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The Influence of Using Different Types of Risers or Chills on Shrinkage Production for Different Wall Thickness for Material EN-GJS-400-18LT

I. Vasková M. Hrubovčáková M. Conev
Archives of Foundry Engineering | 2017 | vol. 17 | No 2 | DOI: 10.1515/afe-2017-0064
Keywords Ductile iron Shrinkage cavity Riser Chill Ultrasound
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Abstract

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.

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Authors and Affiliations

I. Vasková
M. Hrubovčáková
M. Conev

The Process of Vacuum Formation in the Shrinkage Cavity at Castings Crystallization

V. Khrychikov O. Semenov H. Meniailo Y. Aftandiliants S. Gnyloskurenko
Archives of Foundry Engineering | 2022 | vol. 22 | No 4 | 79-84 | DOI: 10.24425/afe.2022.143953
Keywords Shrinkage depression Causes of defects Shrinkage cavity Device for measuring vacuum
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Abstract

The formation process of one of the most common casting defects, a shrinkage depression concerned to shrinkage cavity, was studied. The methodology, device and the experimental set up were developed to study the shrinkage cavity growth. The kinetics of vacuum formation in the cavity of the spherical casting of Al-Si-Mg alloy at its solidification in the sand-and-clay form was investigated. The data were analysed taking in mind the temperature variation in the centre of crystallizing casting. The causes of the shrinkage depression in castings were clarified. It was determined that atmospheric pressure leads to the retraction and curvature of metal layer on the surface of the casting with lower strength below which the shrinkage cavity is formed. To avoid such defects it was recommended to use the external or internal chills, feeders and other known technological methods. Deep shrinkage cavities inside the castings could be removed with an air flow through a thin tubular needle of austenitic steels for medical injections.
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Bibliography

[1] DSTU 9051:2020. Castings of cast iron and steel. Defects. Terms and definitions. Since 01.04.2021. Pg. 15. (in Ukrainian) http://ptima.kiev.ua/images/stories/Standart/IRONSTEEL/dstu19200-80.pdf
[2] Rowley, M.T. (2007). International Atlas of Casting Defects. American Foundry Society. ISBN: 978-0874330533.
[3] GOST 19200-80. Castings of cast iron and steel. Terms and definitions of defects. (1980). (in Russian).
[4] Atlas of foundry defects. (2004). 136 Summit avenue. Montvale, NJ 07645-1720. Institute of Foundry Casting. Technopark. Pg. 23.
[5] Reisa, A., Xub, Z., Tolb, R.V. & Netoc, R. (2012). Modelling feeding flow related shrinkage defects in aluminum castings. Journal of Manufacturing Processes. 14(1), 1-7. DOI: 10.1016/j.jmapro.2011.05.003
[6] Voronin, Y.F., Kamaev V.A. (2005). Atlas of foundry defects. Moscow: Mechanical Engineering. Pg. 327. (in Russian). https://www.twirpx.com/file/914318/
[7] Chokkalingam, B. & Mohamed Nazirudeen, S.S. (2009). Analysis of casting defect through defect diagnostic study approach. Journal of Engineering Annals of the Faculty of Engineering Hunedoara. 2, 209-212. ISSN 1584-2665
[8] Beeley, P. (2001). Foundry Technology. 719. Oxford: Butterworth Heinemann. ISBN 0750645679. https://www.academia.edu/4161769/foundry_technology_by_peter_beeley/
[9] Khrychikov, V.E., Semenov, O.D., Menyaylo, O.V., Shalevskaya, I.A., & Myanovskaya, Ya.V. (2021). Elimination of weights in artistic castings with different wall thickness (Removal of shrinkage depression in art castings with different wall thickness). Casting processes (Затвердіння сплавів). 4(146). 14-21. (in Ukrainian). https://plit-periodical.com.ua/en/arhiv/removal-shrinkage-depression-art-castings-different-wall-thickness
[10] GOST R ISO 9626-2020. (2021). Stainless steel needle pipes for the manufacture of medical devices. Requirements and test methods. Pg. 28. (in Russian).
[11] Dunphy, R.P., Akerlind, C.G. & Pellini, W.S. (1954). Solidification, feed characteristics of gray cast irons and nodular cast irons. Foundry. 82(6), 106-121.
[12] Rogelberg I.L, Beilin V.M. (1983). Alloys for thermocouples (handbook). Moscow: Metallurgy. 76-77. (in Russian) https://knizhen-pazar.net/products/books/597200-splav-dlya-termopar
[13] Leibenzon, V.O., Pilyushenko, V.L., Kondratenko, V.M., Khrychikov, V.E., Nedopyokin, F.V., Bilousov, V.V. Dmitriev, Yu.V. (2009). Hardening of metals and metal compositions. Kyiv: Scientific thought. 447. (in Ukrainian. https://nmetau.edu.ua/file/tverdinnya_metaliv_i_metalevih_kompozitsiy._pidruchnik.pdf
[14] Khrychikov, V.E., Semenov, O.D., Menyaylo, O.V. (2021). Application for the patent № a202101129. Ukraine. IPC (2021.01) B22D 27/13 (2006.01), B22D 25/00. Method of removing weights in castings with thickened parts of wall. (in Ukrainian). https://base.uipv.org/searchInvStat/showclaimdetails.php?IdClaim=336807&resId=1

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Authors and Affiliations

V. Khrychikov
1
ORCID: ORCID
O. Semenov
1
ORCID: ORCID
H. Meniailo
1
ORCID: ORCID
Y. Aftandiliants
2
ORCID: ORCID
S. Gnyloskurenko
2 3
ORCID: ORCID
  1. Ukrainian State University of Science and Technologies, Ukraine
  2. National University of Life and Environmental Sciences of Ukraine, Ukraine
  3. Physical and Technological Institute of Metals and Alloys, National Academy of Sciences of Ukraine, Ukraine

Numerical Model of Solidification Including Formation of Multiple Shrinkage Cavities

T. Skrzypczak L. Sowa E. Węgrzyn-Skrzypczak
Archives of Foundry Engineering | 2020 | vol. 20 | No 1 | 37-42 | DOI: 10.24425/afe.2020.131280
Keywords solidification process Castings defects Shrinkage cavity Numerical simulation Finite element method
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Abstract

Presented paper shows the mathematical and numerical approaches for modelling of binary alloy solidification solved by the Finite Element Method (FEM). The phenomenon of shrinkage cavities formation process is included in the numerical model. Multiple macroscopic cavities can be modelled within the single casting volume. Solid, liquid and gaseous phases with different material properties are taken into account during solidification process. Mathematical model uses the differential equation of heat diffusion. Modification of specific heat is used to describe the heat releasing during liquid-solid phase change. Numerical procedure of shrinkage cavities evolution is based on the recognition of non-connected liquid volumes and local shrinkage computation in the each of them. The recognition is done by the selection of sets of interconnected nodes containing liquid phase in the finite element mesh. Original computer program was developed to perform calculation process. Obtained results of temperature and shrinkage cavities distributions are presented and discussed in details.

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Authors and Affiliations

T. Skrzypczak
L. Sowa
E. Węgrzyn-Skrzypczak

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