In modern times, there are increasing requirements for products quality in every part of manufacturing industry and in foundry industry it is not different. That is why a lot of foundries are researching, how to effectively produce castings with high quality. This article is dealing with search of the influence of using different types of risers or chills on shrinkage cavity production in ductile iron castings. Differently shaped risers were designed using the Wlodawer´s modulus method and test castings were poured with and without combination of chills. Efficiency of used risers and chills was established by the area of created shrinkage cavity using the ultrasound nondestructive method. There are introduced the production process of test castings and results of ultrasound nondestructive reflective method. The object of this work is to determine an optimal type of riser or chill for given test casting in order to not use overrated risers and thus increase the cost effectiveness of the ductile iron castings production.
Metal casting process involves processes such as pattern making, moulding and melting etc. Casting defects occur due to combination of various processes even though efforts are taken to control them. The first step in the defect analysis is to identify the major casting defect among the many casting defects. Then the analysis is to be made to find the root cause of the particular defect. Moreover, it is especially difficult to identify the root causes of the defect. Therefore, a systematic method is required to identify the root cause of the defect among possible causes, consequently specific remedial measures have to be implemented to control them. This paper presents a systematic procedure to identify the root cause of shrinkage defect in an automobile body casting (SG 500/7) and control it by the application of Pareto chart and Ishikawa diagram. with quantitative Weightage. It was found that the root causes were larger volume section in the cope, insufficient feeding of riser and insufficient poured metal in the riser. The necessary remedial measures were taken and castings were reproduced. The shrinkage defect in the castings was completely eliminated.
The results of testing of the selected group of wax mixtures used in the investment casting technology, are presented in the paper. The measurements of the kinetics of the mixtures shrinkage and changes of viscous-plastic properties as a temperature function were performed. The temperature influence on bending strength of wax mixtures was determined.
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.
The paper presents the results of experimental-simulation tests of expansion-shrinkage phenomena occurring in cast iron castings. The tests were based on the standard test for inspecting the tendency of steel-carbon alloys to create compacted discontinuities of the pipe shrinkage type. The cast alloy was a high-silicone ductile iron of GJS - 600 - 10 grade. The validation regarding correctness of prognoses of the shrinkage defects was applied mostly to the simulation code (system) NovaFlow & Solid CV (NFS CV). The obtained results were referred to the results obtained using the Procast system (macro- and micromodel). The analysis of sensitivity of the modules responsible for predicting the shrinkage discontinuities on selected pre-processing parameters was performed, focusing mostly on critical fractions concerning the feeding flows (mass and capillary) and variation of initial temperature of the alloy in the mould and heat transfer coefficient (HTC) on the casting - chill interface.
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.
US A356 and US 413 cast aluminium alloys shrinkage characteristic have been discussed in the present study. Specific volume reduction leads to shrinkage in castings and it can be envisaged as a casting defect. Finite difference based casting process simulation software has been used to study the shrinkage characteristic and it is quantified using mathematical formulae. The three dimensional model of the shrinkage defect has been constructed using CAD application software. Shrinkage characteristic has also been quantified through experimental validation studies and compared well with casting process simulation. Shrinkage characteristic study and control is essential for producing defect free castings. Influence of casting shape on the shrinkage characteristic has been studied in this paper.
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･℃1/2･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.
This paper presents the results of measurements of liquid metal fluidity and linear shrinkage of nickel alloy IN-713C in vacuum induction melting furnace Balzers VSG-2. Because of limited volume of the furnace chamber special models for technological trials were designed and constructed to fit in the mould of dimensions 170x95x100mm. Two different designs of test models were proposed: horizontal round rods and modified spiral. Preliminary studies were carried out for alloys Al-Si. Horizontal round rods test was useful for evaluation of fluidity of hypoeutectic silumin, however in case of nickel superalloy the mould cavity was completely filled in each test because of high required pouring temperature. Positive results were obtained from the modified spiral test for all alloys used in the research. Relationship between the linear shrinkage for the test rod and a specific indicator of contraction defined on a spiral was observed.
Turbine blades have complex geometries with free form surface. Blades have different thickness at the trailing and leading edges as well as sharp bends at the chord-tip shroud junction and sharp fins at the tip shroud. In investment casting of blades, shrinkage at the tip-shroud and cord junction is a common casting problem. Because of high temperature applications, grain structure is also critical in these castings in order to avoid creep. The aim of this work is to evaluate the effect of different process parameters, such as, shell thickness, insulation and casting temperature on shrinkage porosity and grain size. The test geometry used in this study was a thin-walled air-foil structure which is representative of a typical hot-gas-path rotating turbine component. It was observed that, in thin sections, increased shell thickness helps to increase the feeding distance and thus avoid interdendritic shrinkage. It was also observed that grain size is not significantly affected by shell thickness in thin sections. Slower cooling rate due to the added insulation and steeper thermal gradient at metal mold interface induced by the thicker shell not only helps to avoid shrinkage porosity but also increases fill-ability in thinner sections.
The paper concerns the problem of discontinuity in high pressure die castings (HPDC). The compactness of their structure is not perfect, as it is sometimes believed. The discontinuities present in these castings are the porosity as follow: shrinkage and gas (hydrogen and gas-air occlusions) origin. The mixed gas and shrinkage nature of porosity makes it difficult to identify and indicate the dominant source. The selected parameters of metallurgical quality of AlSi9Cu3 alloy before and after refining and the gravity castings samples (as DI - density index method), were tested and evaluated. This alloy was served to cast the test casting by HPDC method. The penetrating testing (PT) and metallographic study of both kinds of castings were realized. The application of the NF&S simulation system allowed virtually to indicate the porosity zones at risk of a particular type in gravity and high-pressure-die-castings. The comparing of these results with the experiment allowed to conclude about NF&S models validation. The validity of hypotheses concerning the mechanisms of formation and development of porosity in HPDC casting were also analyzed.