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Abstract

The purposes of this study were to investigate the impact of proportions of cast iron scrap, steel scrap, carbon and ferro silicon on hardness and the quality of cast iron and to obtain an appropriate proportion of the four components in iron casting process using a mixture experimental design, analysis of variance and response surface methodology coupled with desirability function. Monte Carlo simulation was used to demonstrate the impacts of different proportions of the four components by varying the proportions of components within ±5% of the four components. Microstructures of the cast iron sample obtained from a company and the cast iron samples casted with the appropriate proportions of the four components were examined to see the differences of size and spacing of pearlite particle. The results showed that linear mixture components were statistically significant implying a high proportion of total variability for hardness of the cast iron samples explained by the casting mixtures of raw materials. The graphite of the sample casted from the appropriate proportion has shorter length and more uniform distribution than that from the company. When varying percentages of the four components within ±5% of the appropriate proportion, simulated hardness values were in the range of 237 to 256 HB.
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Authors and Affiliations

C. Saikaew
1
ORCID: ORCID
S. Harnsopa
1

  1. Department of Industrial Engineering, Khon Kaen University, Khon Kaen 40002 Thailand
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Abstract

Casting is one method of making metal components that are widely used in industry and up to date. The sand casting method is used due to its simplicity, ease of operation, and low cost. In addition, the casting method can produce cast products in various sizes and is well-suited for mass production. However, the disadvantage of casting, especially gravity casting, is that it has poor physical and mechanical properties.
Tin bronze Cu20%wt.Sn is melted in a furnace, then poured at a temperature of 1100°C into a sand mold. The cast product is a rod with 400 mm in length, 10 mm in thickness, and 10 mm in width. The heat treatment mechanism is carried out by reheating the cast specimen at a temperature of 650°C, holding it for 4 hours, and then rapid cooling. The specimens were observed microstructure, density, and mechanical properties include tensile strength and bending strength. The results showed that there was a phase change from α + δ to α + β phase, an increase in density as a result of a decrease in porosity and a coarse grain to a fine grain. In addition, the tensile strength and bending strength of the Cu20wt.%Sn alloy were increased and resulted in a more ductile alloy through post-cast heat treatment.
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Bibliography

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[2] He, Z., Jian, C.A.O. & Ji-cai, F. (2009). Microstructure and mechanical properties of Ti6Al4V / Cu-10Sn bronze diffusion-bonded joint. Transaction Nonferrous Metals Society of China. 19, 414-417.
[3] Chen, X., Wang, Z., Ding, D., Tang, H., Qiu, L., Luo, X. & Shi, G. (2015). Strengthening and toughening strategies for tin bronze alloy through fabricating in-situ nanostructured grains. Material and Design. 1-31. ISSN: 0261-3069.
[4] Kohler, F., Campanella, T., Nakanishi, S. & Rappaz, M. (2008). Application of single pan thermal analysis to Cu – Sn peritectic alloys. Acta Materialia. 56, 1519-1528.
[5] Taslicukur, Z., Altug, G.S., Polat, S., Atapek, Ş.H., Turedi E. (2012). A Microstructural study on CuSn10 bronze produced by sand and investment casting techniques. In 21st International Conference on Metallurgy and Materials METAL 2012, 23-25 May 2012 . Brno, Czech Republic, EU.
[6] Goodway M (1992). Metals of Music. Materials Characterization. 29, 177-184.
[7] Audy J, Audy K (2008). Analysis of bell materials: Tin bronzes. China Foundry. 5, 199-204.
[8] Debut, V., Carvalho, M., Figueiredo, E., Antunes, J. & Silva, R. (2016). The sound of bronze: Virtual resurrection of a broken medieval bell. Jurnal of Cultural Heritage. 19, 544-554.
[9] S.Slamet, Suyitno & Kusumaningtyas, I. (2019). Effect of composition and pouring temperature of Cu(20-24)wt.%Sn by sand casting on fluidity and mechanical properties, Journal of Mechanical Engineering and Science. 13(4), 6022-6035.
[10] S. Slamet, Suyitno and Kusumaningtyas, I. (2019). Effect of composition and pouring temperature of Cu-Sn alloys on the fluidity and microstructure by investment casting. IOP Conf. Series: Materials Science and Engineering. 547, 1-8.
[11] S. Slamet, Suyitno, Kusumaningtyas, I. & Miasa, I.M. (2021). Effect of high-tin bronze composition on physical, mechanical, and acoustic properties of gamelan materials. Archives of Foundry Engineering. 21(1), 137-145.
[12] Fletcher, N. (2012). Materials and musical instruments. Acoustics Australia. 40, 30-134.
[13] Sumarsam, (2002). Introduction to javanese gamelan (Javanese Gamelan-Beginners). Syllabus. 451, 1-28.
[14] Salonitis. K., Jolly. M. & Zeng, B. (2017). Simulation based energy and resource efficient casting process chain selection. A case study. Procedia Manufacturing. 8, 67-74.
[15] Sulaiman, S. & Hamouda, A.M.S. (2001). Modeling of the thermal history of the sand casting process. Journal of Materials Processing Technology. 113, 245-250.
[16] Kim, E., Cho, G., Oh, Y. & Junga, Y. (2016). Development of a high-temperature mold process for sand casting with a thin wall and complex shape. Thin Solid Films. 620, 70-75.
[17] S. Slamet, Suyitno, Kusumaningtyas, I. (2019). Forging process on gamelan bar tin bronze Cu-25 wt. % Sn post casting deformation to changes in microstructure, density, hardness, and acoustic properties. IOP Conf. Series: Materials Science and Engineering. 673, 1-9.
[18] S. Slamet, Suyitno, & Kusumaningtyas, I. (2020). Comparative study of bonang gamelan musical instrument between hot forging and Post Cast Heat Treatment / PCHT on microstructure and mechanical properties. IOP Conf. Series: Materials Science and Engineering. 1430, 1-9.
[19] Morando, C., Fornaro, O., Garbellini, O. & Palacio, H. (2015). Fluidity on metallic eutectic alloys. Procedia Materials Science. 8, 959-967.
[20] Pang, S., Wu, G., Liu, W., Sun, M., Zhang, Y., Liu, Z. & Ding, W. (2013). Effect of cooling rate on the microstructure and mechanical properties of sand-casting Mg-10Gd-3Y-0.5 Zr magnesium alloy. Materials Science Engineering A. 562, 152-160.
[21] Chuaiphan, W. & Srijaroenpramong, L. (2013). The Effect of Tin and heat treatment in brass on microstructure and mechanical properties for solving the cracking of nut and bolt. Applied Mechanics and Materials. 389, 237-244.
[22] Sláma, P., Dlouhý, J. & Kövér, M. (2014). Influence of heat treatment on the microstructure and mechanical properties of aluminium bronze. Materials and Technology. 48(4), 599-604.
[23] Hanson. D, Pell-Walpole, W.T. (1951). Chill-Cast Tin Bronzes. 1-368
[24] Sanchez, J.A.B.F., Bolarin, A.M. , Tello, A. & Hernandez, L.E. (2006). Diffusion at Cu / Sn interface during sintering process. Materials Science of Technology. 22, 590-596.
[25] Gupta, R., Srivastava, S., Kishor, N. & Panthi, S.K. (2016). High leaded tin bronze processing during multi-directional forging : Effect on microstructure and mechanical properties. Materials Science Engineering A. 654, 282-291.

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Authors and Affiliations

S. Slamet
1
S. Suyitno
2
I. K. Indraswari Kusumaningtyas
3

  1. Universitas Muria Kudus, Indonesia
  2. Universitas Tidar Magelang, Indonesia
  3. Universitas Gadjah Mada, Indonesia
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Abstract

High tin bronze alloy (Cu>17wt.%Sn) is commonly as raw material to fabricate musical instruments. Gamelan musical instruments in Indonesia are produced using tin bronze alloy raw materials. The tin bronze alloy used by each gamelan craftsman has a different tin composition, generally in the range of Cu(20-24) wt.% Sn. This study aims to investigate the effect of microstructure, density, and mechanical properties of Cu(20-24)wt.%Sn against the acoustic properties processed by the sand casting method. The material is melted in a crucible furnace until it reaches a pouring temperature of 1100ºC by the sand casting method. The specimens were subjected to microstructure observations, density and porosity as well as mechanical properties testing including tensile strength, bending strength, hardness, and modulus of elasticity. Mechanical properties data then used to calculate several parameters of acoustic properties including speed of sound (c), impedance (z) and radiation coefficient (R). Processes simulation using Finite Element Analysis (FEA) and Experiment Method Analysis (EMA) were carried out to determine acoustic properties including sound intensity, natural frequency and damping capacity.
The experimental result shows that the increase in tin composition in Cu(20-24) wt.% Sn changed the microstructure of coarse grains into dendrite-columned fine grains. Physical properties of density decrease, while porosity increases. Mechanical properties including tensile strength, modulus of elasticity, and bending strength decreased, while the hardness of the alloy increases. The calculation of acoustic parameters such as the speed of sound (c), impedance (z) and radiation coefficient (R) has decreased. Moreover, sound intensity (dB), natural frequency (Hz) and damping capacity also decrease with increasing tin composition. Hence, tin bronze alloy Cu20wt.%Sn is the recommended raw material for the manufacture of gamelan instruments through the sand casting method.
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Bibliography

[1] Sumarsam. (2002). Introduction to Javanese gamelan (Javanese gamelan-beginners). Wesleyan University. Middletown.
[2] Sutton, R.A. (2007). Gamelan: The Traditional Sounds of Indonesia (review). Asian Music. 38(1), 142-144.
[3] Suyanto, Tjokronegoro H.A, Merthayasa I.G.N. & Supanggah R. (2015). Acoustic parameter for javanese gamelan performance in pendopo mangkunegaran Surakarta. Procedia – Social and Behavioral Sciences. 184. 322-327.
[4] Goodway, M. (1992). Metals of music. Materials Characterization. 29. 177-184.
[5] Audy, J. & Audy, K. (2008). Analysis of bell materials: Tin bronzes. China Foundry. 5(3). 199-204.
[6] Debut, V. Carvalho, M. Figueiredo, E. Antunes, J. & Silva, R. (2016). The sound of bronze: Virtual resurrection of a broken medieval bell. Journal of Cultural Heritage. 19. 544-554.
[7] Sugita, I.K.G. Soekrisno, R. Miasa, I.M. & Suyitno. (2011). Mechanical and damping properties of silicon bronze alloys for music applications. International Journal of Engineering &. Technology. 11(6). 81-85.
[8] Sugita, I.K.G. Soekrisno, R. & Miasa, I.M. (2011). The effect of annealing temperature on damping capacity of the bronze 20 % Sn alloy. International Journal of Mechanical & Mechatronics Engineering. IJMME-IJENS. 11(4).1-5.
[9] Slamet, S. Suyitno, & Kusumaningtyas, I. (2019). Effect of composition and pouring temperature of Cu (20-24) wt.% Sn by sand casting on fluidity and Mechanical Properties, Journal of Mechanical Engineering and Science. 13(4). 6022-6035.
[10] Sugita, I.K.G. & Miasa, I.M. (2013). Feasibility Study On The Use Of Silicon-Bronze Alloys As An Alternative Material For Balinese Musical Instruments. 20th International Congress on Sound & Vibration; 7-11 July 2013.1-5. Bangkok, Thailand
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[12] Salonitis, K. Jolly, M. & Zeng, B. (2017). Simulation-based energy and resource-efficient casting process chain selection : A case study. Procedia Manufacturing. 8. 67-74.
[13] Wegst, U.G. (2006). Wood For Sound. American Journal of Botany. 93.1439-1448.
[14] Adams, R. D. & Fox, M.A.O. (1973). Correlation of the damping capacity of cast iron with its mechanical properties and microstructure. Journal of Mechanical Engineering Science. 15(2). 81-94.
[15] Grafov, B.M. (1994). The archimedes law and electrocapillarity. Electrochimica Acta. 39. 467-469.
[16] ASTM. (2015). Standard test methods for bend testing of material for ductility.1.1-10.
[17] Sutiyoko & Suyitno. (2012). Effect of pouring temperature and casting thickness on fluidity, porosity and surface roughness in lost foam casting of gray cast iron. Procedia Engineering. 50. 88-94.
[18] Halvaee, A. & Talebi, A. (2001). Effect of process variables on microstructure and segregation in the centrifugal casting of C92200 alloy. Journal of Materials Processing Technology. 118, 123-127.
[19] Sutiyoko. Suyitno. & Mahardika. M. (2016). Effect of gating system on porosity and surface roughness of femoral stem in centrifugal casting. Adv. Sci. Technol. Soc. AIP Conference Proceedings. 1755, 1-6.
[20] Sulaiman, S. & Hamouda, A.M.S. (2004). Modeling and experimental investigation of the solidification process in sand casting. Journal of Materials Processing Technology. 156, 1723-1726.
[21] Nadolski, M. (2017). The Evaluation of Mechanical Properties of High-tin Bronzes. Archives of Foundry Engineering. 17(1), 127-130.
[22] Nimbulkar, S.L. & Dalu. R.S. (2016). Design optimization of gating and feeding system through simulation technique for sand casting of wear plate. Perspectives in Science. 8.39-42.
[23] Singh, R. & Singh, S. (2013). Effect of process parameters on surface hardness, dimensional accuracy, and surface roughness of investment cast components; Journal of Mechanical Science and Technology. 27(1), 191-197.
[24] Bartocha, D. & Baron, C. (2016). Influence of tin-bronze melting and pouring parameters on its properties and bells ’ tone. Archives of Foundry Engineering. 16(4), 17-22.

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Authors and Affiliations

S. Slamet
1 2
S. Suyitnoa
1
I. Kusumaningtyasa
1
I.M. Miasaa
1

  1. Universitas Gadjah Mada, Yogyakarta, Indonesia
  2. Universitas Muria Kudus, Kudus, Indonesia
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Abstract

In this paper, the authors investigated the size distribution of titanium oxide (TiO2), titanium nitride (TiN) and titanium carbide (TiC) inclusions in a titanium deoxidized 4130 steel and compared it with the 4130 base alloy composition inclusions. TiN and TiC inclusions are of particular interest due to their role as heterogeneous nuclei for various phase reactions in steels. Two types of samples were prepared, a polished sample and a filtered sample. Electrolytic dissolution was employed to make the filter paper samples. The size range of titanium inclusions was found to be more than that of the non-metallic inclusions from 4130 base alloy heat. Titanium inclusions from the filter and polished samples were round in shape. TiC and TiN inclusions were not found in the electrolytic extraction samples. Inclusions and their chemistries were analyzed using scanning electron microscope and energy dispersive spectrometer. The inclusion size range was larger for the titanium deoxidized samples than the base alloy. However, in both steels the majority of inclusions had a size smaller than 10 μm.

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Authors and Affiliations

R.B. Tuttle
S. Kottala
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Abstract

The studied silicon bronze (CuSi3Zn3Mn1) is characterised by good strength and corrosion resistance due to the alloying elements that are present in it (Si, Zn, Mn, Fe). This study analysed the casting process in green sand moulding, gravity die casting, and centrifugal casting with a horizontal axis of rotation. The influences of Ni and Zr alloying additives as well as the casting technology that was used were evaluated on the alloy’s microstructure and mechanical properties. The results of the conducted research are presented in the form of the influence of the technology (GS, GZ, GM) and the content of the introduced alloy additives on the mechanical parameters (UTS, A10, and Proof Stress, BHN).
The analysis of the tests that were carried out made it possible to determine which of the studied casting technologies had the best mechanical properties. Microstructure of metal poured into metal mould was finer than that which was cast into moulding compound. Mechanical properties of castings made in moulding compound were lower than those that were cast into metal moulds. Increased nickel content affected the BHN parameter.
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Bibliography

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[2] Rzadkosz, S., Kranc, M., Garbacz-Klempka, A., Kozana, J. & Piękoś, M. (2015). Refining processes in the copper casting technology. Metalurgija. 54(1), 259-262.
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[16] Guharaja, S., Noorul Haq, A. & Karuppannan, K. M. (2006). Optimization of green sand casting process parameters by using Taguchi’s method. The International Journal of Advanced Manufacturing Technology. 30, 1040-1048. DOI: 10.1007/s00170-005-0146-2.
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Authors and Affiliations

D. Witasiak
1
A. Garbacz-Klempka
1
ORCID: ORCID
M. Papaj
P. Papaj
M. Piękoś
1
ORCID: ORCID
J. Kozana
1
ORCID: ORCID
M. Maj
1
M. Perek-Nowak
1
ORCID: ORCID

  1. AGH University of Science and Technology, Faculty of Foundry Engineering, Poland
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Abstract

The paper presents results of measuring attenuation coefficient of the Al-20 wt.% Zn alloy (AlZn20) inoculated with different grain

refiners. During experiments the melted alloys were doped with Al-Ti3-C0.15 refining master alloy. Basing on measurements performed

by Krautkramer USLT2000 device with 1MHz ultrasound wave frequency it was stated that grain refinement reduces the attenuation

coefficient by about 20-25%. However, the examined alloys can be still classified as the high-damping ones of attenuation greater than 150

dB/m.

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Authors and Affiliations

P.K. Krajewski
W.K. Krajewski
J. Buraś
G. Piwowarski
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Abstract

In sand casting, Fused Deposition Modeling (FDM) printing by using Poly Lactic Acid (PLA) filament is one of the innovative foundry technologies being adopted to substitute traditional pattern making. Several literatures have reported the influence of process parameters such as raster angle and print speed on some mechanical properties of FDM-printed, PLA-prototypes used in other applications. This study investigated the effects of interior fill, top solid layer, and layer height on the compressive strength of rapid patterns for sand casting application. Different values of the process parameters were used to print the pre-defined samples of the PLA-specimens and a compression test was performed on them. The coupled effects of the process parameters on compressive strength were investigated and the optimum values were determined. Interior fill of 36%, layer height of 0.21 mm and top solid layer of 4 were found to produce a FDM-printed, PLApattern that sustained a compaction pressure of 0.61 MPa. A simulation analysis with ANSYS® to compare failure modes of both experiment and model shows a similarity of buckling failure that occurred close to the base of each specimen.
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Authors and Affiliations

P.I. Anakhu
C.C. Bolu
A.A. Abioye
G. Onyiagha
H. Boyo
K. Jolayemi
J. Azeta

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