Academic literature on the topic 'Die castings'

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Journal articles on the topic "Die castings"

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Zhengwuvi, L. B., and A. O. Akii Ibhadode. "Risering of a Four-Cavity Die Production Mould by Convectional Method." Advanced Materials Research 62-64 (February 2009): 664–70. http://dx.doi.org/10.4028/www.scientific.net/amr.62-64.664.

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This paper demonstrates the possibility of developing skill in producing sound metal casting from a four-cavity die production mould by assessing the riser design criteria and the castings. The assessment takes into account the location of the casting’s hot spots, casting modulus, liquid metal mass in the risers and the principle of directional solidification. The mould flask is oriented in such a way that a riser is placed directly on top of the casting’s hot spots for proper feeding during solidification. The assessment result of casting modulus shows that the feeder modulus Mf = 5.85 x 10-3 M and the casting hot spot modulus Mh = 1.88 x 10-3 M .The assessment result of castings solidification time shows that the castings solidify within 12 seconds while the feeders solidify within 30 seconds. From the assessment results it is observed that the risers hold liquid metal, feed the castings to full solidification and solidify later than the castings which they feed. Examinations at the cross sections of the finished castings revealed the absence of void formation which is a clear indication of effective and functional risers. Thus, the risers have achieved the desired requirement.
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Chaikin, A. V. "Theory and practice of inoculation for high-grade gray cast iron railway castin." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 80, no. 5 (June 20, 2024): 37–44. http://dx.doi.org/10.32339/0135-5910-2024-5-37-44.

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JSC “Cheboksary Aggregate Plant” has mastered the production of high-strength gray cast iron "wedge friction" railway castings (grade SCH30) intended for freight wagon bogies. According to the casting's technical specifications, the presence of interdendritic graphite and cementite in the vertical and sloping walls of the casting is not allowed. However, in separate batches, interdendritic graphite and up to 10 % cementite were found in the controlled walls of the castings. To solve the problem of obtaining castings with a blemish-free microstructure, the iron modification technology was changed. Instead of ferrosilicon FS 75, a more effective composite dispersed inoculant was developed and implemented. The advantages of the latter, which consisted of chemically treated ultrafine modifier (USM) and a by-product of organosilane production (KSM), were theoretically substantiated. The advantages of the developed modifier over FS75 were confirmed by modeling the behavior of inoculant’s particles when filling the “wedge friction” cavities in the FLOW-3D program. USM and KSM particles were evenly distributed throughout the volume of the castings at all observed heights of the controlled casting walls. They served as graphite crystallization centers throughout the solidification time of the castings, ensuring the absence of blemishes in the castings. The introduction of the developed material into production allowed reducing the modifier consumption by 6.25 times, ensuring the absence of blemishes in the castings, achieving the required mechanical properties of the iron, and an economic effect of over 4 million rubles
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Kordas, P. "Influence of the conditions of casting and heat treatment on the structure and mechanical properties of the AlMg10 alloy." Journal of Achievements in Materials and Manufacturing Engineering 1, no. 83 (July 1, 2017): 26–32. http://dx.doi.org/10.5604/01.3001.0010.5137.

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Purpose: Assessment of the possibilities of shaping the structure and improvement of mechanical properties of casting from AlMg10 alloy through a selection of casting technology and precipitation hardening. Design/methodology/approach: the work evaluated the impact of casting and heat treatment technology on the mechanical properties and structure of AlMg10 alloy castings. The tests were performed on 200 mm × 100 mm × 25 mm plate castings produced by gravity casting methods for sand and metal moulds and by a liquid state press moulding technology. Castings made with these technologies solidify in substantially different heat- evaporation conditions and exhibit varying degrees of primary structure fragmentation. Metallographic and strength tests were performed on raw castings and after heat treatment. Findings: The changes in the morphology and size of primary crystals and the dispersion of the reinforcing phase according to the casting solidification rate and the precipitation hardening treatment were analyzed. Solidifying castings in the form of sand show a globular structure, whereas in die and press castings, a typically dendritic structure occurs, with the dendritic crystals in pressed castings being much smaller in size than the die castings. In castings which were not heat-treated, the reinforcing phase of Al3Mg2 occurs in interdendritic spaces, and its dispersion increases with the rate of cooling. After supersaturation and ageing treatments, the phase α has a grain structure in all samples. The largest dispersion of reinforcing molecules is characterized by press castings. In a raw state, the highest mechanical properties are shown by castings made in the form of sand and the method of pressing in a liquid state. Heat treatment of AlMg10 alloy castings significantly influences the increase of mechanical indexes in all castings investigated. The highest features of Rm are approx. 330 MPa and A5 above 10% is obtained in castings made by the press method. Research limitations/implications: Particular attention should be paid to the avoidance of the effects of slag inclusion, shrinkage and magnesium oxidation during casting of AlMg10 alloys. In die castings of a plate type, due to own stresses, a significant decrease in mechanical properties occurs. Practical implications: The most advantageous mechanical properties of AlMg10 alloy castings are obtained by using liquid-state pressing technology. In addition, this technology makes it possible to produce thin-walled castings of high dimensional accuracy, high air- tightness, fine grain structure, lack of surface defects and low roughness. Originality/value: The paper presents the possibility of improving the mechanical properties of AlMg10 castings by applying heat treatment. It has been proven that the casting method has a significant effect on the mechanical properties of the castings.
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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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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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Ten, E. B., and O. A. Kol’. "Dependence of cast iron chill from its carbon equivalent." Izvestiya. Ferrous Metallurgy 63, no. 1 (March 30, 2020): 57–62. http://dx.doi.org/10.17073/0368-0797-2020-1-57-62.

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Numerical relation of cast iron chill characteristics (distance of chilled layer H and volume quota of ledeburite in it Qл ) with its carbon equivalent СE was investigared. This data helps to prognosticate with high probability the evolution of the surface chilled layer forming at the production of castings with different thickness from cast iron of various chemical compositions. The object of study is the unalloyed induction melted cast iron with eight variants of chemical composition with carbon equivalent from 3.30 up to 5.53 %. From these cast irons we made the step-by-step castings with steps sizes of 10×60 mm and thickness of 5, 10, 20 and 40 mm. The distance (depth) of chilled layer was measured at the fractures of the castings and gaged on thickness of full chill zone. Ledeburite volume quota was detected by metallographic method using “Nexsys-Image expert pro 3” computer program. According to experimental data, when the casting thickness is 5 and 10 mm the through (at all thickness) full chill is formed at carbon equivalent ≤ 4.08 % and ≤ 3.67 % consequently. At the castings with 20 and 40 mm thickness the zone of full chill is absent, and in this case the chilled layer depth increases with a decrease of carbon equivalent and decreases with an increase of casting’s thickness X. The dependence of H from СЕ have the exponential character and can be described by the equation H = A exp (–k СE ), where A and k are empirical coefficients. Ledeburite volume quota near the contact surface of casting with chiller is near 90 %, but with an increase in the distance from the surface it decreases with different intensity depending on changes of carbon equivalent and casting’s thickness. By mathematical processing of the experimental data received for the distance of 5 mm from the contact surface of the casting with chiller, we have detected that numerical re lation Qл in casting chilled layer with value of CE can be described by the exponential dependence
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Majernik, Jan, Stefan Gaspar, Jan Kmec, Monika Karkova, and Jozef Mascenik. "Possibility of Utilization of Gate Geometry to Modify the Mechanical and Structural Properties of Castings on the Al-Si Basis." Materials 13, no. 16 (August 11, 2020): 3539. http://dx.doi.org/10.3390/ma13163539.

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The mechanical properties of die castings correlate with the inner structure of a casting, distribution of the eutectic phases, and with the content and distribution of porous cavities in the casting volume. This submitted paper deals with the issue of the possibility to influence the basic parameters affecting the quality of castings through structural modifications of the gating system. The structural parameter under assessment is the gate height. In the case of the diverse height of the gate, five sets of castings were produced. The individual sets of castings were subjected to examination of selected mechanical properties, i.e., of permanent deformation and surface hardness. At the same time, the individual sets of castings were subjected to metallographic examination of the eutectic structure of the casting. It was proved that the gate height influences the aforementioned properties of the castings and significantly affects the ratio of the eutectic phases in the volume of the casting. The conclusion describes the mutual correlation between the gate structure, the mechanical properties of the casting, and its structural composition.
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Silva, Rui Pedro, Rui Soares, Rui Neto, Ana Reis, Ricardo Paiva, Rui Madureira, and José Silva. "Grain Refinement of Inconel 718 Superalloy—The Effect of Rotating Magnetic Field." Materials 15, no. 6 (March 10, 2022): 2038. http://dx.doi.org/10.3390/ma15062038.

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The effect of the application of a rotating magnetic field on the average grain size of IN718 castings was experimentally studied. For the purpose, four parts were produced by investment casting and characterized. The first casting was produced without application of RMF for comparison. The remaining ones were submitted to different RMF frequencies for 15 min and subsequently to the pouring of the nickel-based superalloy. In these three castings, the RMF frequencies applied were, respectively, 15 Hz, 75 Hz and 150 Hz. All the other process parameters were kept constant during the execution of the experimental procedure. The average grain size of the samples was determined according to the ASTM E112-13 standard, using intercept methods. Macro hardness measurements, tensile testing and SEM-EDS analysis were conducted in order to evaluate the casting’s mechanical properties and microstructures. The results demonstrate a noticeable grain size reduction in the samples submitted to rotating magnetic field. An average grain area reduction, greater than 96%, was achieved in the castings where RMF frequencies of 75 Hz and 150 Hz were applied. The application of RMF also caused a morphological change in the casting’s dendrites from cellular to almost equiaxed. Additionally, it originated the decrease of the size and amount of needle-like δ phase. Regarding mechanical properties of the cast parts, no major differences were verified.
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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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Ahmed, Kamal. "Design and Development of LM24 plate Casting using Solid Cast Simulation Technique." International Journal for Research in Applied Science and Engineering Technology 12, no. 5 (May 31, 2024): 1202–9. http://dx.doi.org/10.22214/ijraset.2024.61786.

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Abstract: This research deals with the elimination of defects in aluminium alloy castings and enhancement in the casting yield and quality. The main intention of the work is to improve the quality of a cast component using Computer Aided Casting Simulation Software. SOLID Cast simulation software is used for simulating the solidification process of casting and visualizing outputs showing possible problematic areas or defects which may occur in the cast product. Plate Castings of aluminium alloy - LM 24 are produced with different designs of gating systems and tested for defects like porosity using Archimedes immersion Technique and also Radiographic testing is used to check the quality of the castings. The produced castings are observed to be sound, and the results obtained are in agreement with the simulation results. Hence it is verified that solidification simulation helps in improving the quality of castings without any shop-floor trails. Casting yield and percentage porosity values are determined for 12 castings produced with different gating systems. The best results are observed to be produced by the castings having a 1-Ingate system in horizontal or lateral positions.
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Dissertations / Theses on the topic "Die castings"

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Hosking, Timothy Donald, and mikewood@deakin edu au. "Casting yield improvement in graphitic iron castings." Deakin University. School of Engineering and Technology, 2001. http://tux.lib.deakin.edu.au./adt-VDU/public/adt-VDU20051017.122220.

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A well designed runner and feeding system should produce castings with minimal defects and low pour weight. This thesis investigates how the filling regime and solidification of the mould influences defects in the castings produced from that mould. Design guidelines to reduce such defects are proposed and tested. An existing shrinkage fault in a Grey Iron disc brake casting is simulated using a commercial finite-difference computer program. Three criteria are used to predict the defect and the effect of changes to the feeder geometry. Critical Fraction Solidification analysis is used to determine whether the feeder remains in liquid contact with the casting during solidification and this approach is shown to correctly predict the presence or absence of porosity* The feeder block is extended below the ingate of the casting to improve liquid contact between the casting and feeder without significantly increasing the feeder mass. Plant trials confirm the change to the feeder eliminates the porosity defect. The runner system and mould venting for a thin walled Ductile Iron casting are investigated. Trials show that by setting the total mould vent area to be greater than the net ingate area of the castings, the cold-shut frequency is halved. A method for runner system design based on peak linear flow velocity in the runner during mould filling is proposed. A new pressurised runner system produces castings with significantly fewer defects and reduced pour weight when runner areas are designed to maintain peak velocity below 1 m/s. Peak velocity and magnesium levels are demonstrated to be critical factors in the elimination of cold-shut defects. A pressurised runner system is also shown to isolate inclusion defects from castings more effectively than an unpressurised system. From this work, a technique is proposed which allows the yield of an existing runner and feeder system for iron castings to be improved with confidence in the results.
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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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Low, Chun Yu Danny. "Prediction of the dimensional accuracy of small extra-coronal titanium castings." University of Sydney, 1998. http://hdl.handle.net/2123/4655.

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Master of Science in Dentistry
This work was digitised and made available on open access by the University of Sydney, Faculty of Dentistry and Sydney eScholarship . It may only be used for the purposes of research and study. Where possible, the Faculty will try to notify the author of this work. If you have any inquiries or issues regarding this work being made available please contact the Sydney eScholarship Repository Coordinator - ses@library.usyd.edu.au
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Deez, Brent Steven. "An investigation on the suitability of layer manufacturing methods for rapid tooling development in investment casting of light metal alloys." Thesis, Cape Peninsula University of Technology, 2010. http://hdl.handle.net/20.500.11838/2228.

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Thesis (MTech (Mechanical Engineering))--Cape Peninsula University of Technology, 2010.
The research presented in this report focuses on Investment Casting capabilities for light metal alloys in South Africa and forms part of the Advanced Manufacturing Technology Strategy's (AMTS): Light Weight Metals flagship programme. The research is centred on the suitability of rapid prototyping (RP)/Iayer manufacturing (LM) methods to produce patterns for the investment casting of aluminium (AI), magnesium (Mg) and titanium (Ti) alloys, together known as Rapid Investment Casting. Three core RP technologies are investigated namely: Three Dimensional Printing - Drop-on-Bed from Z-corporation, Three Dimensional Printing - Drop-on- Drop from ThermoJet - 3D Systems and Selective Laser Sintering from EOS. Various RP/LM processes are discussed in detail and highlight the technologies selected in this study. A standard benchmark part, adapted from the European project framework FP6, designed and utilised in similar studies is used as the basis for the research. The Investment Casting process is discussed fully and compared to the Rapid Investment Casting, listing both the advantages and disadvantages of the above mentioned methods. In addition a special study has been conducted on investment casting of large components using layer manufactured patterns. This study not only helped to establish and validate the shrinkage value calculated for the aluminium castings but also showed substantial capability lacks in SA foundries to handle this type of components, which are by definition most often of high added value.
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Dewhirst, Brian A. "Castability Control in Metal Casting via Fluidity Measures: Application of Error Analysis to Variations in Fluidity Testing." Worcester, Mass. : Worcester Polytechnic Institute, 2008. http://www.wpi.edu/Pubs/ETD/Available/etd-121608-125755/.

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Thesis (Ph. D.)--Worcester Polytechnic Institute.
Keywords: castability; metal casting; error analysis; casting fluidity; a356; solidification processing; fluidity. Includes bibliographical references (leaves 85-90).
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Spataro, Mark Paul. "Comparison of mechanical performance between magnesium alloy sand castings and high pressure die castings /." [St. Lucia, Qld.], 2004. http://www.library.uq.edu.au/pdfserve.php?image=thesisabs/absthe18378.pdf.

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Morey, Erica Frances. "The effect of casting ring liners on the dimensional accuracy of full crown castings." Thesis, The University of Sydney, 1986. http://hdl.handle.net/2123/4770.

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Whateley, Philip N. "Defects in steel investment castings." Thesis, Aston University, 1991. http://publications.aston.ac.uk/11879/.

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A general investigation was performed, in an industrial environment, of the major types of defect specific to investment castings in steel. As a result of this work three types of metallurgical defect were selected for further study. In the first of these, defects in austenitic stainless steel castings were found to result from deoxidation by-products. As a result of metallographic investigation and the statistical analysis of experimental data, evidence was found to support the hypothesis that the other two classes of defects - in martensite stainless and low alloy steels -both resulted from internal or grain boundary oxidation of the chromium alloy constituent This was often found to be followed by reaction between the metal oxides and the ceramic mould material. On the basis of this study, proposals are made for a more fundamental investigation of the mechanisms involved and interim suggestions are given for methods of ameliorating the effect in an industrial situation.
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Palanisamy, Suresh. "Ultrasonic inspection of gas porosity defects in aluminium die castings." Australasian Digital Thesis Program, 2006. http://adt.lib.swin.edu.au/public/adt-VSWT20060828.103450.

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Thesis (PhD) - Swinburne University of Technology, Industrial Research Institute Swinburne - 2006.
A thesis submitted to the Industrial Research Institute Swinburne, Swinburne University of Technology in fulfilment of the requirements to the degree of Doctor of Philosophy, 2006. Typescript. Includes bibliographical references (p. 199-211).
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Umaru, Darma Katsina. "Task and need analysis of metal work casting in Katsina State of Nigeria." Online version, 2009. http://www.uwstout.edu/lib/thesis/2009/2009darmak.pdf.

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Books on the topic "Die castings"

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V, Kondic, and Thomas Susan P, eds. Basic elements of feeding investment castings. Des Plaines, Ill: American Foundrymen's Society, 1994.

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John, Campbell. Castings. 2nd ed. Burlington, Mass: Butterworth Heinemann, 2003.

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John, Campbell, and Campbell John. Castings. Oxford: Butterworth-Heinemann, 1991.

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John, Campbell. Castings. 2nd ed. Oxford: Butterworth-Heinemann, 2003.

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Campbell, John. Castings. Oxford: Butterworth Heinemann, 1991.

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Campbell, John. Castings. 2nd ed. Oxford: Butterworth Heinemann, 2003.

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Irving, W. R. Continuous casting of steel. London: Institute of Materials, 1993.

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Hester, Edward, and Diana E. Kole. Industrial castings. Cleveland (767 Beta Dr., Cleveland 44143-2326): Freedonia Group, 2002.

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North Atlantic Treaty Organization. Advisory Group for Aerospace Research and Development. Castings airworthiness. Neuilly sur Seine, France: AGARD, 1989.

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International, Conference Continuous Casting (4th 1988 Brussels Belgium). 4th International Conference Continuous Casting: Preprints. Düsseldorf: Stahleisen, 1988.

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Book chapters on the topic "Die castings"

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Krautkrämer, Josef, and Herbert Krautkrämer. "Castings." In Ultrasonic Testing of Materials, 423–30. Berlin, Heidelberg: Springer Berlin Heidelberg, 1990. http://dx.doi.org/10.1007/978-3-662-10680-8_28.

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Hague, D. C., E. Oakeshott, and A. Strain. "Fulham Castings." In Devaluation and Pricing Decisions, 272–76. London: Routledge, 2022. http://dx.doi.org/10.4324/9781003261032-18.

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Hill, Terry. "Jackson Precision Castings." In Manufacturing Strategy, 348–63. London: Macmillan Education UK, 2000. http://dx.doi.org/10.1007/978-1-349-14018-3_16.

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Kontou, Tatiana, Victoria Mills, and Kate Nichols. "‘Large Bronze Castings’." In Victorian Material Culture, 130–31. London: Routledge, 2022. http://dx.doi.org/10.4324/9781315400266-40.

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Bidwell, H. T. "Finishing Investment Castings." In Investment Casting, 183–211. London: CRC Press, 2023. http://dx.doi.org/10.1201/9781003419228-7.

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Colás, Rafael, Eulogio Velasco, and Salvador Valtierra. "Castings." In Encyclopedia of Aluminum and Its Alloys. Boca Raton: CRC Press, 2019. http://dx.doi.org/10.1201/9781351045636-140000398.

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An overview of the effect of elemental composition on resulting properties of castings will be provided in this article. Additional topical coverage includes: molten metal processes, solidification, casting processes, die casting, heat treating, computational modeling, and microstructural evolution and control.
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"Aluminum Casting Processes." In Aluminum Alloy Castings, 21–37. ASM International, 2004. http://dx.doi.org/10.31399/asm.tb.aacppa.t51140021.

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Abstract This chapter begins with information on the historical development of aluminum alloy castings. It then covers the basic factors involved in the selection of a casting process. This is followed by sections describing the various categories of casting processes and their variants: expendable mold gravity-feed casting, nonexpendable (permanent) mold gravity feed casting, and pressure die casting. Next, the chapter describes the technologies used to produce premium engineered castings and when such castings may be relevant. The chapter concludes with descriptions of other process technologies used with castings, including metallurgical bonding, metal-matrix composites, and hot isostatic pressing.
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"Casting and Molding Processes." In Steel Castings Handbook, 13–1. 6th ed. ASM International, 1995. http://dx.doi.org/10.31399/asm.tb.sch6.t68200173.

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Abstract This chapter discusses the following conventional molding processes for static casting: green sand molding, dry sand molding, vacuum molding, and expendable pattern casting. It also discusses core and mold processes for steel castings. The chapter provides an overview of sand molds for large steel castings and a special sand molding process. It describes the following precision processes for static casting: investment casting, ceramic molding, and centrifugal casting.
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"Introduction to Steel Castings." In Steel Castings Handbook, 1–1. 6th ed. ASM International, 1995. http://dx.doi.org/10.31399/asm.tb.sch6.t68200001.

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"Nickel-Base Castings." In Steel Castings Handbook, 21–1. 6th ed. ASM International, 1995. http://dx.doi.org/10.31399/asm.tb.sch6.t68200295.

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Abstract Nickel-base castings are produced from a group of alloys with compositions that are typically greater than 50% Ni and less than 10% iron. This chapter presents the casting compositions of nickel-base alloys. It then provides an overview of heat treatment, mechanical properties, and applications of nickel-base castings.
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Conference papers on the topic "Die castings"

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Gimbutis, Brad, Griffin Palmer, Justin Beardsley, and Holly Quinn. "Tolerance Relief on Transmissions Castings for Producibility." In Vertical Flight Society 78th Annual Forum & Technology Display. The Vertical Flight Society, 2022. http://dx.doi.org/10.4050/f-0078-2022-17569.

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Helicopter gearbox transmission castings must be designed for adequate strength, adequate stiffness for gear meshes and flight loads, clean-up of all machined surfaces, adequate edge distance for all clamped connections and minimum weight. Castings manufacturers generally request relatively large tolerances due to the nature of the casting processes in the order of +/- 0.100 inch while designers will require casting tolerances in the order of +/- 0.030 inch for cast surfaces. Excess casting material can lead to assembly interferences and excess weight while insufficient material can lead to thin wall conditions, lack of damage repair capability and potential performance issues. This paper describes how skewed (unilateral or unequally disposed) casting tolerances can eliminate casting rejections, eliminate Material Review Board (MRB) delays, eliminate reworks, ensure proper performance, and have negligible impact on weight.
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Voyer, J., C. Peterlechner, and U. Noster. "Flame Sprayed Al-12Si Coatings for the Improvement of the Adhesion of Composite Casting Profiles." In ITSC2008, edited by B. R. Marple, M. M. Hyland, Y. C. Lau, C. J. Li, R. S. Lima, and G. Montavon. Verlag für Schweißen und verwandte Verfahren DVS-Verlag GmbH, 2008. http://dx.doi.org/10.31399/asm.cp.itsc2008p1326.

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Abstract Flame sprayed Al-12Si coatings were produced onto the surface of composite castings parts in order to enhance the adhesion of such castings. Due to the high surface roughness and the presence of pores in the coatings combined with the formation of an intermetallic phase at the interface, the adhesion of flame sprayed composite castings could be enhanced by a factor of 2 in comparison to blank castings and by a factor of 1.3 when compared to sand-blasted castings. However, results also show that gaps are mostly present at the interface between the Al profiles and the flame sprayed coatings and these gaps have a negative effect on the adhesion values of the composite casting parts. Therefore, an optimization of the adhesion of the coating on the Al profiles through an optimization of both the sand-blasting and the flame spraying parameters would be beneficial for further enhancement of the adhesion of composite casting parts.
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Murugesan, R., Puritipati Rohit Reddy, Rahul Pabolu, and M. V. Ravinder. "Study of shaped castings using vertical centrifugal casting method." In PROCEEDINGS OF THE INTERNATIONAL CONFERENCE ON RECENT ADVANCES IN MANUFACTURING ENGINEERING RESEARCH 2021: ICRAMER 2021. AIP Publishing, 2022. http://dx.doi.org/10.1063/5.0096525.

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Kurasov, D. A. "Injection Molding Technology." In Modern Trends in Manufacturing Technologies and Equipment. Materials Research Forum LLC, 2022. http://dx.doi.org/10.21741/9781644901755-44.

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Abstract. The injection molding process is one of the most efficient and economical casting processes. The process is becoming increasingly common in various industries in large-scale and mass production of castings. It should be noted that by having great advantages over other methods of obtaining high-quality castings of higher accuracy, injection molding makes it possible to bring the dimensions of the castings as close as possible to the dimensions of the finished parts.
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Duncan, Scott R., and Michelle A. Kramer. "Product Enhancement Through Ceramic Shell Casting." In ASME 1998 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 1998. http://dx.doi.org/10.1115/imece1998-0344.

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Abstract For the past thirty years, foundries have been experimenting with the use of polystyrene patterns to produce high quality castings. It is only in recent years that the ceramic shell (CS) casting process has been successfully implemented for the commercial production of steel castings. This paper describes the ceramic shell (CS) casting process and highlights how its unique characteristics facilitated the optimization of railroad center plate designs.
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Groneck, Daniel, and Dave Harmon. "Design Development of Unitized Titanium Structure." In ASME Turbo Expo 2001: Power for Land, Sea, and Air. American Society of Mechanical Engineers, 2001. http://dx.doi.org/10.1115/2001-gt-0450.

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Traditional airframe primary structure is fabricated from wrought product forms that are transformed by machining, forming, and joining into structural components. These individual parts are assembled together by fasteners to create the structure. Under the program reported herein, and in conjunction with a casting vendor, prototype titanium (Ti-6Al-4V) cast airframe components were designed and fabricated. The typical overall dimensions of each casting are 50 inches × 40 inches × 30 inches (127 cm × 102 cm × 76 cm), and weigh approximately 190 pounds (86 kg) per casting. The castings were modeled on generic aircraft fuselage structure that incorporated smooth inner moldline surface and integral webs and keels, capped by a T-element, web stiffeners, access holes, and other detail features. Multiple castings are joined to create the airframe structure. A rapid prototyping method was utilized to create the pattern, which eliminated the requirement for expensive metal tooling. The prototype castings successfully demonstrated the producibility of this generic airframe structure.
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Jones, Kerry, Matt DeGeorge, and Monique Stewart. "Improved Truck Castings." In 2018 Joint Rail Conference. American Society of Mechanical Engineers, 2018. http://dx.doi.org/10.1115/jrc2018-6231.

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This paper examines alternative, improved materials for truck castings. The first part looks at steels that would not require post-weld heat treatment after repair welding. The second part investigates specific applications for temperatures below −50 °F. The rapid, dramatic temperature changes that occur during welding can form brittle phases or cracking in some steels. The weld has three areas of differing structure: the weld, the heat affected zone (HAZ), and the parent metal. The maximum hardness occurs in the HAZ and is the limiting factor in determining weldability. An ultraweldable steel is a steel that does not require post-weld heat treatment. Many steels were evaluated for their chemical composition and susceptibility to cracking; those that were likely to form brittle phases were eliminated from consideration. Four low alloy steels and one carbon steel were selected as being potentially ultraweldable. To evaluate the ultraweldability of these steels, groove welds and two types of spot welds were made on the five candidate alloys. The welds were then sectioned and prepared for microstructural and microhardness evaluation. Microhardness readings were taken across the weld, spanning the weld, HAZ, and base material. Three of the steels formed hard, brittle phases during most of the tests. This indicates these materials are not ultraweldable. Two of the low alloy steels did meet the requirements for ultraweldability. Future work in this area would include producing truck castings from these materials. At low temperatures, plain carbon steels, such as the types used in truck castings, can fracture in a brittle manner, with no visible deformation. The material property of deforming without fracture is toughness or ductility. Using materials that retain their toughness in low temperatures could prevent brittle failures of truck castings. Six grades of steel currently used in low temperature applications were selected for this research. Specimens from each of the six materials were evaluated for tensile properties at multiple temperatures. Charpy impact specimens were tested at temperatures ranging from −20 °F to −120 °F. The measured room temperature tensile properties of each of the six steels met or exceeded the requirements for Grade B+, the steel currently used for truck castings. Four of the steels showed impact energies far above that of the current Grade B+, but two of them gave consistently higher impact energies than all others. These would be the best candidates for future work in this area. Future work would involve producing full size truck castings from one or more of these alloys, then testing them for fatigue performance, preferably at low temperatures.
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PACANA, A. "Analysis of the Causes of the Non-Conformity of the Bearing Shell Casting Used on Rail Vehicles." In Terotechnology XII. Materials Research Forum LLC, 2022. http://dx.doi.org/10.21741/9781644902059-29.

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Abstract. Continuous improvement of the quality of manufactured products and monitoring of the production process is the key to the success of every company. Skillful use of available technologies and quality management instruments makes it possible to eliminate casting incompatibilities and prevent their recurrence in the future. The aim of the article was to analyze the types of defects occurring in castings, locate the areas with the most frequent occurrence of defects and identify the reasons for the presence of defects in castings of bearing housings used in railway vehicles. The paper presents the usefulness of a combination of quality management instruments for diagnosing material discontinuities in the analyzed castings.
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Shenefelt, Jeffrey R., Rogelio Luck, John T. Berry, and Robert P. Taylor. "Solidification Modeling and Porosity Control in Aluminum Alloy Castings." In ASME 1999 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 1999. http://dx.doi.org/10.1115/imece1999-0710.

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Abstract Commercial software packages enable the thermal environment of shaped castings to be determined provided the boundary conditions are well understood. Criteria functions (CF’s) based on the thermal environment provide a means for estimating shrinkage porosity within a casting. However, the CF’s do not account for gas driven porosity forming within the casting. This paper reviews the CF’s and additional approaches to account for hydrogen evolution in aluminum-copper and aluminum-silicon alloys.
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GRYC, Karel, Ladislav SOCHA, Jana SVIŽELOVÁ, Tomáš PRÁŠIL, Ivan HOTOVÝ, Pavel ČÍŽEK, and Jan ŠTEFÁNEK. "Optimization of numerical simulations of gravity casting of ductile iron castings." In METAL 2021. TANGER Ltd., 2021. http://dx.doi.org/10.37904/metal.2021.4094.

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Reports on the topic "Die castings"

1

Poweleit, David R., and Raymond W. Monroe. Performance Steel Castings. Fort Belvoir, VA: Defense Technical Information Center, September 2012. http://dx.doi.org/10.21236/ada566349.

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J.F. Cuttino, D.M. Stefanescu, and T.S. Piwonka. Thin Wall Iron Castings. Office of Scientific and Technical Information (OSTI), October 2001. http://dx.doi.org/10.2172/792702.

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Roy, Sandra O. Densification of Weapon Castings. Fort Belvoir, VA: Defense Technical Information Center, March 1990. http://dx.doi.org/10.21236/ada221490.

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SYNTRONICS INC DAYTON OH. Agile Manufacturing Development of Castings. Fort Belvoir, VA: Defense Technical Information Center, September 2000. http://dx.doi.org/10.21236/ada389127.

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Cooperman, Aubryn. Large Castings for Wind Turbines. Office of Scientific and Technical Information (OSTI), August 2023. http://dx.doi.org/10.2172/1995803.

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Robert C. Voigt, Joseph Bertoletti, Andrew Kaley, Sandi Ricotta, and Travis Sunday. Fillability of Thin-Wall Steel Castings. Office of Scientific and Technical Information (OSTI), July 2002. http://dx.doi.org/10.2172/801749.

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Royer, Jacqueline, Sina Shahrezaei, Ayoub Soulami, Kriston Brooks, Matthew Athon, Zachary Huber, Mark Rhodes, et al. Hot Forging Options for Thick Castings. Office of Scientific and Technical Information (OSTI), July 2022. http://dx.doi.org/10.2172/2346211.

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Han, Q. Reinforcement of Aluminum Castings with Dissimilar Metals. Office of Scientific and Technical Information (OSTI), January 2004. http://dx.doi.org/10.2172/885813.

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Professor Robert C. Voigt. Heat Treatment Procedure Qualification for Steel Castings. Office of Scientific and Technical Information (OSTI), February 2003. http://dx.doi.org/10.2172/807809.

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Viswanathan, S. Nelson, C. D. Prediction of Microporosity in Shrouded Impeller Castings. Office of Scientific and Technical Information (OSTI), September 1998. http://dx.doi.org/10.2172/2137.

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