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Abstract

Hot tearing is a casting defect responsible for external and internal cracks on casting products. This irregular undesired formation is often observed during solidification and freezing. The solidification of molten metal also causes thermal contraction and shrinkage, indicating the occurrence of hot tearing when the alloy is restrained by the mould design. The parameters affecting this process include the pouring and mould temperatures, the chemical composition of the alloy, and the mould shape. Also, the factors affecting hot tearing susceptibility include pouring and mould temperatures, the grain refiner, as well as pouring speed. There are many methods of measuring the level of susceptibility to hot tearing, one of which is the thermal contraction evaluation during metal solidification, observed in cast products through several mould types. This paper discusses the hot tearing overview, the effect of pouring temperature, mould temperature, grain refiner, pouring speed on hot tearing, the type of mould, and criterion for hot tear observation.
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Authors and Affiliations

Akhyar
1

  1. Department of Mechanical Engineering, Univeritas Syiah Kuala, Jl. Syech Aburrauf No.7, Darussalam, Banda Aceh, 23111, Indonesia
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Abstract

For the die casting conditions of aluminium bronzes assumed based on the literature data, a thick-walled bush was cast, made of complex

aluminium bronze (Cu-Al-Fe-Ni-Cr). After the cast was removed from the mould, cracks were observed inside it. In order to identify the

stage in the technological production process at which, potentially, the formation of stresses damaging the continuity of the microstructure

created in the cast was possible (hot cracking and/or cold cracking), a computer simulation was performed. The article presents the results

of the computer simulation of the process of casting the material into the gravity die as well as solidifying and cooling of the cast in the

shape of a thick-walled bush. The simulation was performed with the use of the MAGMA5 program and by application of the

CuAl10Ni5,5Fe4,5 alloy from the MAGMA5 program database. The results were compared with the location of the defects identified in

the actual cast. As a result of the simulation of the die-casting process of this bush, potential regions were identified where significant

principal stresses accumulate, which can cause local hot and cold cracking. Until now, no research has been made of die-cast aluminium

bronzes with a Cr addition. Correlating the results of the computer simulation validated by the analysis of the actual cast made it possible

to clearly determine the critical regions in the cast exposed to cracking and point to the causes of its occurrence. Proposals of changes in

the bush die casting process were elaborated, in order to avoid hot tearing and cold cracking. The article discusses the results of

preliminary tests being a prologue to the optimization of the die-casting process parameters of complex aluminium bronze thick-walled

bushs.

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Authors and Affiliations

T. Pacyniak
B.P. Pisarek
D. Kołakowski
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Abstract

Recycling of aluminium returnable material through its reuse is now an essential component of the production of aluminium alloy castings. The main goal is to find a suitable ratio of the primary alloy and the returnable material in the batch, thus determining the right compromise between the price and the quality of the casting. Experimental alloys were evaluated by thermal analysis, combination of structural analytical techniques and selected mechanical properties. The alloys were also subjected to tearing susceptibility testing. The increase in the returnable material amount resulted in changes in the alloy properties at the first increase in volume to 20%. After exceeding the balanced ratio (50:50), there was considerable degradation of the microstructure, failure to achieve the minimum values of some mechanical properties required by the standard, and the alloy showed increased susceptibility to tearing.

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Authors and Affiliations

M. Matejka
ORCID: ORCID
D. Bolibruchová
ORCID: ORCID
M. Chalupová
ORCID: ORCID
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Abstract

The current trend of continuous improvement of various components constantly pushes the development of new materials forward. The basic goal of research into new and better materials is to improve their properties compared to the original material. One of the essential properties of the newly developed aluminum alloys is their resistance to the formation of tearing. Tears appear during the solidification of the casting and break the integrity due to tension arising while cooling. Several factors influence the susceptibility to tearing, but they can be minimized and reduce the chance of their occurrence. As part of the experiment, the AlSi5Cu2Mg alloy was evaluated in four material variants, without additives (in the reference state), with the addition of transition elements Zr, Ti and their combination Zr + Ti. Susceptibility to the formation of teras was assessed using a qualitative method supplemented by microscopic analysis of the tear profile and determination of the dendritic coherence temperature. The evaluation shows that the addition of Zr increased the susceptibility to tear formation. On the contrary, the addition of Ti had a positive effect and reduced the susceptibility to the formation of tears. The effect of the addition of Zr and Ti in the AlSi5Cu2Mg alloy showed a similar values as without the addition of alloys (reference condition). Microstructural analysis of the tear profile pointed to the negative influence of phases rich in Zr. The subsequent evaluation of the dendritic coherence temperature of individual AlSi5Cu2Mg alloys did not show a correlation with the results of a quantitative evaluation of susceptibility to tears.
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Authors and Affiliations

M. Matejka
1
ORCID: ORCID
D. Bolibruchová
1
ORCID: ORCID
E. Kantoríková
1
ORCID: ORCID

  1. University of Zilina, Faculty of Mechanical Engineering, Department of Technological Engineering, Slovak Republic

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