Journal articles: 'Permanent mold casting'

1

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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Yulianto, Agus, Rudy Soenoko, Wahyono Suprapto, and As’ad Sonief. "EFFECT OF COOLING RATE ON MICROSTRUCTURE AND HARDNESS IN GRAY CAST IRON CASTING PROCESS." Acta Metallurgica Slovaca 27, no. 3 (September 13, 2021): 127–32. http://dx.doi.org/10.36547/ams.27.3.996.

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This study aims to investigate the thermal conditions of the molds, changes in microstructure and hardness of casting products using sand mold and permanent mold. The use of sand mold and permanent mold results in different cooling rates. Thermal analysis was performed using a thermocouple to obtain a temperature versus time curve. Metallographic observations were carried out using a Scanning Electron Microscope equipped with Energy-Dispersive X-ray Spectroscopy. The Vickers hardness test was carried out in three areas with different thicknesses. The results showed a constant temperature at 691 oC where the eutectoid phase reaction occurred. Testing with sand mold showed that cast iron with flake graphite was finer and spreader than graphite in cast iron produced by permanent mold. Meanwhile, gray cast iron from a casting process with a permanent mold has a higher hardness than gray cast iron from a casting process using a sand mold.

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Elsayed, Fady Refaat, Norbert Hort, Mario Alberto Salgado Ordorica, and Karl Ulrich Kainer. "Magnesium Permanent Mold Castings Optimization." Materials Science Forum 690 (June 2011): 65–68. http://dx.doi.org/10.4028/www.scientific.net/msf.690.65.

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Permanent mold casting is a well-established route for casting large magnesium alloys components. Casting parameters like superheat, mold temperature, and holding time can often result in inhomogeneous properties, porosity, and segregation problems in the cast part. In order to optimize the casting process, control of the casting parameters including mold temperatures and holding times is essential to promote directional solidification, and ensure defect free homogenous structure. Binary Mg-9wt.%Al and Mg-10wt.%Gd alloys were used to investigate the effect of casting parameters such as melt temperature and holding time on the part macro and microstructure.

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Suyitno, Suyitno, Urip Agus Salim, and Muslim Mahardika. "Aplikasi Cetakan Permanen untuk Meningkatkan Produksi dan Kualitas Produk IKM Pengecoran Logam Kuningan di Ngawen, Sidokarto, Godean, Yogyakarta." Jurnal Pengabdian kepada Masyarakat (Indonesian Journal of Community Engagement) 2, no. 1 (December 15, 2016): 66–79. http://dx.doi.org/10.22146/jpkm.22218.

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Small and Medium Enterprises (SME) brass foundry in Ngawen Sidokarto, District of Godean, Sleman, Yogyakarta mostly produced cow necklace accessories (klonthong) and jathilan accessories (klinthing). Te industry and business management are arranged within the scope of family. Te products are relatively low in quality and its market share is limited and tend to be traditional. Tis condition is caused by the weak knowledge of the management and the method of casting metals and metal science. Brass casting methode, that was used at IKM partner, is casting with mold of sand or soil. Tis process requires the making process of sand molds, that is removed afer the brass solidify. For large quantities products, this process is inefcient and takes a long time. It would require a more efcient and faster method in the production process. Method of sand casting and ceramics have been used by SMEs cast brass in Yogyakarta, however it has many disadvantages in terms of increased productivity and quality as well as the expansion of product applications. Te permanent mold casting of iron is a casting method which has many advantages over other methods, but the use for SMEs has not been applied in the SME of cast brass. Te permanen mold casting methods was introduced to SME partners. Tis replaces the sand mold materials and molding sand. It is expected the casting process is faster because the mold can be used for a large number of products. Te results show that the application of the technology results in products with precision and consistent in shape and size. Community Service of UGM with Appropriate Technology has also collaborated with Industry and Trade service of Yogyakarta donation of production machinery for making permanent mold. It can be concluded that the application of permanen mold in the brass foundry industry improve the product precision and the speed of produsction.

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Liang, Zhi, Jiashi Miao, Anil K. Sachdev, James C. Williams, and Alan A. Luo. "Titanium alloy design and casting process development using an Integrated Computational Materials Engineering (ICME) approach." MATEC Web of Conferences 321 (2020): 10013. http://dx.doi.org/10.1051/matecconf/202032110013.

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The application of titanium components is generally limited by their high raw material and manufacturing costs. In this paper, a lower cost cast titanium alloy based on the Ti-Al-Fe system has been designed using an ICME approach. The new alloy Ti-6Al-5Fe-0.05B-0.05C (all wt.%) significantly reduces raw material cost and demonstrates improved castability compared with the baseline Ti-6Al-4V alloy. The fine primary and secondary α phase microstructure in the new alloy, due to Fe partitioning, provides exceptionally high strength (1023 MPa yield strength and 1136 MPa ultimate tensile strength) and reasonable ductility (3.7% elongation) for structural applications. On the manufacturing front, the high cost multi-step investment casting process currently used can now be replaced with a low-cost permanent mold casting process using steel molds and a novel ceramic coating. An experimental casting setup, including an induction skull melting (ISM) system, a gravity tilt-pour system and a ceramic-coated H13 steel mold, has been used to produce near-net-shape permanent metallic mold castings with the new titanium alloy developed. Using this setup, and aided by casting process simulation, a prototype automotive connecting rod was cast successfully. The ZrO2 ceramic coating applied to the H13 steel mold was proven effective in minimizing the metal-mold reactions.

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Gašpár, Štefan, Tomáš Coranič, Ján Majerník, Jozef Husár, Lucia Knapčíková, Dominik Gojdan, and Ján Paško. "Influence of Gating System Parameters of Die-Cast Molds on Properties of Al-Si Castings." Materials 14, no. 13 (July 5, 2021): 3755. http://dx.doi.org/10.3390/ma14133755.

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The resulting quality of castings indicates the correlation of the design of the mold inlet system and the setting of technological parameters of casting. In this study, the influence of design solutions of the inlet system in a pressure mold on the properties of Al-Si castings was analyzed by computer modelling and subsequently verified experimentally. In the process of computer simulation, the design solutions of the inlet system, the mode of filling the mold depending on the formation of the casting and the homogeneity of the casting represented by the formation of shrinkages were assessed. In the experimental part, homogeneity was monitored by X-ray analysis by evaluating the integrity of the casting and the presence of pores. Mechanical properties such as permanent deformation and surface hardness of castings were determined experimentally, depending on the height of the inlet notch. The height of the inlet notch has been shown to be a key factor, significantly influencing the properties of the die-cast parts and influencing the speed and filling mode of the mold cavity. At the same time, a significant correlation between porosity and mechanical properties of castings is demonstrated. With the increasing share of porosity, the values of permanent deformation of castings increased. It is shown that the surface hardness of castings does not depend on the integrity of the castings but on the degree of subcooling of the melt in contact with the mold and the formation of a fine-grained structure in the peripheral zones of the casting.

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GILLOT, F., P. MOGNOL, B. FURET, and J. Y. HASCOET. "PERMANENT RAPID PROTOTYPED MOLDS FOR THIN WALL MAGNESIUM CASTING." Journal of Advanced Manufacturing Systems 04, no. 02 (December 2005): 185–93. http://dx.doi.org/10.1142/s0219686705000643.

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Rapid tooling processes are now well known and largely implemented in the plastic injection industries. Harsh conditions related to metal casting or injection do not allow such rapid tooling processes to be directly applicable. This paper focuses on magnesium alloy casting in rapid prototyped mold with thin walls created by Direct Metal Laser Sintering. Such molds are anisotropic, due to special laser exposure between their skin and core. Hence, experimental results from casting are described and analyzed. The results can help companies improve their rapid prototyping means in the field of magnesium casting of precise parts in permanent molds.

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Li, Qiang, Hai Jun Wu, Shao Ping Lu, Ling Jiao Kong, and Qi Tang Hao. "Microstructure and Mechanical Properties of Permanent Mold Low-Pressure Casting and Sand Mold Gravity Casting of A357 Alloy." Advanced Materials Research 1004-1005 (August 2014): 1055–61. http://dx.doi.org/10.4028/www.scientific.net/amr.1004-1005.1055.

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The microstructure and mechanical properties of permanent mold low-pressure casting (PMLPC) and sand mold gravity casting (SMGC) of A357 alloy were studied. The grain size of alloys formed by PMLPC is finer than that formed by sand mold gravity casting because of higher freezing rate of the former. The secondary dendrite arm spacing of PMLPC is approximately 15.2 μm (SD=4) while that of SMGC is 33.2 μm (SD=6). The ultimate tensile strength of PMLPC has a wider range from 350 MPa to 299.9 MPa and an elongation from 1.2 to 4.9. In comparison, the ultimate tensile strength of SMGC ranges from 307 MPa to 315 MPa and its elongation ranges from 2.1 to 3.7. These differences may be attributed to various factors, such as filling speed, filling pressure, and cooling rate, that affect the quality of permanent molds during the filling process.

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Maekawa, Tatsuya, Mitsuaki Furui, Susumu Ikeno, Tomoyasu Yamaguchi, and Seiji Saikawa. "Microstructure Observation of AM60 Magnesium Alloy Solidified by Rapidly Quench." Advanced Materials Research 409 (November 2011): 339–42. http://dx.doi.org/10.4028/www.scientific.net/amr.409.339.

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In solidification theory, with a slow cooling rate such as sand mold casting, it is easy to segregate the solute aluminum near the grain boundary of primary α-Mg phase under the solidification in Mg-Al system alloys. Thus, volume fraction of none-equilibrium crystallized β-Mg17Al12 phase showed the higher value compared with metal mold casting with faster cooling rate. However, in our microstructure observation results, the volume fraction of β phase in permanent mold castings was larger than that of sand mold castings. In the present study, these contradictory behavior was investigated by observation of as-solidified microstructure obtained from rapid cooling castings at the just below the solidus temperature of 723, 773 and 823K.

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10

Kobryn, P. A., R. Shivpuri, and S. L. Semiatin. "Mold Wear during Permanent-Mold Casting of Ti-6Al-4V." Journal of Materials Engineering and Performance 10, no. 3 (June 1, 2001): 290–98. http://dx.doi.org/10.1361/105994901770345006.

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Yulianto, Agus, Rudy Soenoko, Wahyono Suprapto, As’ad Sonief, Agung Setyo Darmawan, and Muhammad Debi Setiawan. "Microstructure and Hardness of Gray Cast Iron as a Product of Solidification in Permanent Mold." Materials Science Forum 991 (May 2020): 37–43. http://dx.doi.org/10.4028/www.scientific.net/msf.991.37.

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Molds of metal are widely used in the casting process. The cooling rate in solidification of castings product with metal molds on the outer side and inner side is different. Therefore, sizes and types of phase will be also different. This study aims to investigate the microstructure andhardness of gray cast iron. To realize this research, the gray cast iron melting process was carried out in an induction furnace. Melted gray cast iron was poured into a Ferro Casting Ductile mold that has been through a preheating process at a temperature of 300 o C. The gray cast iron is then tested for composition, microstructure and hardness. The test results show that the part containing morecementite phase will be harder.

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12

Władysiak, R. "Computer Control the Cooling Process in Permanent Mold Casting of Al-Si Alloy." Archives of Metallurgy and Materials 58, no. 3 (September 1, 2013): 977–80. http://dx.doi.org/10.2478/amm-2013-0114.

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Abstract The paper presents the test results of a computerized control system the sequential cooling process of permanent mold with use of water mist in the gravity die casting process. It describes the process for preparing high-quality casts made of AlSi7Mg alloy that achieves enhanced mechanical properties. A scheme of developed device and drivers for selected methods of sequence cooling for manufacturing of castings made in permanent steel mold was presented here. Also the microstructure and mechanical properties of received aluminium casts were described. It was shown that the use of a computer system to control the water mist cooling point of the mold not only accelerates the cooling of the cast and the gravity die casting cycle shortens, but also it has a positive effect on the microstructure and mechanical properties of castings made of unmodified AlSi7Mg alloy in a raw state.

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Baumeister, G., D. Buqezi-Ahmeti, J. Glaser, and H. J. Ritzhaupt-Kleissl. "New approaches in microcasting: permanent mold casting and composite casting." Microsystem Technologies 17, no. 2 (February 2011): 289–300. http://dx.doi.org/10.1007/s00542-011-1237-7.

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14

Su, Yan Qing, Xi Cong Ye, Jing Jie Guo, Liang Shun Luo, L. Wang, and H. Z. Fu. "Permanent Mold Suction Casting for TiAl Based Alloys." Advanced Materials Research 79-82 (August 2009): 1651–54. http://dx.doi.org/10.4028/www.scientific.net/amr.79-82.1651.

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A novel precision casting technique for TiAl based alloy was described in this work, called the permanent mold suction casting technology，and the blades of Ti-47Al-2Si、Ti-47Al-2W-0.5Si、Ti-47Al-2W-0.5Si -0.5B were get by this technology. The structures of these blades were studied. The results of this study indicate that microstructure is sensitive to heat treatment and composition. The average grain size is 30 um before heat treatment. The grain size of TiAl based alloy is grossed by heat treatment at 1573 for 5h and furnace cooling, especially Ti-47Al-2Si. The addition of boron, the grain size of Ti-47Al-2W-0.5Si-0.5B is smaller than Ti-47Al-2W-0.5Si. The γ-TiAl based alloys have equiaxed grain in cross section, but the surface microstructure of γ-TiAl based alloys have more fine equiaxed grain than inside due to high cooling rate of mold.

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15

Neff, David, B. Lynn Ferguson, Dan Londrico, Zhichao Li, and Justin M. Sims. "Analysis of Permanent Mold Distortion in Aluminum Casting." International Journal of Metalcasting 14, no. 1 (May 9, 2019): 3–11. http://dx.doi.org/10.1007/s40962-019-00337-w.

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Bichler, Lukas, and Comondore Ravindran. "Formation of Fold Defects in Permanent Mold Cast AE42 Magnesium Alloy." Materials Science Forum 638-642 (January 2010): 1591–95. http://dx.doi.org/10.4028/www.scientific.net/msf.638-642.1591.

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Application of magnesium alloys potentially plays a key role in weight reduction of automotive and aerospace components. Majority of magnesium components are manufactured via the high-pressure die-casting (HPDC) or permanent-mold casting (PMC) processes. In general, castability of magnesium alloys is comparable to aluminum alloys. However, unique defects related to the high susceptibility of magnesium to rapidly solidify, dissolve hydrogen or form oxides potentially contribute to material failure. In this research, AE42 magnesium alloy castings were manufactured via the PMC process. Formation of fold defects in regions of high melt turbulence was observed on the macro-scale as visible surface flow-lines. Microstructural analysis revealed that folds in the AE42 alloy we related to the rapid solidification and short alloy freezing range. Further, segregation of Al2RE intermetallics at the metal front hindered proper fusion of merging metal fronts.

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Gong, Wen Bang, Li Liang Chen, and Jing Hao. "Derivation and Application for Time Step Model in Simulation of Solidification Process." Materials Science Forum 575-578 (April 2008): 14–21. http://dx.doi.org/10.4028/www.scientific.net/msf.575-578.14.

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The heat transfer during the casting solidification process includes: the heat radiation of the high temperature casting and the mold, the heat convection between the casting and the mold, and the heat conduction in the casting and the casting to the mold. In this paper, a formula of time step in simulation of solidification is derived, considering the heat radiation, convection and conduction based on the conservation of energy. The different heat transfer condition between the ordinary sand casting and the permanent mold casting is taken into account in this formula. The characteristic of heat transfer in the interior and surface of the casting is also considered. The numerical experiments show that this formula can avoid radiation of the computation, and can improve the computational efficiency about 20% in the simulation of solidification process.

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Reihle, Matthias, Michael Hofmann, Uwe Wasmuth, Wolfram Volk, Hartmut Hoffmann, and Winfried Petry. "In Situ Strain Measurements during Casting Using Neutron Diffraction." Materials Science Forum 768-769 (September 2013): 484–91. http://dx.doi.org/10.4028/www.scientific.net/msf.768-769.484.

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Composite castings exhibit high residual stresses, mainly because of different thermal expansion of the used materials. Similar to the in-cast cylinder liners in a motor block, a composite specimen, consisting of a steel insert and an aluminum cast surrounding, was analyzed by neutron diffraction. The temperature- and time-dependent change of lattice spacing and thus the strain evolution was investigated by in-situ experiments directly after casting and during the cooling of the part. Different cooling conditions were investigated using two different molds, namely a sand and a permanent (steel) mold, optimized for in-situ neutron diffraction.

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Chen, Ping, Jian Min Zeng, Wu Kui Gan, and Jin Bo Liu. "Mechanical Properties of A356 Aluminum Cast Alloy Shaped by Permanent Mold Casting." Advanced Materials Research 941-944 (June 2014): 89–92. http://dx.doi.org/10.4028/www.scientific.net/amr.941-944.89.

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A356 is a heat treatable cast alloy which has been widely applied in aviation and automobile industries. In this paper a Sb modified A356 alloy cast with permanent mold has been investigated in order to improve its mechanical properties by changing the needle morphology of the eutectic silicon. The results show that a small amount of Sb addition can contribute refined eutectic silicon morphology and enhance the mechanical properties, especially elongation of the A356 cast alloy poured in permanent molds. The optimal addition of Sb is 0.2 wt.%.

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Zhang, Li Qiang, and Rong Ji Wang. "Determination of Interface Heat Transfer Coefficient for Cylindrical Casting by Using an Inverse Heat Conduction Model." Applied Mechanics and Materials 184-185 (June 2012): 151–54. http://dx.doi.org/10.4028/www.scientific.net/amm.184-185.151.

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For accurate simulation of the casting process with permanent mold, the correct Interfacial Heat Transfer Coefficient (IHTC) is highly important. However, its value is not easily obtained through the experimental or theoretical method in the complex solidification process. In this paper, an inverse conduction model is introduced to determine the IHTC at casting-mold during solidification of the cylindrical casting based on the temperature-measured data. The established inverse model is verified to be a feasible and effective tool for estimation of the metal-mold IHTC during solidification of cylindrical casting by the analysis of calculated results.

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Moro, L., J. Srnec Novak, D. Benasciutti, and F. de Bona. "How Material Properties Affect the Thermal Distortion of a Mold for Continuous Casting of Steel." Key Engineering Materials 774 (August 2018): 429–34. http://dx.doi.org/10.4028/www.scientific.net/kem.774.429.

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Copper molds are adopted in continuous casting to provide an initial solidification of steel. The presence of molten steel induces relevant temperature gradients across mold walls. This, in turn, generates high stress levels, exceeding the yielding limit of the material. Recent works confirm that thermal distortion occurs due to both creep and cyclic plasticity. In this work a numerical investigation is developed, simulating the mold behavior under repeated heating and cooling sequences. The aim of this work is to compare the performances in terms of permanent distortion of different copper alloys usually adopted for such application. It can be observed that both material properties and operating temperature have a significant influence in the permanent distortion evolution.

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22

Major, J., and M. Hartlieb. "Advances in Aluminum Foundry Alloys for Permanent and Semi-Permanent Mold Casting." International Journal of Metalcasting 3, no. 3 (July 2009): 43–53. http://dx.doi.org/10.1007/bf03355452.

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23

Sadayappan, M., M. Sahoo, C. Lavender, and P. Jablonski. "Permanent Mold Casting of Titanium Alloy Ti-6Al-4V." International Journal of Metalcasting 2, no. 1 (January 2008): 69–74. http://dx.doi.org/10.1007/bf03355423.

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24

Liu, Mengyun, Zhan Zhang, Francis Breton, and X. Grant Chen. "Investigation of the Quench Sensitivity of an AlSi10Mg Alloy in Permanent Mold and High-Pressure Vacuum Die Castings." Materials 12, no. 11 (June 11, 2019): 1876. http://dx.doi.org/10.3390/ma12111876.

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The quench sensitivities of an AlSi10Mg alloy in permanent mold (PM) and high-pressure vacuum die (HPVD) castings were investigated with time–temperature–transformation and time–temperature–property diagrams using an interrupted quench technique. The quench-sensitive temperature range of the HPVD casting sample is 275–450 °C, and its nose temperature is 375 °C. The quench-sensitive range of the PM casting sample is 255–430 °C, and the nose temperature is 350 °C. The mechanical strength versus the cooling rate in both casting samples were predicted via a quench factor analysis and verified experimentally. The critical cooling rate of the HPVD casting sample is 20 °C/s whereas it is 17 °C/s for the PM casting sample. With a shorter critical time, higher nose temperature, and higher critical cooling rate, the HPVD casting sample exhibits a higher quench sensitivity than the PM casting sample. The differences in the quench sensitivities of the AlSi10Mg alloy due to the different casting processes is explained via the different precipitation behavior. At the nose temperature, coarse β-Mg2Si precipitates mainly precipitate along the grain boundaries in the HPVD casting sample, whereas rod-like β-Mg2Si precipitates distribute in the aluminum matrix in the PM casting.

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Władysiak, R., A. Kozuń, and T. Pacyniak. "Effect of Casting Die Cooling on Solidification Process and Microstructure of Hypereutectic Al-Si Alloy." Archives of Foundry Engineering 16, no. 4 (December 1, 2016): 175–80. http://dx.doi.org/10.1515/afe-2016-0105.

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Abstract The work is a continuation of research concerning the influence of intensive cooling of permanent mold in order to increase the casting efficiency of aluminium alloys using the multipoint water mist cooling system. The paper presents results of investigation of crystallization process and microstructure of synthetic hypereutectic alloys: AlSi15 and AlSi19. Casts were made in permanent mold cooled with water mist stream. The study was conducted for unmodified silumins on the research station allowing the cooling of the special permanent probe using a program of computer control. Furthermore the study used a thermal imaging camera to analyze the solidification process of hypereutectic silumins. The study demonstrated that the use of mold cooled with water mist stream allows in wide range the formation of the microstructure of hypereutectic silumins. It leads to higher homogeneity of microstructure and refinement of crystallizing phases and also it increases subsequently the mechanical properties of casting.

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Abu-Dheir, Numan. "Metallurgical and Numerical Correlation of Mold Vibration with the Refinement of Al-Si Alloy." Advanced Materials Research 83-86 (December 2009): 601–10. http://dx.doi.org/10.4028/www.scientific.net/amr.83-86.601.

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Applying mechanical vibration with subsonic frequencies during permanent mold casting enhances nucleation and improves mold-casting heat transfer. Despite the several published papers in this field, little attention was given to correlating the vibration parameters of frequency and amplitude with the casting microstructure. In this paper microstructure examination and numerical simulation are used to explain the microstructure refinement using mold-vibration. A 1-D numerical model is used to explain the different mechanisms that mold-vibration has at different frequencies of 100 Hz, 500 Hz, and 2000 Hz. Microstructure examination for samples of Al-12.6wt%Si are presented and a correlation with the numerical results using inverse heat conduction method is attempted. Results show that increasing the value of the apparent thermal diffusivity of the casting is as a result of vibration is a major factor in achieving the desired refinement. Improving the mold-casting heat transfer coefficient showed significant influence on the process only at high frequency of 2 kHz due to the low vibration amplitude used.

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Moon, B. M., Bong Hwan Kim, Je Sik Shin, and Sang Mok Lee. "Permanent Mold Casting Practice and Microstructure and Mechanical Properties of Thin-Sectioned ADI Casting." Advanced Materials Research 26-28 (October 2007): 531–34. http://dx.doi.org/10.4028/www.scientific.net/amr.26-28.531.

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For thin-walled casting development of austempered ductile iron (ADI), permanent mold casting and accompanied heat treatment practice were systematically investigated to suppress and/or remove chill defects of ductile cast iron (DCI) with various thickness of 2 to 9 mm and to ensure mechanical properties of the final ADI casting. Si content was increased up to 3.8% to reduce the chill formation tendency under a high cooling rate. The residual Mg content remarkably affected the nodule count, while the nodule size and spherodization were proven to have weak relationships. Austenitizing process followed by austempering was very sensitive to chemical compositions (Si and Sn) and heat treatment temperature. As a practical application, the steel bar coupler for a structural frame was tried to produce without subsequent machining.

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Medovar, B. I. "Centrifugal electroslag casting and electroslag permanent mold casting: A new generation in electroslag technology." Journal of Vacuum Science & Technology A: Vacuum, Surfaces, and Films 5, no. 4 (July 1987): 2678–81. http://dx.doi.org/10.1116/1.574717.

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29

Chiesa, Franco, Bernard Duchesne, and Gheorghe Marin. "Low-Pressure Casting of Aluminium AlSi7Mg03 (A356) in Sand and Permanent Molds." MATEC Web of Conferences 326 (2020): 06001. http://dx.doi.org/10.1051/matecconf/202032606001.

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Aluminium A356 (AlSi7Mg03) is the most common foundry alloy poured in sand and permanent molds or lost-wax shells. Because of its magnesium content, this alloy responds to a precipitation hardening treatment. The strength and ductility combination of the alloy can be varied at will by changing the temper treatment that follows the solutionizing and quenching of the part. By feeding the mold from the bottom, the low-pressure process provides a tranquil filling of the cavity. A perfect control of the liquid metal stream is provided by programming the pressure rise applied on the melt surface. It compares favorably to the more common gravity casting where a turbulent filling is governed by the geometry of the gating system.

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Skrzypczak, T., E. Węgrzyn-Skrzypczak, and L. Sowa. "Computer Simulation of the Solidification Process Including Air Gap Formation." Archives of Foundry Engineering 17, no. 4 (December 20, 2017): 147–50. http://dx.doi.org/10.1515/afe-2017-0147.

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Abstract The paper presents an approach of numerical modelling of alloy solidification in permanent mold and transient heat transport between the casting and the mold in two-dimensional space. The gap of time-dependent width called "air gap", filled with heat conducting gaseous medium is included in the model. The coefficient of thermal conductivity of the gas filling the space between the casting and the mold is small enough to introduce significant thermal resistance into the heat transport process. The mathematical model of heat transport is based on the partial differential equation of heat conduction written independently for the solidifying region and the mold. Appropriate solidification model based on the latent heat of solidification is also included in the mathematical description. These equations are supplemented by appropriate initial and boundary conditions. The formation process of air gap depends on the thermal deformations of the mold and the casting. The numerical model is based on the finite element method (FEM) with independent spatial discretization of interacting regions. It results in multi-mesh problem because the considered regions are disconnected.

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Kouki, Yosra, Sebastian Müller, Torsten Schuchardt, and Klaus Dilger. "Development of an Instrumented Test Tool for the Determination of Heat Transfer Coefficients for Die Casting Applications." Metals 10, no. 9 (September 8, 2020): 1206. http://dx.doi.org/10.3390/met10091206.

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In the case of casting processes with permanent molds, there is still a relatively pronounced lack of knowledge regarding the locally prevailing heat transfer between casts and mold. This in turn results in an insufficient knowledge of the microstructure and the associated material properties in the areas of the casting component close to the surface. Therefore, this work deals with the design and evaluation of a test tool with an integrated sensor system for temperature measurements, which was applied to obtain a time-dependent heat transfer coefficient (HTC) during casting solidification. For this purpose, the setup, design and computational approach are described first. Special attention is paid to the qualification of the multi-depth sensor and the calculation method. For the calculations, an inverse estimation method (nonlinear sequential function) was used to obtain the HTC profiles from the collected data. The developed sensor technology was used in a test mold to verify the usability of the sensor technology and the plausibility of the obtained calculation results under real casting conditions and associated temperature loads. Both the experimental temperature profiles and the HTC profiles showed that, in the evaluated casting series, the peak values determined were close to each other and reached values between 6000 W/(m2·K) and 8000 W/(m2·K) during solidification.

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Władysiak, R., A. Kozuń, K. Dębowska, and T. Pacyniak. "Analysis of Crystallization Process of Intensive Cooled AlSi20CuNiCoMg Alloy." Archives of Foundry Engineering 17, no. 2 (June 27, 2017): 137–44. http://dx.doi.org/10.1515/afe-2017-0065.

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Abstract The work is a continuation of research concerning the influence of intensive cooling of permanent mold in order to increase the casting efficiency of aluminium alloys using the multipoint water mist cooling system. The paper presents results of investigation of crystallization process and microstructure of multicomponent synthetic hypereutectic alloy AlSi20CuNiCoMg. The study was conducted for unmodified silumin on the research station allowing the cooling of the special permanent sampler using a program of computer control. Furthermore, the study used a thermal imaging camera to analyze the solidification process of multicomponent alloy. The study demonstrated that the use of mold cooled with water mist stream allows in wide range to form the microstructure of hypereutectic multicomponent silumin. It leads to higher homogeneity of microstructure and refinement of crystallizing phases of casting.

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Suprapto, Wahyono, Bambang Suharno, Johny Wahyuadi Soedarsono, and Dedi Priadi. "Analytical and Experimental Models of Porosity Formation of Duralumin Cast in Vacuum Casting System." Advanced Materials Research 277 (July 2011): 76–83. http://dx.doi.org/10.4028/www.scientific.net/amr.277.76.

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Porosity in cast metals often leads to cracking of components due to stress concentration and leakage, and as the result, the castings need be repaired or rejected. Disharmony in casting process was resulting in porosity. Prediction of porosity in the casting is necessary as a step to avoid the waste products and reduce costs. But to ensure whether these predictions are accurate and precise, it is still necessary to validate the test trials and testing. This paper aims to provide early information when, where, and how large a defect occurs in particular foundry casting porosity on duralumin. The analytical study of porosity formation based analytic equilibrium wt% of element, the behavior of the thermodynamic, hydrodynamic, and rules of metallurgical on vacuum casting of duralumin. Experiments as a validation study are conducted by duralumin remelting on stainless-steel bowl in a vacuum casting furnace. Analytical simulation and experiments of the casting that has been vacuumed by melting 10 cmHg pressures higher than the pressure solidification, and duralumin melt is poured automatically into permanent mold carbon steel. In the study cast duralumin created five different thicknesses. Both these studies assume the addition of copper (2.5%, 3.0%, 3.5 %, 4.0%, and 4.5% Cu) and vacuum pressure (76, 50, 40, cmHg), as independent variables, while dependent variable in the studies is porosity characteristics, which includes morphology, number and dimensions of the porosity. Optical emission spectrometry test, Reynold's and Niyama numbers, Sievert's law, Archimedes' principle (Pycnometry and Straube-Pfeiffer tests), and Eichenauer equation are instruments which are used to determine the characterization of duralumin casting porosity. Duralumin ingots remelting process was performed by the control pressure (p1) and temperature (T1). Vacuuming process performed after the smelting room temperature reaches 600 °C. Once melted, it followed by duralumin into a permanent mold (p2, T2). As a control parameter is the height of pouring (7 cm), pour temperature and mold temperature respectively at 750 °C and 300 °C. The porosity characteristics studies of two models produce two types of porosity (gas and shrinkage), the quantity dimension and porosity, and distribution of porosity in the cast duralumin.

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Cao, G., and S. Kou. "Hot Cracking Susceptibility of Ternary Mg-Al-Ca Alloys." Advanced Materials Research 15-17 (February 2006): 501–6. http://dx.doi.org/10.4028/www.scientific.net/amr.15-17.501.

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Hot cracking of ternary Mg-Al-Ca alloys in permanent mold casting was studied. The alloys are the base of some potential creep-resistant Mg alloys. The Mg-xAl-yCa alloys included Mg-4Al-1Ca, Mg-4Al-2Ca, Mg-4Al-3Ca, Mg-4Al-4Ca, Mg-5Al-3Ca, and Mg-6Al-3Ca. Constrained-rod casting was conducted with a steel mold. Rods were cast with their ends enlarged to act as anchors, which kept the rods from free contraction and thus induced tension in the rods to cause cracking during solidification. The susceptibility to hot cracking was evaluated based on both the widths and locations of cracks in the resultant castings. Both binary Mg-4Al and commercial alloy AZ91E, which is known to have a low susceptibility to hot cracking, were also included for comparison. It was found that within the composition range studied, the crack susceptibility decreased significantly with increasing Ca content (y) but did not change much with the Al content (x).

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Saikawa, S., G. Aoshima, S. Ikeno, K. Morita, N. Sunayama, and K. Komai. "Microstructure And Mechanical Properties Of An Al-Zn-Mg-Cu Alloy Produced By Gravity Casting Process." Archives of Metallurgy and Materials 60, no. 2 (June 1, 2015): 871–74. http://dx.doi.org/10.1515/amm-2015-0221.

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Abstract High-strength aluminum alloy are widely used for structural components in aerospace, transportation and racing car applications. The objective of this study is to enhance the strength of the Al-Zn-Mg-Cu alloy used for gravity casting process. All alloys cast into stepped-form sand mold (Sand-mold Casting; SC) and Y-block shaped metal mold(Permanent mold Casting; PC) C and then two –step aged at 398-423 K after solution treated at 743 K for 36 ks. The tensile strength and total elongation of the two-step aged SC alloys were 353-387 MPa and about 0.4% respectively. This low tensile properties of the SC alloys might be caused by remaining of undissolved crystallized phase such as Al2CuM, MgZn2 and Al-Fe-Cu system compounds. However, good tensile properties were obtained from PC alloys, tensile strength and 0.2% proof stress and elongation were 503-537 MPa, 474-519 MPa and 1.3-3.3%. The reason of the good properties in PM alloys, is the lowed amount of undissolved crystallized phase than that of SC ones and primary crystallized alpha-Al phase was finer due to high cooling rate at solidification in casting.

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Han, Sang Won, and Hyuck Mo Lee. "Substructures and Fatigue Crack Growth in HIPing and Semi-Liquid Die Casting A356 Alloys." Materials Science Forum 539-543 (March 2007): 469–74. http://dx.doi.org/10.4028/www.scientific.net/msf.539-543.469.

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Permanent mold and semi-liquid die A356 cast alloys were used to examine the roles of microstructures and aging conditions on fatigue crack growth. HIP treatment to the A356 alloy generates substructure like dendritic arm boundaries as well as reduction of pores, which improves fracture elongation and fatigue fracture toughness. The similar substructure occur at primary α-Al and inter Si particles of semi-liquid die cast, too. Fracture elongation of HIPed permanent mold cast is comparable to that semi-liquid die cast, the fatigue crack growth is faster than in semi-liquid die cast. Plastic hardening occurs around fatigue crack flank, which decreases fatigue crack growth rate, and such effect appears highly in under aged alloy.

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Goll, Dagmar, Felix Trauter, Ralf Loeffler, Thomas Gross, and Gerhard Schneider. "Additive Manufacturing of Textured FePrCuB Permanent Magnets." Micromachines 12, no. 9 (August 31, 2021): 1056. http://dx.doi.org/10.3390/mi12091056.

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Permanent magnets based on FePrCuB were realized on a laboratory scale through additive manufacturing (laser powder bed fusion, L-PBF) and book mold casting (reference). A well-adjusted two-stage heat treatment of the as-cast/as-printed FePrCuB alloys produces hard magnetic properties without the need for subsequent powder metallurgical processing. This resulted in a coercivity of 0.67 T, remanence of 0.67 T and maximum energy density of 69.8 kJ/m3 for the printed parts. While the annealed book-mold-cast FePrCuB alloys are easy-plane permanent magnets (BMC magnet), the printed magnets are characterized by a distinct, predominantly directional microstructure that originated from the AM process and was further refined during heat treatment. Due to the higher degree of texturing, the L-PBF magnet has a 26% higher remanence compared to the identically annealed BMC magnet of the same composition.

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Kim, Bong Hwan, and Sang Mok Lee. "Mechanism and Tendency of Die Erosion in Al-Si Casting Alloy for Permanent Mold Casting Process." Advanced Materials Research 421 (December 2011): 77–80. http://dx.doi.org/10.4028/www.scientific.net/amr.421.77.

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The mechanism of die erosion in Al-Si alloys was investigated based on the formation behavior of iron-containing intermetallics. And the metallurgical parameters affecting on the erosion tendency were discussed as functions of chemical composition for a guideline of melt control in Al-Si foundry. It was found that the intermetallic layers of α-AlFeSi, β-AlFeSi and θ-AlFe were formed through metallurgical reactions. The erosion tendency of die material was determined by not only the gradient of iron content through the interface between die material and molten alloy but also the relative formation temperature of primary intermetallics.

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Lu, Hua Feng, Rong Fa Chen, Yi Hong Zhao, Long Wu, Zhi Long Li, and Hua Yang. "Numerical Simulation and Process Optimization of Aluminum Alloy Connecting Rod Based on ProCAST." Advanced Materials Research 712-715 (June 2013): 549–52. http://dx.doi.org/10.4028/www.scientific.net/amr.712-715.549.

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The structural feature and technical indexes of 2A14 aluminum alloy connecting rod was analyzed. The pouring system of gravity die-casting process was initially designed according to the technical requirements. The gravity filling and solidification stages in the permanent mold were simulated by ProCAST. The simulation results show that the casting defects are predicted and the casting process are improved. The most possible section of crack defects are the transition part between the shaft and the connecting rod small or big end.

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Sheng, Wen Bin, Chun Xue Ma, and Wan Li Gu. "Properties and CA4GE-Engine Test of TiAl-Based Alloy Valves by Permanent Mold Casting." Advanced Materials Research 139-141 (October 2010): 557–60. http://dx.doi.org/10.4028/www.scientific.net/amr.139-141.557.

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TiAl-based alloy valves were manufactured by combining charges compressed /vacuum arc melting (VA)/ induction skull melting (ISM) procedure with permanent mold centrifugal casting method. Microstructures, compositions and mechanical properties of as-cast and hot isostatical pressed (HIPed) valves are detected. Results show that the permanent mold centrifugal casting process obviously refines the size of grain in TiAl alloy and the tensile strength of as-cast and HIPed valves are 550MPa and 580MPa at 20°C, 370MPa and 470MPa at 815°C, respectively. As-cast specimens show ~0% elongation at 20°C and 1~2% at 815°C, while HIPed ones show an elongation of 1~2% at room temperature and about 10% at 815°C. Furthermore, a 200-hour test was carried out with CA4GE-engine, which demonstrated the possibility of as-cast TiAl alloy valves for the substitution of present steel ones.

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41

LIU, Zhao-jing, Feng ZUO, Shan-zhi REN, and Feng-zhen LI. "Preparation of helicopter rotor counterbalance component by means of permanent-mold casting." Transactions of Nonferrous Metals Society of China 17, no. 2 (April 2007): 357–62. http://dx.doi.org/10.1016/s1003-6326(07)60098-3.

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42

Pokorny, M., C. Monroe, C. Beckermann, L. Bichler, and C. Ravindran. "Prediction of Hot Tear Formation in a Magnesium Alloy Permanent Mold Casting." International Journal of Metalcasting 2, no. 4 (October 2008): 41–53. http://dx.doi.org/10.1007/bf03355435.

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Prabhu, K. Narayan, and K. M. Suresha. "Effect of Superheat, Mold, and Casting Materials on the Metal/Mold Interfacial Heat Transfer During Solidification in Graphite-Lined Permanent Molds." Journal of Materials Engineering and Performance 13, no. 5 (October 1, 2004): 619–26. http://dx.doi.org/10.1361/10599490420647.

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44

Kuo, Jer-Haur, Ruey-Jer Weng, and Weng-Sing Hwang. "Effects of Solid Fraction on the Heat Transfer Coefficient at the Casting/Mold Interface for Permanent Mold Casting of AZ91D Magnesium Alloy." MATERIALS TRANSACTIONS 47, no. 10 (2006): 2547–54. http://dx.doi.org/10.2320/matertrans.47.2547.

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45

Esaka, Hisao, Jun-Nichi Hiramoto, Shota Miyahara, and Kei Shinozuka. "In Situ Observation of Solidification in Horizontal Centrifugal Casting Process." Materials Science Forum 649 (May 2010): 325–30. http://dx.doi.org/10.4028/www.scientific.net/msf.649.325.

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Horizontal centrifugal casting is widely used for production of water pipes, rolls and so on. Advantage of this process is to press molten metal against the permanent mold due to centrifugal force. Thanks to this, one can obtain fine structure and sound castings1). On the other hand, macroscopic segregation on tangential direction sometimes forms. The formation mechanism of macroscopic segregation has not well understood. This is because the solidification process itself is still uncertain since it is very complex2-4). Thus, in order to understand the solidification process in horizontal centrifugal casting an in-situ observation has been made in this study. Transparent organic substance has been used to simulate the metal solidification.

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46

Zhao, Li Li, Lv Ming Yang, and Tie Tao Zhou. "Influence of Different Pouring Temperature to Properties and Organization of A356 Aluminum Alloy under Specified Conditions." Materials Science Forum 749 (March 2013): 119–24. http://dx.doi.org/10.4028/www.scientific.net/msf.749.119.

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Due to the excellent casting performance, good corrosion resistance, high strength and casting manufacturing costs, A356 casting aluminum alloy is widely used in automobile wheel industry of China. However, for the restrictions of the production equipment, technology and the production craft level, there are problems that product quality is not satisfied and the production efficiency is low in the mass manufacturing. In this paper, the effect of pouring temperature and mold temperature on the microstructure and mechanical properties were investigated on the basis of cooperation project with Bin Zhou wheel hub manufacturing company. The quantitative relationship between mechanical properties and microstructure was studied by statistical methods. The results indicate that pouring temperature is the main element to affect the mechanical properties of permanent mold casting A356 and the optimum pouring process parameter is about 744 .Mechanical properties have a liner relationship with secondary dendrite arm spacing in a certain extent.

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47

Miwa, Kenji, Rudi S. Rachmat, and Takuya Tamura. "Effect of Solid Fraction on Microstructure and Casting Faults of AZ91D Alloys in New Type Semi-Solid Injection Process." Solid State Phenomena 116-117 (October 2006): 441–44. http://dx.doi.org/10.4028/www.scientific.net/ssp.116-117.441.

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We have developed new type semi-solid injection process, that is, runner-less injection process. In order to investigate the effects of solid fraction on microstructure and casting defects of AZ91D in new type semi solid injection process, semi-solid forming testing machine which has the same system as a runner-less injection machine has been made on an experimental basis. Its temperature controlling system has been established to obtain the homogeneous solid-liquid coexisted state in its injection cylinder. AZ91D billets are injected into a permanent mold by this machine in the semi-solid state. A shearing in the part of nozzle of injection cylinder is the most important to reveal thixotropic property of alloy slurry in semi solid forming process by injection machine. So it needs controlling of solid fraction to affect thixotropic property. In order to decrease casting defects and hold homogeneous structure, solid fraction more over 50% is needed. But when the solid fraction increases more than 50%, primary solid particles grow coarser, and then controlling method is required to suppress coarsening. In the case of less than 50% of solid fraction, liquid part preferentially fills inside the permanent mold and alloy slurry continue to fill the mold behind alloy liquid. Then large casting defects form at the boundary of both flows.

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Hamasaiid, A., M. S. Dargusch, C. J. Davidson, S. Tovar, T. Loulou, F. Rezaï-Aria, and G. Dour. "Effect of Mold Coating Materials and Thickness on Heat Transfer in Permanent Mold Casting of Aluminum Alloys." Metallurgical and Materials Transactions A 38, no. 6 (June 23, 2007): 1303–16. http://dx.doi.org/10.1007/s11661-007-9145-2.

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Chankitmunkong, Suwaree, Dmitry G. Eskin, and Chaowalit Limmaneevichitr. "Structure Modification upon Ultrasonic Processing of an AA4032 Piston Alloy: Comparison of Permanent Mold and Direct-Chill Casting." Metallurgical and Materials Transactions A 51, no. 2 (December 9, 2019): 818–29. http://dx.doi.org/10.1007/s11661-019-05575-5.

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AbstractPiston Al-Si alloys have very complex compositions and multi-phase heterogeneous structure, so it is necessary to control the formation of primary and eutectic compounds. In this study, the ultrasonic melt processing (USP) of a eutectic Al-Si piston alloy (AA4032-type) was performed in a permanent mold and during direct-chill (DC) casting to study its effects on the structure refinement and modification. The principal difference between these two ways of casting is that in the permanent mold the solidification front progressively moves towards the ultrasound source, while in the DC casting the position of the solidification front is fixed in space. The results showed that the USP can successfully refine primary Si, Fe-containing intermetallics and aluminum grains. Refinement of primary Si was accompanied by the increase in its amount, which was attributed to both enhanced heterogeneous nucleation and fragmentation. The refinement of Fe-containing intermetallics and Al grains resulted from the fragmentation mechanism and were more pronounced when USP was applied below the liquidus temperature in the permanent mold. However, the eutectic phases coarsened upon USP, and this effect was most pronounced when USP was applied to the semi-solid material. This was related to the strong attenuation of acoustic waves, which effectively heats the semi-solid material and induces corresponding coarsening of the phases. Acoustic streaming induced by an oscillating sonotrode affected the depth of the sump while simultaneously decreasing the macrosegregation, which reflects the dominant role of the melt flow directed against natural convection. The results demonstrated the importance of the solidification stage at which the USP was applied and the specifics of the USP mechanisms acting at the different stages of solidification.

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Lee, Sang Mok, S. Yang, S. T. Kim, Y. S. Park, and B. M. Moon. "Centrifugal Casting Practice and Microstructure and Mechanical Properties of a 2205 Duplex Stainless Steel." Materials Science Forum 475-479 (January 2005): 2527–32. http://dx.doi.org/10.4028/www.scientific.net/msf.475-479.2527.

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Microstructural features, mechanical properties, and corrosion properties of a SAF2205 duplex stainless steel (DSS) were systematically investigated as functions of cooling rate during casting and heat treatment conditions. The choice of a duplex stainless steel was a SAF2205 alloy, of which composition is 0.03C, 21~23Cr, 4.5~6.5Ni, 2.5~3.5Mo, 0.08~0.2N, 1.0Si, and 2.0Mn with remaining Fe. A 5-stepped sand mold and the permanent Y-block mold were used to check the effect of cooling rate during solidification. The microstructural characteristics, such as grain size, the d/γ ratio, the existence of the carbides and σ phase has been noticed to greatly change with the variation of cooling rate during the casting procedure. Various heat treatment conditions were also examined to achieve the optimized mechanical properties of DSS. Based on the preliminary examination, the feasibility study of utilization of centrifugal casting has been carried out for the production of better quality DSS pipe components. Melting and casting practices of DSS during centrifugal casting in an air atmosphere were systematically investigated in order to obtain the optimized process parameters.

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Journal articles on the topic 'Permanent mold casting'

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