water a number of advantages follow immediately. The mold is ablated (i.e. eroded) away by the water without fume or dust and the ‘air gap’ is eliminated by direct contact with the water, enhancing the rate of solidification to levels normally unattainable, resulting in significantly enhanced properties. The unusual microstructures of Al-Si alloys having large DAS but micron-sized eutectic silicon indicates, in agreement with earlier predictions, that DAS per se does not control strength or ductility. The process is currently proving itself in commercial operation, having the additional advantages of modest start-up and tooling costs as well as low competitive piece part costs because of the use of low cost materials and the recycling of aggregate and water.

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Mi, J., R. A. Harding, and J. Campbell. "The tilt casting process." International Journal of Cast Metals Research 14, no. 6 (May 2002): 325–34. http://dx.doi.org/10.1080/13640461.2002.11819450.

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Tsuji, Makoto. "Automation of Die Casting." International Journal of Automation Technology 2, no. 4 (July 5, 2008): 285–88. http://dx.doi.org/10.20965/ijat.2008.p0285.

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Die-casting is a process to manufacture high-accuracy castings at high productivity using nonferrous metals such as zinc, copper, aluminum and magnesium. Die-casting includes many processes such as lubricant spray to the die, injection of molten metal, taking off the casting from the die, and trimming of unnecessary parts. Nowadays all these processes of die casing can be conducted by fully automated die-casting machines. TOSHIBA MACHINE CO., LTD has taken the lead in development of die-casting machines. Here we will be introducing the common process flow and details of some of major components of the die-casting equipment.

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He, Li Tong, Yi Dan Zeng, and Jin Zhang. "Solidification and Microstructure Simulation of A356 Aluminum Alloy Casting." Materials Science Forum 1033 (June 2021): 18–23. http://dx.doi.org/10.4028/www.scientific.net/msf.1033.18.

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To obtain an A356 aluminum alloy casting with a uniform structure and no internal shrinkage defects, ProCAST software is used to set different filling and solidification process parameters for an A356 aluminum alloy casting with large wall thickness differences, And multiple simulations are conducted to obtain optimized casting process; then, based on the process, the microstructure of the thickest and thinnest part of the casting are simulated. The size, morphology, and distribution of the simulated microstructure of the thinnest part and the thickest part of the casting are very similar. The simulated microstructure is similar to that of the actual casting. This shows that castings with uniform structure and no internal shrinkage defects can be obtained through the optimized casting process .

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Marukovich, E. I., A. M. Branovitskiy, A. A. Kruglov, V. A. Dement’ev, and N. P. Sadovskiy. "PRODUCTION OF ROTARY ENGINES’ PARTS FROM ALUMINUM ALLOYS USING LOST FOAM CASTING PROCESS." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 1 (April 6, 2018): 16–21. http://dx.doi.org/10.21122/1683-6065-2018-1-16-21.

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The production technology of casting details for rotary engine from the aluminum alloy АК12М2 is developed. The bulk density of expanded polystyrene to ensure the best quality of the surface of castings has been experimentally established. The lost foam casting shop was organized in the experimental department of the Institute.

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Vanko, B., and L. Stanček. "Utilization of Heat Treatment Aimed to Spheroidization of Eutectic Silicon for Silumin Castings Produced by Squeeze Casting." Archives of Foundry Engineering 12, no. 1 (January 1, 2012): 111–14. http://dx.doi.org/10.2478/v10266-012-0021-1.

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Utilization of Heat Treatment Aimed to Spheroidization of Eutectic Silicon for Silumin Castings Produced by Squeeze Casting This paper describes the possibility of using very short periods of solution annealing in the heat treatment of unmodified hypoeutectic silumin alloy AlSi7Mg0,3 casted by method of casting with crystallization under pressure with forced convection (direct squeeze casting process). Castings prepared at different casting parameters were subjected to special heat treatment called SST (Silicon Spheroidization Treatment), which were originally used only for the modified silumin alloys to spheroidization of eutectic silicon. Temperature holding time in solution annealing of T6 heat treatment is limited in the SST process to only a few minutes. It was studied the effect of casting parameters and periods of solution annealing on ultimate strength, yield strength, and especially ductility that in the unmodified silumin alloy castings is relatively low.

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Tang, Jin Jun, Li Qun Hou, Liang Jun Fei, Yu Lei Li, and Xiao Yu Jin. "Air Conditioning Compressor Front Cover of Squeeze Casting Process Design and Numerical Simulation." Applied Mechanics and Materials 602-605 (August 2014): 209–13. http://dx.doi.org/10.4028/www.scientific.net/amm.602-605.209.

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This paper is mainly on the research of squeeze casting production automobile air conditioner front cover FS170C, due to the development and optimization of the part in the production process, design and manufacture of low cost mould, the rules of structure and properties of castings is lack of corresponding research, seriously affected the development and market competition ability of the air conditioning compressor front cover. In order to solve the above problems, and to provide reference data and process scheme is necessary, this study to optimize the design of squeeze casting technology of the front cover of the air conditioner, finalized a most reasonable extrusion casting scheme, namely the gating system is more suitable and exhaust system design, and the squeeze casting process parameters, in this scheme next, carries on the mold design, production of squeeze casting of high quality.

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Liu, Jiang. "The Shell Molding Process Study for Mass Production of Single-Cylinder Diesel Engine Crankshaft." Applied Mechanics and Materials 44-47 (December 2010): 284–88. http://dx.doi.org/10.4028/www.scientific.net/amm.44-47.284.

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Crankshaft is a key transmission part in single-cylinder diesel engine, but its mass casting production is a problem. Based on the traditional shell molding process of ductile iron castings, this study did lots of techniques optimization for the crankshaft castings of single-cylinder diesel engine. Through increasing the multi-block or a combination of chill iron at sector-plate and upper spindle neck, increasing the pressure head of blind risers and the cross section of sprue, improving the fill compaction of iron pills, and other improvements, produces qualified ductile iron crankshaft castings without or almost without the shrinkage and other casting defects.

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Zeng, Yi Dan, Li Tong He, and Jin Zhang. "Numerical Simulation of Casting Deformation and Stress of A356 Aluminum Alloy Thin-Walled Frame Casting." Materials Science Forum 1033 (June 2021): 24–30. http://dx.doi.org/10.4028/www.scientific.net/msf.1033.24.

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One of the main reasons for the scrap of cast thin-wall frame aluminum alloy castings is deformation and cracking. It is an effective method for solving the problem by predicting the distribution of casting stress, clarifying the size of the deformation and the location of the crack, and taking necessary measures in the process. This paper uses the ProCAST software to simulate the thermal stress coupling of A356 thin-walled frame castings, analyzes the influence of pouring temperature, pouring speed and mold temperature on the stress field distribution of castings, predicts the hot cracking trend and deformation, and optimizes Casting process..

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Prikhod’ko, O. G., V. B. Deev, E. S. Prusov, and A. I. Kutsenko. "Influence of thermophysical characteristics of alloy and mold material on castings solidification rate." Izvestiya. Ferrous Metallurgy 63, no. 5 (July 1, 2020): 327–34. http://dx.doi.org/10.17073/0368-0797-2020-5-327-334.

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Obtaining castings of given quality is the main task of foundry production. One of the stages of casting technology is solidification of melt in the mold. When studying the process of castings solidification, it is necessary to fully take into account all the features of heat transfer between casting and mold. Influence of various thermophysical parameters of alloy and mold material on casting formation is considered. In the analysis, original mathematical models were used to calculate the coefficient and time of complete solidification of castings in sand-clay and metal forms. These models take into account geometric parameters of casting, main thermophysical parameters of casting metal and mold material, heat transfer conditions at crystallization front, on casting-mold boundary and on the mold surface. Analysis of dependence of time and rate of castings solidification on thermophysical parameters (heat capacity, density, heat conductivity of casting material and mold, specific heat of metal crystallization) was carried out. Storage capacity and process of heat storage are quite fully characterized by the value of heat storage coefficient. This coefficient practically determines the rate of heat loss by the casting which plays a decisive role in its properties forming. Therefore, this parameter is selected for a comprehensive analysis of thermal processes occurring in casting and mold. The influence of thickness and thermal conductivity of chill paint layer on solidification of castings in metal molds is considered. The basic calculation formulas and initial data are presented. Calculations were carried out for castings of the following types: endless plate, endless cylinder, ball. The results of simulation of solidification process parameters are presented in graphic form. Using various alloys as an example, it has been shown by calculation that when changing composition and properties of mold material, it is possible to change time and speed of alloys solidification in a wide range. In this case, processes of forming the structure and properties of castings are controlled.

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Gavariev, R. V., and I. A. Savin. "Improvement of Surface Quality of Casting Produced by Casting under Pressure." Solid State Phenomena 265 (September 2017): 988–93. http://dx.doi.org/10.4028/www.scientific.net/ssp.265.988.

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The article considers the surface roughness of compression molds castings received by casting under pressure depending on the condition of the form-building surface. The technological process of casting under pressure is presented for the "Strike plate" product, concrete technological parameters values are specified. The pilot studies of the roughness of the castings throughout the entire period of operation of a compression mold are conducted. Based on the received values the recommendations about improvement of quality of a surface of castings by drawing sheetings are submitted by phisical vapour deposition method.

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Zhang, Zhuang Ya, Hai Guang Zhang, Nan Nan Xu, Tian Lv, Yuan Yuan Liu, and Qing Xi Hu. "Study on Regulated Pressure Vacuum Casting Method for Larger & Thin-Wall Castings." Key Engineering Materials 522 (August 2012): 8–12. http://dx.doi.org/10.4028/www.scientific.net/kem.522.8.

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Aiming at the problem that current vacuum casting method lack of the filling ability in filling large & thin-wall castings. Therefore, a regulated pressure vacuum casting method is proposed, which using regulated pressure to improve the filling ability. The process and mechanism for regulated pressure vacuum casting method is presented and proved it through the home-made V450N-VD vacuum casting prototype. The results show that the regulated pressure vacuum casting method has higher filling capacity and can provide higher negative pressure during the whole filling process. So regulated pressure vacuum casting method has profound development potential.

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Yang, Da Chun. "Influence of Casting Process for Technological Yield of Thin Wall Steel Castings by Last Solidifying Feeding Mechanism." Advanced Materials Research 538-541 (June 2012): 1134–37. http://dx.doi.org/10.4028/www.scientific.net/amr.538-541.1134.

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For the steel castings which is thin wall, uniform thickness, complex structure, and no special mechanical properties, it is feasible that the foundry technology was designed according to the last solidifying feeding mechanism. Adopting this process for the thin wall steel castings, the pouring temperature must be controlled and the gating system be designed rationally. Using self-feeding shrinkage in solidification, and the casting was poured and congealing at the same time. The shrinkage of finally congealing part was fed by small riser or gating system (no riser). Using this foundry technology, the casting process yield and surface quality of casting may be improved, the production cost is reduced, and the requirements of mechanical properties can be met.

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Cheng, Le, Hong Xing Lu, Qiang Zhu, Xiang Kai Zhang, Ai Di Shen, and Peng Yang. "Evolution of Microstructure and Mechanical Properties of Semi-Solid Squeeze Cast A356.2 Aluminum Alloy during Heat Treatment." Solid State Phenomena 285 (January 2019): 139–45. http://dx.doi.org/10.4028/www.scientific.net/ssp.285.139.

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Semi-solid squeeze casting (SS-SC) is a new processing technology which combines semi-solid processing (SSP) and squeeze casting (SC). In this process, semi-solid slurry fills mold by using its rheological property and solidifies under high pressure. It has several advantages, such as stable filling, small heat impact to the mold, low cost, high density and excellent mechanical properties of castings, which receives more and more attention. The microstructure of castings provided by SS-SC is quite different from that of casting provided by conventional SC in as-cast condition, which leads to differences in the evolution of microstructure and mechanical properties in heat treatment process. In this study, A356.2 aluminum alloys castings were provided by both SS-SC and conventional SC respectively. The evolution of microstructure and mechanical properties of castings during heat treatment was investigated to obtain the best mechanical properties of semi-solid squeeze castings. Keywords:Microstructure, Mechanical properties, Heat treatment, A356 alloy, Semi-Solid Squeeze Casting

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Liu, Yan Gai, Zhao Hui Huang, Hao Ding, Ming Hao Fang, and Shou Mei Xiong. "Study on Pressure Variations in the Mold of Magnesium Alloy Die Castings." Key Engineering Materials 353-358 (September 2007): 1614–16. http://dx.doi.org/10.4028/www.scientific.net/kem.353-358.1614.

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High pressure die casting is the most common method in making magnesium alloys for both auto parts and 3C products. Pressure variations in the mold during mold filling and solidification process have direct influences on the quality and properties of die castings. In this paper, a cylinder head cover was produced to experimentally study pressure variations in the mold during magnesium alloy die-casting process in real time for the first time. Pressure varies at different positions in the mold during die casting process. This study indicates that mold filling and solidification process of magnesium alloy die castings can be described by pressure curves obtained by pressure measurement at different test positions in the cavity in real time.

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Huang, Pei Hsing, Wei Jen Wu, and Chung Han Shieh. "Compute-Aided Design of Low Pressure Die-Casting Process of A356 Aluminum Wheels." Applied Mechanics and Materials 864 (April 2017): 173–78. http://dx.doi.org/10.4028/www.scientific.net/amm.864.173.

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The lightweight design of aluminum automobile wheel can easily bring about all kinds of defects during die-casting, which often causes wheel frame deformation and creep damages in the future use and in turn affects traffic safety. To understand the evolution of mold flow, temperature field, and solidification, the low pressure die-casting processes of A356 aluminum wheel were simulated by Anycasting software package. Various casting parameters combined with the designs of flow channel and overflows were adopted to reduce the defects occurred in wheel products. In addition, we adopted the retained melt modulus (RMM) to predict the position of defects to be formed as well as their distribution so as to eliminate the shrinkage voids and porosity defects during die-casting. The research findings showed that the setting up of overflow tank could effectively prevent the formation of shrinkage void and porosity of die-castings and significantly promote the quality and productivity of die-casting wheel products.

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Tang, Hong Tao, Li Li, Lang Huang, and Shun Sheng Guo. "A New Process CAD Design Method for Steel Casting Based on PDF File." Advanced Materials Research 1049-1050 (October 2014): 2100–2104. http://dx.doi.org/10.4028/www.scientific.net/amr.1049-1050.2100.

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The process CAD design is the key part for steel casting production in general foundry enterprises. Formerly, for those parts with PDF file from customers, especially foreign customers, the process CAD design was done just by 2D casting process CAD system depending on AutoCAD system; so the designer must spend much time drawing part by AutoCAD according the PDF file which cause low efficiency. In this paper, a new process CAD design method is proposed based on PDF file in order to avoid drawing part by AutoCAD. Fist, the framework of process CAD design is constructed. Second, as the base part of process CAD design, the practical 2D CAD frame is established. Third, the part drawing with PDF file is resolved to be displayed clearly through the Mupdf rendering engine. Finally, the casting processes design of two actual steel castings, including a pump cover casting and a large gear casting, are presented to illustrate this new process CAD design method.

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Journal articles on the topic 'Die casting process'

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