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Effect of Filter Type on Mechanical Properties During Aluminium Alloy Casting

M. Bruna M. Galčík
Archives of Foundry Engineering | 2022 | vol. 22 | No 3 | 95-98 | DOI: 10.24425/afe.2022.140241
Keywords Aluminium alloys Filtration Mechanical properties Reoxidation Melt velocity
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Abstract

The naturally pressurized gating system was used for reoxidation suppression during aluminium alloy casting. A naturally pressurized gating system appears to be a suitable solution to reduce reoxidation processes, which was proven by our previous works. The disadvantage of this system is that without inserting deceleration elements, the melt velocity is supercritical. Therefore, the aim of paper is to find a proper way to reduce the melt velocity, which is the main parameter affecting the scale of reoxidation processes. For the purpose of the melt velocity reduction, labyrinth filters, foam filters and flat filters effect on the melt velocity and the number of oxides were investigated by numerical simulation software in the first stage of the experiment. After simulations observation, the effect of filters on the mechanical properties was investigated by experimental casts. The simulations and experimental casts proved that filters had a positive effect on the melt velocity reduction and it was associated with increased mechanical properties of castings. The best results were achieved by the foam filter.
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Bibliography

[1] Campbell, J. (2015). Complete Casting Handbook. (2nd ed.). Oxford: Elsevier Ltd.
[2] Dobosz, St.M., Grabarczyk, A., Major-Gabrys, K. & Jakubski, J. (2015). Influence of quartz sand quality on bending strength and thermal deformation of moulding sands with synthetic binders. Archives of Foundry Engineering. 15(2), 9-12. ISSN (1897-3310)
[3] Lakoma, R., Camek, L., Lichý, P., Kroupová, I., Radkovský, F. & Obzina, T. (2021). Some possibilities of using statistical methods while solving poor quality production. Archives of Foundry Engineering. 21(1), 18-22. DOI: 10.24425/afe.2021.136073
[4] Baghani, A., Kheirabi, A., Bahmani, A. & Khalilpour, H. (2012). Removal of double oxide film defects by ceramic foam filters. Journal of Materials Engineering and Performance. 21(7), 1352-1362. DOI: 10.1007/s11665-011-9991-3
[5] Jezierski, J., Dojka, R. & Janerka, K. (2018). Optimizing the Gating System for Steel Castings. Metals. 8(266), 1-13. DOI: 10.3390/met804026
[6] Pastirčák, R. & Ščury, J. (2016). Effect of technological parameters on microstructure in alloy AlCu4Ti using squeeze casting technology. The application of experimental and numerical methods in fluid mechanics and energy. ISBN 978-0-7354-1402-0.
[7] Gyarmati, G., Fegyverneki, G., Mende, T. & Tokár, M. 2019. Characterization of the double oxide film content of liquid aluminum alloys by computed tomography. Materials Characterization. 157, 109925.
[8] Remišová, A. & Brůna, M. (2019). Analysis of reoxidation processes with aid of computer simulation. Archives of Foundry Engineering. 19(4), 55-60.
[9] Brůna, M., Galčík, M., Sládek, A. & Martinec, D. (2021). Possibilities of bifilm amount reduction in Al castings by gating system design optimization. Archives of Metallurgy and Materials. 66(2), 549-559. ISSN 1733-3490

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Authors and Affiliations

M. Bruna
1
ORCID: ORCID
M. Galčík
1
  1. University of Žilina, Slovakia

Casting Quality Improvement by Gating System Optimization

M. Bruna M. Galčík
Archives of Foundry Engineering | 2021 | vo. 21 | No 1 | 132-136 | DOI: 10.24425/afe.2021.136089
Keywords Reoxidation Gating system Numerical simulation Aluminium alloys Mechanical properties
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Abstract

One of the main reason for decreased internal homogeneity of aluminium alloy castings is reoxidation. The resulting products of reoxidation are doubled oxides, so called "bifilms". Submitted paper deals with optimization of gating system design in order to reduce reoxidation processes taking place in mold cavity. Experimental work compares and evaluates three gating systems designs based on non-pressurized and naturally pressurized principles. Unconventional spin trap extension of runner was used in third design. Among the evaluated aspects were: mechanical properties, hot tearing index, visual inspection of average porosity amount, numerical simulation of velocity, turbulence and oxide amount. Paper aim is also to clarify the reoxidation phenomenon by visualization with the aid of ProCAST numerical simulation software. Results of mechanical properties and hot tear index clearly confirmed the positive effect of the naturally pressurized gating system with applied element for velocity reduction.
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Bibliography

[1] Svoboda, J.M., Monroe, R.W., Bates, C.E. & Griffin, J. (1987). TAFS. 95, 187-202.
[2] Campbell, J. (2006). Entrainment defects. Materials Science and Technology. 22(2), 127-145. ISSN 0267-0836. https://doi.org/10.1179/174328406X74248.
[3] Campbell, J. (1993). Invisible Macrodefects in castings. Journal de Physique Archives. 03(C7), 861-872. https://doi.org/10.1051/jp4:19937135.
[4] Dojka, R. Jezierski, J. & Campbell, J. (2018) Optimized gating system for steel castings. Journal of Materials Engineering and Performance. 10. DOI: 10.1007/s11665-018-3497-1.
[5] Sladek, A., Patek, M. & Mician, M. (2017). Behavior of steel branch connections during fatigue loading‎. Archives of Metallurgy and Materials. 62 (3), 1597-1601‏.
[6] Brůna, M., Bolibruchová, D. & Pastirčák, R. (2017). Archives of Foundry Engineering. 17, 23-26. https://doi.org/10.1515/afe-2017-0084.
[7] Lin, S., Aliravci, C. & Pekguleryuz, N.I.O. (2007). Hot-tear susceptibility of aluminum wrought alloys and the effect of grain refining. Materials Science and Engineering. A Sci. 38A, 1056-1068. https://doi.org/10.1007/s11661-007-9132-7.
[8] Campbell, J. (2006). An overview of the effects of bifilms on the structure and properties of cast alloys. Metallurgical and Materials Transaction B. 37, 857-863. https://doi.org/ 10.1007/BF0273500.

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Authors and Affiliations

M. Bruna
1
ORCID: ORCID
M. Galčík
1
  1. Department of Technological Engineering, University of Zilina, Univerzitna 1, 010 26 Zilina, Slovakia

Possibilities of Bifilm Amount Reduction in Al Castings by Gating System Design Optimization

M. Brůna M. Galčík A. Sládek D. Martinec
Archives of Metallurgy and Materials | 2021 | vol. 66 | No 2 | 549-559 | DOI: 10.24425/amm.2021.135892
Keywords reoxidation bifilm gating system aluminium alloys mechanical properties
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Abstract

Submitted work deals with the possibilities of reducing reoxidation by improved gating system design. The result of the reoxidation is the of furled oxide layers – bifilms. During experimental works, non-pressurized and naturally pressurized gating systems designs were introduced and evaluated. Mechanical properties, fracture area, hot tearing index, bifilm index and EDX analysis were used during evaluation. Paper aim is also to clarify the reoxidation phenomenon by visualization with the aid of ProCAST numerical simulation software. Achieved results clearly confirmed the positive effect of the naturally pressurized gating system, main emphasis needs to focus on finding the proper way to reduce the melt velocity. By using vortex element extension at the end of the runner was achieved positive results in term of reoxidation suppression.
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Authors and Affiliations

M. Brůna
1
ORCID: ORCID
M. Galčík
1
A. Sládek
1
D. Martinec
1
  1. University of Žilina, Faculty of Mechanical Engineering, Department of Technological Engineering, Univerzitná 8215/1, 010 26 Žilina, Slovakia

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