Journal articles: 'Solidification shrinkage'

1

Zhu, Li Guang, Jian Chen, Ying Xu, Cai Jun Zhang, and Shuo Ming Wang. "Simulation on Steel Solidification and its Shrinkage in Mould of FTSC Slab." Advanced Materials Research 472-475 (February 2012): 2018–23. http://dx.doi.org/10.4028/www.scientific.net/amr.472-475.2018.

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The solidification shrinkage of liquid steel has an important impact on thermal deformation behavior of high-temperature thin shell. Solidification shrinkage of liquid steel is an important basis for structure and shap optimization of the mould. In this paper, a direct coupled model was built on heat transfer in solidification and stress-strain by using the ANSYS software. And solidification shrinkage of liquid steel with the interior temperature and stress distribution were studied in the process of steel solidification, and it provided a theoretical basis for the further optimization of shape of the thin slab FTSC mould. This study was based on analysis of temperature and stress, deriving calculation of solidification shrinkage of steel’s phase change on macro-state by calculating the variation discipline of the distance between nodes.

2

Rashid, Abira. "Optimization of Shrinkage Porosity in Grinding Media Balls by Casting Design Modification and Simulation Technique." International Journal for Research in Applied Science and Engineering Technology 9, no. VIII (August 15, 2021): 344–53. http://dx.doi.org/10.22214/ijraset.2021.37352.

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Shrinkage porosity or cavity are associated with the solidification of the metal either due to gas/air entrapment or when the shrinkage occurring during solidification is not entirely compensated by the riser. Shrinkage cavities occurring in the casting reduces its strength which leads to unfulfillment of the desired serviceability. In this paper, casting design has been modified using the DISA manual to achieve directional solidification which directly relates to improvement of casting quality. The running of metal from pouring basin into casting along with solidification has been analysed through PROCAST which is a casting simulation software based on Finite Element Method and CAFE (Cellular Automata Finite Element) Model. The feeding system of the casting has been modified in terms of shape and volume to minimize air aspiration effect and promote directional solidification. The model used is of grinding media balls casting of high chromium cast iron. The feeding pattern, feeding velocity and solidification with respect to pouring temperature, pouring rate, ambient temperature and film coefficient has been analysed. The final optimum range of all parameters with corresponding minimum shrinkage porosity in casting was obtained. Main aim was to minimize shrinkage porosity in the main casting, ignoring gating and feeding system. The actual minimization of shrinkage porosity comes out around 56 %.

3

He, Bin Feng, and Zhu Qing Zhao. "Numerical Simulation of Chilled Cast Iron Camshaft in Sand Casting Process." Applied Mechanics and Materials 44-47 (December 2010): 117–21. http://dx.doi.org/10.4028/www.scientific.net/amm.44-47.117.

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There are many kinds of casting defects such as insufficient pouring, cooling separation, crack, and shrinkage and soon on were formed in the mold filling and the solidification process, which affect the final casting performance. Based on the mathematical models of mold filling and solidification process, the numerical simulation of chilled cast iron camshaft in sand casting process has been done. The filling behaviors at each stage in the filling process were presented. The temperature distributions in the solidification process were obtained, and the positions of shrinkages were predicted. According to the simulation results, an improved technology is proposed, and the shrinkages were eliminated efficiently. The simulation results are in good agreement with practical.

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Boonmee, Sarum, and Letrit Chuencharoen. "The Study of Solidification Behavior in Cast Irons Using the Linear Displacement Method." Solid State Phenomena 263 (September 2017): 77–81. http://dx.doi.org/10.4028/www.scientific.net/ssp.263.77.

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This study aims to assess the solidification shrinkage and expansion during the solidification of cast irons. The solidification shrinkage and expansion in cast irons are due to the formation of austenite and graphite respectively. In this study, the linear displacement method was used to observe the solidification event combined with the cooling curve analysis. It was found that the cooling and displacement curves show good correlations in time of events during solidification. The displacement due to graphite expansion increased with the carbon equivalent. The linear expansion of 0.2 to 1.9 mm was observed for the carbon equivalents ranged from 3.7 to 4.5. On the other hand, the displacement due to the austenite shrinkage was found to decrease with increasing carbon equivalents.

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Xiao, Feng, Renhui Yang, Liang Fang, and Chi Zhang. "Solidification shrinkage of Ni–Cr alloys." Materials Science and Engineering: B 132, no. 1-2 (July 2006): 193–96. http://dx.doi.org/10.1016/j.mseb.2006.02.019.

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Ghomy, M. Emamy, and J. Campbell. "Solidification shrinkage in metal matrix composites." Cast Metals 8, no. 2 (July 1995): 115–22. http://dx.doi.org/10.1080/09534962.1995.11819199.

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

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

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Microsegregation and solidification shrinkage were studied on copper-lead base alloys. A series of solidification experiments was performed, using differential thermal analysis (DTA) to evaluate the solidification process. The chemical compositions of the different phases were measured via energy dispersive X-ray spectroscopy (EDS) for the Cu-Sn-Pb and the Cu-Sn-Zn-Pb systems. The results were compared with the calculated data according to Scheil's equation. The volume change during solidification was measured for the Cu-Pb and the Cu-Sn-Pb systems using a dilatometer that was developed to investigate the melting and solidification processes. A shrinkage model was used to explain the volume change during solidification. The theoretical model agreed reasonably well with the experimental results. The deviation appears to depend on the formation of lattice defects during the solidification process and consequently on the condensation of those defects at the end of the solidification process. The formation of lattice defects was supported by quenching experiments, giving a larger fraction of solid than expected from the equilibrium calculation.

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Liu, Jin Xiang, Ri Dong Liao, and Zheng Xi Zuo. "Numerical Study on Solidification Process and Shrinkage Porosity for Engine Block Casting." Applied Mechanics and Materials 37-38 (November 2010): 753–56. http://dx.doi.org/10.4028/www.scientific.net/amm.37-38.753.

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The latent heat releasing and the criterion for shrinkage porosity in solidification progress of casting are studied. A numerical analysis is presented for solidification progress of the cylinder head casting using finite element method. The temperature distributions of the casting in different solidification phases are solved, and the shrinkage porosity is predicted. Based on this, the solidification progress of casting is evaluated. The simulation results can offer a helpful reference for casting design of cylinder head casting.

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Xie, Shi Kun, Rong Xi Yi, Zhi Gao, Xiang Xia, Cha Gen Hu, and Xiu Yan Guo. "Effect of Rare Earth Ce on Casting Properties of Al-4.5Cu Alloy." Advanced Materials Research 136 (October 2010): 1–4. http://dx.doi.org/10.4028/www.scientific.net/amr.136.1.

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The effects of adding rare earth Cerium on Al-4.5Cu alloy microstructure, solidification range and volume changes in the solidification process are researched. Experiments show that rare earth Cerium will bring remarkable effects on the alloy microstructure, solidification and solidification shrinkage interval. When the quantity of rare earth Cerium is about 4 wt%, the solid-liquid two phase of Al-4.5Cu alloy will range from 640°C to 600°C. The grains of the alloy are refined, round. The volume shrinkage is only 68.6% of that without adding rare earth Cerium.

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Hou, Hua, Guo Wei Zhang, Hong Kui Mao, and Jun Cheng. "A New Prediction Way to Shrinkage Cavity Formation for Ductile Iron Castings." Materials Science Forum 575-578 (April 2008): 127–34. http://dx.doi.org/10.4028/www.scientific.net/msf.575-578.127.

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Based on the solidification features of ductile iron and affecting factors for ductile iron shrinkage defect, the model of the ductile iron solidification is built and put forward a new defect predictive method EIECAM (Enclosed-Isolated area Expansion and Contraction Accumulation Method) model to predict defect. in DECAM, the liquid shrinkage, solidified shrinkage and graphitizing expansion during solidification are computed dynamically in the enclosed-isolated area , and the effect of graphite expansion on the wall movement is also accounted. Based on this method end cover of QT500 ductile iron casting is simulated and made the defect predictive, study its solidification process and the defect generation position, and make the experimental identification on the defect. It is resulted that the method can be able to predict the casting defect authentically.

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Burbelko, Andriy A., Daniel Gurgul, Wojciech Kapturkiewicz, and Edward Guzik. "Modelling of the Density Changes of Nodular Cast Iron During Solidification by CA-FD Method." Materials Science Forum 790-791 (May 2014): 140–45. http://dx.doi.org/10.4028/www.scientific.net/msf.790-791.140.

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Formation of the shrinkage defects in ductile iron castings is far more complicated phenomenon than in other casting alloys. In the presented paper changes the ductile iron density during solidification is analyzed. During the solidification path the influence of the temperature, phase fractions and phase composition is taking into account. Computer model, using cellular automata method, for estimation of changes in density of ductile iron during its solidification is applied. Results of the solidification modeling for Fe-C binary alloys with different composition in the castings with a different wall thickness are presented. As a result of calculations it was stated that after undercooling ductile iron below liquidus temperature volumetric changes proceed in three stages: pre-eutectic shrinkage (minimal in eutectic cast iron), eutectic expansion and the last shrinkage.

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FUKUMOTO, Shigeo, and Yuma YOSHIOKA. "Estimation of Critical Strain Caused by Solidification Shrinkage during Weld Solidification." QUARTERLY JOURNAL OF THE JAPAN WELDING SOCIETY 38, no. 4 (2020): 291–96. http://dx.doi.org/10.2207/qjjws.38.291.

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Korojy, B., and H. Fredriksson. "On solidification and shrinkage of brass alloys." International Journal of Cast Metals Research 22, no. 1-4 (August 2009): 183–86. http://dx.doi.org/10.1179/136404609x367623.

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Sun, Dawei, and Suresh V. Garimella. "Numerical and Experimental Investigation of Solidification Shrinkage." Numerical Heat Transfer, Part A: Applications 52, no. 2 (July 5, 2007): 145–62. http://dx.doi.org/10.1080/10407780601115079.

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Sulfredge, C. David, Louis C. Chow, and Kaveh A. Tagavi. "INITIATION AND GROWTH OF SOLIDIFICATION SHRINKAGE VOIDS." Annual Review of Heat Transfer 10, no. 10 (1999): 221–78. http://dx.doi.org/10.1615/annualrevheattransfer.v10.80.

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Chemezov, Denis Alexandrovich. "SHRINKAGE OF SOME METAL ALLOYS AFTER SOLIDIFICATION." Theoretical & Applied Science 50, no. 06 (June 30, 2017): 87–89. http://dx.doi.org/10.15863/tas.2017.06.50.10.

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Zheng, Hong Liang, Yu Cheng Sun, Ning Zhang, Kai Zhang, and Xue Lei Tian. "Shrinkage Porosity Simulation of Spheroidal Graphite Iron Castings Based on Macro-Micro Models." Materials Science Forum 689 (June 2011): 190–97. http://dx.doi.org/10.4028/www.scientific.net/msf.689.190.

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Shrinkage porosity is often found in Spheroidal graphite iron (S. G. Iron) castings because of the mushy zone and special volume change during their solidification. Although the volume expansion is very important to the shrinkage porosity simulation of S.G. Iron castings, conventional methods for predicting the porosity defects do not consider it. A Series of macro-micro models such as macro heat transfer calculation and microstructure formation simulation are proposed to simulate the solidification of S. G. Iron castings. The nucleation and growth models are employed to calculate the accurate latent heat and volume change especially graphite expansion during the solidification. The pressure induced by graphite expansion is introduced as a parameter to predict the shrinkage porosity and a new shrinkage porosity criterion is developed. Cooling curves and solid fraction of each phase are compared with experimental castings. At the same time, the porosity area ratio of castings is compared with the results calculated by several porosity criterions. The results show that the new shrinkage porosity simulation criterion of S. G. Iron castings based on macro-micro models is accurate on shrinkage porosity shape, size and distribution simulation.

19

Fecko, D., I. Vasková, Ľ. Eperješi, and M. Závodný. "Usage of Connor Inlets to Eliminate Shrinkage." Archives of Foundry Engineering 12, no. 3 (September 1, 2012): 25–28. http://dx.doi.org/10.2478/v10266-012-0076-0.

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Abstract The demand for castings of high quality and sound work is nowadays very high. The production of sound castings without foundry errors is the big issue in modern foundries. Foundry simulation software can do a lot to help improve the disposition of castings, gating system and feeder system, and assure good filling and solidification conditions, and also produce sound casting without the need of the old method of "try and error". One can easily change a lot of parameters for filling and solidification, and create the best proposal for production. Connor inlets have two functions. One is that it serves as an ingate, through which molten metal passes and comes into the mould cavity. The second function is that it serves as a feeder and substitutes the metal contracted during solidification and cooling of the castings. It can also save quite a lot of metal in comparison to classic feeders.

20

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

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This paper concerns the modelling of the solidification process including the phenomena of heat transfer and fluid flow during the initial stage of the metal casting process. During this period, the molten metal motions have an essential influence on solidification kinetics. An analysis of solidification kinetics, by determining the velocity and temperature fields in a system of riser-casting was made. Velocity fields were obtained by solving the momentum equations and the continuity equation, while the thermal fields were obtained by solving the conduction equation containing the convection term. After completion of the filling process the main solidification of molten metal takes place and its shrinkage. The phenomenon of casting shrinkage cannot be avoided, but it is possible to minimize its negative effects on the casting quality. One with ways to solve this problem is to design the mould in such a way that the solidification proceeds in accordance to the assumed direction and finished in the riser. Generally, the aim of search is to obtain a casting without shrinkage defects.

21

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

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In this work, the meaning of the solidification structure and how it is related to defect formation in grey cast iron will be discussed. The work also confirms observations made earlier. In previous work the formation of shrinkage porosity in grey cast iron cylinder heads was investigated. It was found that the defect is located around solidification units resembling primary austenite grains. The solidification of grey cast iron starts with the formation of primary austenite grains, followed by the eutectic solidification. The primary grains nucleate and grow either as columnar or equiaxed grains, creating a columnar to equiaxed transition between the two zones. Based on the presence of a migrating hot spot, and other characteristics found on the cylinder heads, a geometry was developed that promote the formation of shrinkage porosity. The primary solidification structure, normally transformed during the solid state transformation, was preserved using a technique called Direct Austempering After Solidification (DAAS). After solidification, the samples were cut and prepared for investigation using a Scanning Electron Microscope (SEM) equipped with a detector for Electron Back Scattered Diffraction (EBSD). Individual grains were identified and the primary solidification structure around the defects was revealed. The investigation shows how shrinkage porosity is formed and located between primary austenite grains. This confirms that the primary solidification structure has a large influence on the formation of defects in grey cast iron. The investigation also confirms the correctness of earlier results as well as the validity of the DAAS technique.

22

Gao, Cun Zhen, Di Xin Yang, Jing Pei Xie, Ai Qin Wang, and Wen Yan Wang. "Casting Process Optimization for Large Bearing Bush of Zinc-Base Alloy." Materials Science Forum 704-705 (December 2011): 40–44. http://dx.doi.org/10.4028/www.scientific.net/msf.704-705.40.

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The numerical simulation of temperature gradient in the solidification process for large bushing castings of zinc-base alloy was made with HUAZHU CAE/Inte-CAST10.0 software in this paper. Tendency and the position of shrinkage were predicted,and the effect of cooling water rate and cooling time on temperature gradient and shrinkage during the molten metal solidification was discussed. The results show that:seting chilled iron at bottom of bearing bush and using water-cooling metal core in inner cavity of casting simultaneously, can eliminated shrinkage hole and porosity.

23

He, Bin Feng. "Application of View Cast Software in Foundry Technique Designing." Advanced Materials Research 538-541 (June 2012): 572–75. http://dx.doi.org/10.4028/www.scientific.net/amr.538-541.572.

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Taking large scale steel casting for example; View Cast software was introduced to the designing process of the large scale steel casting technique. Solidification results show that the annular pop gate is beneficial to the casting. The side risers are used but it cannot eliminate the shrinkages because of the limited feeding distance according to the simulation results. So a top riser replaced it and some chills are used in the necessary regions. The results show that the new feeding system can help to progressive solidification and the shrinkages are eliminated. The temperature distribution is very clearly and the solidified part of casting is transparent which improved the visible effect and made it easy to read. People can estimate the shrinkage position easily.

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

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The shrinkage porosity that was caused by the insufficient feeding during solidification, was a common defect in the semi-solid die casting process. This defect decreased significantly the mechanical properties of the casting. In order to avoid the shrinkage porosity in casting, the die design, slug preparation and die casting process were carefully considered. In this study, a designed mold was used to make the sequential solidification of the slug. The process parameters, including intensification pressure, die temperature and biscuit thickness of the casting, were studied to show their influence on shrinkage porosity defects. The experimental results show that the high intensification pressure, high die temperature and long biscuit can be beneficial to obtain castings with no shrinkage porosity.

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Monde, Aniket D., Anirban Bhattacharya, and Prodyut R. Chakraborty. "Shrinkage induced flow and Free surface evolution during solidification of pure metal." E3S Web of Conferences 128 (2019): 06011. http://dx.doi.org/10.1051/e3sconf/201912806011.

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A numerical model is developed to study Shrinkage induced convection and free surface evolution caused by the density difference between the solid and liquid phases during the solidification of pure aluminium. For the analysis, a 2–D rectangular cavity field with aluminium melt undergoing solidification process is considered. Conservation of mass, momentum, and energy are formulated based on volume averaging technique and are solved using the SIMPLER algorithm. The free surface evolution is captured using the Volume of fluid (VOF) method. The proposed model focuses on predicting macro–scale shrinkage induced surface defects during the solidification process.

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Yang, Da Chun. "Foundry Technology of the Pressure Board Steel Casting Based on Proportional Solidification Theory." Advanced Materials Research 314-316 (August 2011): 691–94. http://dx.doi.org/10.4028/www.scientific.net/amr.314-316.691.

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For plate steel castings, the foundry technology was designed according to the dynamic directional solidification of proportional solidification theory. Adopting chilling process for the thick and large plane, it may cause the casting basically even cooling. Using self-feeding shrinkage in solidification achieved the dynamic directional feeding of molten steel, and the casting was poured and congealing at the same time. The shrinkage of finally congealing part was fed by small riser. Adopting this foundry technology, the large plane downwards avoided appearing the defects such as sand buckle, slag, pinhole porosity, and pore, etc.; the process yield was greatly increased with this foundry technology, too.

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Hetmaniok, Edyta, Damian Słota, and Adam Zielonka. "Solution of the direct alloy solidification problem including the phenomenon of material shrinkage." Thermal Science 21, no. 1 Part A (2017): 105–15. http://dx.doi.org/10.2298/tsci160405239h.

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In the paper we describe the solution technique for solving the direct problem of the alloy solidifying within the casting mould with the phenomenon of material shrinkage taken into account. Due to the difference between densities of the liquid and solid phases, the shrinkage of metal often appears during the solidification. The investigated process is modeled by means of the solidification in the temperature interval basing on the heat conduction equation with the source element enclosed which includes the latent heat of fusion and the volume contribution of solid phase. Whereas the shrinkage of metal is modeled by the proper application of the mass balance equation.

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Li, Qing Chun, Bo Wang, Xu Dong Yue, Guang Can Jin, and Guo Wei Chang. "Research of Shrinkage Process for Fe-0.18%C Cast Ingot during Solidification." Advanced Materials Research 299-300 (July 2011): 350–54. http://dx.doi.org/10.4028/www.scientific.net/amr.299-300.350.

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The testing device self-designed was used to measure the shrinkage ratio of Fe-0.18%C alloy in the length direction of cast ingot with the dimension of 200×80×100 mm. The results show that the total linear shrinkage mass of cast ingot is 0.0281 mm in the range of 4 mm near the inner surface of water-cooled crystallizer from the beginning of solidification to the end of δ→γ transformation. The shrinkage mass of δ phase and δ→γ transformation is 0.0211 mm and 0.007 mm, which is 75% and 25% of total shrinkage mass, respectively. The shrinkage rate of δ phase and δ→γ transformation is 0.45 μm·s-1and 1.45 μm·s-1, respectively. The shrinkage mass in the cross section of cast ingot is less than the free shrinkage mass observed by using a confocal laser scanning microscope.

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Zhang, Ying, Guo Rui Jia, Xian Jiao Xie, Shui Sheng Xie, Jin Yu He, De Fu Li, Wen Sheng Sun, and Mao Peng Geng. "Numerical Simulation and Optimization in Solidification of Zinc Alloy." Advanced Materials Research 287-290 (July 2011): 2902–5. http://dx.doi.org/10.4028/www.scientific.net/amr.287-290.2902.

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Numerical method was used to simulate the solidification process of zinc-aluminum alloy Zamak 5, shrinkage porosity of the zinc-aluminum alloy ingot with big diameter (114mm) was simulated using the shrinkage criterion, orthogonal test was designed to analysis the influence of different casting parameters as casting temperature, preheating temperature of the mold and the heat transfer coefficient between the mold and the environment. The result shows that the shrinkage value was minimal when the casting temperature was 480, the preheating temperature was 200 and the heat transfer coefficient was 200.

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

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Meanwhile the calculation of cooling and solidification is a well introduced tool into the foundry industry for calculating gating and riser systems. However, knowing the areas of last solidification is often no answer to the question if there are any defects in the casting or not. Of course one requirement is an exact description of the heat flow and the heat transfer between melt and mould. But furthermore the liquid/liquid and liquid/solid shrinkage influence the temperature fields due to a convective heat flux. Also auxiliary material influence the liquid/solid behaviour. Auxiliary materials can be on one hand the inoculation material and on the other chills with and without coating. This is the reason, why defects near the gating often can not be detected by a conventional solidification calculation, which doesn’t take into account the impact of the auxiliary material on the convective flow. With new algorithms within the FEM program SIMTEC/WinCast it is possible to respect this behaviour during the simulation of solidification. Special attention was turned to the expansion of graphite in ductile irons. The graphite first nucleates in the liquid, and then continues to grow in the solid phase depending on the alloy compositions and the solidification parameters. With the knowledge about the physical properties of the alloy the location and the size of defects can be predicted precisely.

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Khalajzadeh, Vahid, and Christoph Beckermann. "Simulation of Shrinkage Porosity Formation During Alloy Solidification." Metallurgical and Materials Transactions A 51, no. 5 (March 10, 2020): 2239–54. http://dx.doi.org/10.1007/s11661-020-05699-z.

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Sobolev, V. V. "Formation of shrinkage porosity in solidification of granules." Soviet Powder Metallurgy and Metal Ceramics 30, no. 2 (February 1991): 91–93. http://dx.doi.org/10.1007/bf00797276.

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Chen, Shuying, Shengnan Ma, Zhilin Chen, Xudong Yue, and Guowei Chang. "Casting Defects in Transition Layer of Cu/Al Composite Castings Prepared Using Pouring Aluminum Method and Their Formation Mechanism." High Temperature Materials and Processes 38, no. 2019 (February 25, 2019): 199–206. http://dx.doi.org/10.1515/htmp-2017-0124.

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AbstractIn this study, Cu/Al composite castings were prepared using the pouring aluminum method, and the casting defects in the transition layer and their formation mechanism were investigated. Shrinkage cavities, shrinkage porosities, and cracks were easily formed in the transition layer, and the thickness of the transition layer was uneven after recombination of the solid Cu and liquid Al. Shrinkage cavities easily formed within the α + eutectic (α + CuAl2) phase, and cracks mainly appeared within the Cu9Al4 and CuAl2 phases. The transition layer with uneven thickness and irregular shape readily formed where the metals solidified last during the solidification; the difference in density between solid Cu and liquid Al, as well as the natural convection in the melt, were responsible for these irregular shapes. As the metals shrunk, shrinkage cavities and porosities formed without external melt feeding. Cracks formed in the Cu9Al4 and CuAl2 phases and at the Cu9Al4/CuAl2 and CuAl2/eutectic (α(Al + CuAl2) interfaces during the solid shrinkage process after the solidification was complete.

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Kwon, Hong Kyu, and Kwang Kyu Seo. "Simulation Study on HPDC Process for Automobile Part with Aluminum Alloy." Materials Science Forum 761 (July 2013): 79–82. http://dx.doi.org/10.4028/www.scientific.net/msf.761.79.

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In this research, in order to optimize casting design of an automobile part (Gear Box), Computer Aided Engineering (CAE) was performed by using the simulation software (Z-Cast). The simulation results were analyzed and compared with experimental results. During the filling process, internal porosities caused by air entrap were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were predicted and reduced by the modification of the gate system. For making better permanent High Pressure Die Casting (HPDC) mold, cooling systems on several thick areas are proposed in order to reduce internal porosities caused by the solidification shrinkage.

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Kim, Sung Bin, Young Hoon Yim, Joong Mook Yoon, and Doru Michael Ştefănescu. "Prediction of Shrinkage Defects in Iron Castings Using a Microporosity Model." Materials Science Forum 925 (June 2018): 411–18. http://dx.doi.org/10.4028/www.scientific.net/msf.925.411.

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A numerical model for prediction of shrinkage defects in iron castings has been developed. The model is based on gas pores evolution during solidification. It describes the evolution of gas concentration using mass conservation, and the change in melt pressure due to solidification contraction using Darcy’s equation, with mixture continuity assumption in the liquid and the mushy zone. Gas pores nucleation has been calculated using the partial pressure of gas obtained from Sievert’s law. The growth of porosity has been estimated using an equation based upon the total melt pressure on the pore, concentration and temperature of the gas. The porosity model was calibrated against literature data for microporosity, and then applied to the prediction of shrinkage defects in a ductile iron casting. Comparison between the model predictions and experimental measurements indicated that the porosity model can be applied not only to the prediction of micro-shrinkage but also to that of macro-shrinkage. Existing shrinkage prediction models based upon thermal models, such as Niyama criterion and the modulus of retained melt in mushy regions cannot predict correctly both micro- and macro-shrinkage.

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Wang, Hai Tao, Hua Shun Yu, and Hui Zhong Xu. "Effects and Mechanism of Titanium Modification on Shrinkage Cavity and Porosity of Cast Steel." Applied Mechanics and Materials 34-35 (October 2010): 1687–91. http://dx.doi.org/10.4028/www.scientific.net/amm.34-35.1687.

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The effects of titanium modification, which was added along with the pouring liquid in ladles, on the shrinkage porosity and cavity of cast steel ZG35 smelted in intermediate frequency induction furnace were studied. Proper content of titanium could effectively increase the volume of concentrated shrinkage cavity, and restrain the forming of shrinkage porosity. The concentrated shrinkage cavity was analyzed quantitatively by stuffing wet gluten and draining water method. The maximal cavity arrived at 0.15wt.% titanium modification. By scanning electron microscope (SEM) and energy disperse spectroscope (EDS) analysis, it was found that TiC, acting as heterogeneous nuclei, could refine the structure grains, diminish the strong dendrites, and increase the fluidity and feeding capacity of steel liquid. However, overdoes titanium modification easily caused mass nitrides or oxides, which kept solid phases with high meting point in metal liquid to increase its viscosity and decrease the fluidity. On the other hand, these solid state titanium compounds enlarged the composition supercooling, so the metal liquid changed from sequential solidification to simultaneous solidification, resulting in inadequate metal liquid feeding, less oncentrated shrinkage cavity and serious shrinkage porosity.

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He, Bin Feng. "Foundry Technique Designing of the Nodular Cast Iron Casting." Advanced Materials Research 1004-1005 (August 2014): 1162–65. http://dx.doi.org/10.4028/www.scientific.net/amr.1004-1005.1162.

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The traditional method has been used to the foundry technique for the melt block mobile plate. The pouring position,the parting face and some of the casting parameters were determined, such as the allowance for finish, stripping taper, the rate of shrinkage and soon on. The commercial casting simulation software was introduced into the casting process, the filling and solidification process were calculated by it. The results shown that there are some shrinkage exists in the original technique and the filling process were inordinate. The gating system was optimized and according to the simulation results, the shrinkages in the original technique were eliminated and the filling process is smoothly which could help the designer to make a correct determination.

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Skrzypczak, Tomasz, Ewa Węgrzyn-Skrzypczak, and Leszek Sowa. "Investigation of the impact of geometry of the riser on the location and shape of shrinkage cavity." MATEC Web of Conferences 254 (2019): 02010. http://dx.doi.org/10.1051/matecconf/201925402010.

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During solidification process the phenomenon of shrinkage cavity is often observed. It has negative impact on the structure and physical properties of the final product. To minimize the negative effect of shrinkage cavity the riser is commonly introduced to the solidifying system. If the riser is properly designed shrinkage cavity rather appears within its volume than in the other parts of the casting. It makes possible to obtain defect-free main part of the casting. Presented work shows the impact of the different shapes of the riser on the localization of the shrinkage cavity. The results are obtained with the use of an original computer program based on the finite element method (FEM). They are presented for three-dimensional case of solidification of three types of the riser. The comparison of the results is discussed in details.

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

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

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Hou, Hua, Hong Hao Ge, Yu Hong Zhao, and Wei Ming Yang. "A New Numerical Simulation Model for Shrinkage Defect during Squeeze Casting Solidification Process." Advanced Materials Research 641-642 (January 2013): 309–14. http://dx.doi.org/10.4028/www.scientific.net/amr.641-642.309.

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In this paper, according to the characteristics of squeeze casting solidification process, the calculation model (FDM format) of the partial differential equations with high thermal conductivity is used to the numerical simulation of temperature field. Dynamic isolated multi-molten pool judgment method is used to determine the position of the pool and FEM is used to calculate the pressure of pool center. If the pressure of molten pool center has been down to 0, the liquid metal closed in the scale will be solidification under the condition of no pressure, and will shrinkage based on the way of gravity shrinkage. The equivalent liquid surface descending method of isolated molten pool is used to predict the formation of shrinkage defect; the simulation result is coinciding with experimental data.

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Wang, Hai Tao, Hui Zhong Xu, and Hua Shun Yu. "Effects and Mechanism of Titanium on Cast Fluidity of ZG45." Advanced Materials Research 146-147 (October 2010): 1243–46. http://dx.doi.org/10.4028/www.scientific.net/amr.146-147.1243.

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The effects of titanium modification, which was added along with the pouring liquid in ladles, on the shrinkage porosity and cavity of cast steel ZG45 smelted in intermediate frequency induction furnace were studied. The metal liquid fluidity was measured by casting spiral samples. 0.2 wt.% titanium modification achieved the highest fluidity for steel liquid. Proper content of titanium could effectively increase the volume of concentrated shrinkage cavity, and restrain the forming of shrinkage porosity. By scanning electron microscope (SEM) and energy disperse spectroscope (EDS) analysis, it was found that TiC, acting as heterogeneous nuclei, could refine the structure grains, diminish the strong dendrite, and increase the fluidity and feeding capacity of steel liquid. However, overdoes titanium modification easily caused mass oxide TiO2, which kept solid phases with high meting point in metal liquid to increase its viscosity and decrease the fluidity. Meanwhile, these solid state titanium compounds enlarged the composition supercooling, so the metal liquid changed from sequential solidification to simultaneous solidification, resulting in inadequate metal liquid feeding, less oncentrated shrinkage cavity and serious shrinkage porosity.

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Zhang, C., Y. Bao, M. Wang, and L. Zhang. "Shrinkage Porosity Criterion and Its Application to A 5.5 Ton Steel Ingot." Archives of Foundry Engineering 16, no. 2 (June 1, 2016): 27–32. http://dx.doi.org/10.1515/afe-2016-0021.

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Abstract In order to predict the distribution of shrinkage porosity in steel ingot efficiently and accurately, a criterion R√L and a method to obtain its threshold value were proposed. The criterion R√L was derived based on the solidification characteristics of steel ingot and pressure gradient in the mushy zone, in which the physical properties, the thermal parameters, the structure of the mushy zone and the secondary dendrite arm spacing were all taken into consideration. The threshold value of the criterion R√L was obtained with combination of numerical simulation of ingot solidification and total solidification shrinkage rate. Prediction of the shrinkage porosity in a 5.5 ton ingot of 2Cr13 steel with criterion R√L>0.21 m · °C1/2 · s−3/2 agreed well with the results of experimental sectioning. Based on this criterion, optimization of the ingot was carried out by decreasing the height-to-diameter ratio and increasing the taper, which successfully eliminated the centreline porosity and further proved the applicability of this criterion.

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Wang, Dong Lei, Zhi Yi Xie, Wen Xu Sun, and Yong Huang. "Solidification Simulation of Melt-Cast Explosive under Pressurization." Materials Science Forum 704-705 (December 2011): 71–75. http://dx.doi.org/10.4028/www.scientific.net/msf.704-705.71.

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The flow field, temperature field and stress field on the melt-cast explosive process have been studied by using software of Procast combined with experimental method，from which the thermodynamic characteristics of the explosives melt-casting process has been researched. The simulation results show that the charge shrinkage, cracks and pore formation could be effectively reduced by adjusting the temperature and pressure. The simulation results could be used for the optimization of casting processes, thereby improved the safety performance of Melt-cast explosive. Keywords: explosive; casting; simulation; shrinkage defects; cracks;

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Anjos, Vítor, and Carlos A. Silva Ribeiro. "Maximization and Control of Nodular Iron Melt’s Self-Feeding Characteristics to Minimize Shrinkage." Materials Science Forum 925 (June 2018): 147–54. http://dx.doi.org/10.4028/www.scientific.net/msf.925.147.

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This paper describes one possible method to anticipate and control the development of solidification shrinkage, during solidification of nodular cast iron melts, based upon industrial trials made using special designed test castings and closed volume thermal analysis cartridges.The methodology considers both the solidification morphology and solidification shrinkage critical size, which is always a difficult component of analysis, along with a developed contraction defect index, that allows the application to several types of molten metal and inoculation practices.The use of thermal analysis allows the recognition of unique melt characteristics, in real time, that are not accessed by more traditional measurement equipment. This allows the definition of thermal analysis patterns that characterize the best melt quality for self-feeding. This is a practical to use and powerful tool for modern foundries, taking advantage of new metric, data collection and data analysis. We aim to contribute to scientific knowledge and simultaneously to provide information that can be useful for foundries to improve their process efficiency.

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Zhao, Si Cong, Er Jun Guo, and Li Ping Wang. "Research Materials of Chills Effect on the Solidification Process of ZM5 Shell." Advanced Materials Research 399-401 (November 2011): 1820–25. http://dx.doi.org/10.4028/www.scientific.net/amr.399-401.1820.

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A commercial software, MAGMASOFT, was used to simulate the ZM5 shell with different materials of chills. The calculated results of solidification are obtained. Shrinkage porosity is predicted by means of a built-in porosity criterion. It shows that using the different materials of chills, such as copper, gray iron and steel, a large amount of shrinkage porosity defects are formed in ZM5 shell. However, with graphite as the material of chills, shrinkage porosity defects of ZM5 shell can be effectively reduced.

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Natsume, Yukinobu. "Numerical Simulation of Macrosegregation Formed Due to Solidification Shrinkage and Bridging of Solidification Structures." Tetsu-to-Hagane 103, no. 12 (2017): 738–46. http://dx.doi.org/10.2355/tetsutohagane.tetsu-2017-062.

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Yang, Hai Bo, Guang Liang Wang, Xue Wen Chen, and De Ying Xu. "The Numerical Simulation and Optimization in Squeeze Casting of the Air Conditioning Compressor Front Cover." Advanced Materials Research 803 (September 2013): 317–20. http://dx.doi.org/10.4028/www.scientific.net/amr.803.317.

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Using the ProCast casting simulation software to make squeeze casting process simulation and analysis of the solidification process of the air conditioning compressor front cover and predict the location of gas volumes and shrinkage defects in the filling process. When adjusted the process parameters, volumes gas defects were eliminated, but there was still shrinkage occurs in the center. When imposed a secondary pressure on the central part, shrinkage was eliminated.

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Liang, Xiang Feng, Yu Tao Zhao, Zhen Li Zuo, and Zhi Hong Jia. "Manufacture and Analysis of Directional Solidification Organization of CMSX-6 Nickel-Base Superalloy." Key Engineering Materials 575-576 (September 2013): 394–97. http://dx.doi.org/10.4028/www.scientific.net/kem.575-576.394.

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In this paper, we use the High rate solidification to study process parameters and CMSX-6 super-alloy solidification structure. And then, it can provide more basis for the industrial directionally solidified casting of superalloys blades. The results show that: under certain process parameters, it can be obtained parallel columnar crystals directional solidification structure. The organization is composed of the matrix γ phase and the secondary precipitated γ ' phase; under an optical microscope, it can be observed the shrinkage porosity due to the volumes reduction arising solidification.

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Mahardika, Muslim, and A. Syamsudin. "Prediction of Shrinkage Porosity in Femoral Stem of Titanium Investment Casting." Archives of Foundry Engineering 16, no. 4 (December 1, 2016): 157–62. http://dx.doi.org/10.1515/afe-2016-0102.

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Abstract Design of gating system is an important factor in obtaining defect-free casting. One of the casting defects is a porosity caused by internal shrinkage in solidification process. Prediction of the internal shrinkage porosity in the femoral stem of commercially pure titanium (CP-Ti) is investigated based on the gating system design. The objective of this research is to get the best gating system between three gating system designs. Three gating system designs of the femoral stem were simulated in an investment casting method. The internal shrinkage porosity occurs on the largest part and near the ingate of the femoral stem. The gating system design that has ingates cross section area: 78.5; 157; and 128.5 mm2 has the least of the internal shrinkage porosity. This design has the most uniform solidification in the entire of the femoral stem. An experiment is conducted to validate the simulation data. The results of internal shrinkage porosity in the three gating system designs in the simulation were compared with the experiment. Based on the comparison, the trend of internal shrinkage porosity at the three gating system designs in the simulation agrees with the experiment. The results of this study will aid in the elimination of casting defect.

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Zhou, Yan Jun, Ke Xing Song, Yan Min Zhang, and Xiu Hua Guo. "Numerical Simulation Analysis on Shrinkage and Porosity of ZL101A Alloy Mechanism Box." Materials Science Forum 704-705 (December 2011): 28–32. http://dx.doi.org/10.4028/www.scientific.net/msf.704-705.28.

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The Shrinkage and porosity of ZL101A alloy mechanism box prepared by sand gravity casting process was investigated. The solidification process was simulation analysis by using InteCAST software and the original casting process was optimized based on the above simulated results. The results showed that the shrinkage and porosity defects’ position of ZL101A alloy mechanism box were accurately predicted by the analysis procedure which was from liquid distribution to shrinkage formation and then to Niyama shrinkage porosity. The shrinkage and porosity of the ZL101A alloy mechanism box prepared by optimized process were clearly reduced and the distribution of them was reasonable. Keywords: InteCAST software;ZL101A; Mechanism box; Shrinkage and porosity; Numerical simulation

Journal articles on the topic 'Solidification shrinkage'

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