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Casting Processes and Modelling of Metallic Materials

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Nguyễn Gia Hào

Academic year: 2023

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The speed gearbox on the Rolls-Royce Ultrafan® aircraft engine was one of the main projects in which Dr. Thus, bubbles can create macroscopic crack-like defects out of all proportion to the original bubble size.

Gravity casting

The falling stream spouting from the bottom of the ladle enters the beginning of the filling system at the conical inlet (often known as the trumpet). Dropping the metal into the initially empty mold is a huge setback that must be eliminated - piling scrap into the mold is a bad starting technique that doesn't help at all.

Counter-gravity casting

The consequence of this geometry is that at least 50 percent of the liquid enters the conical basin as air. The overall result is that the internal quality of the bottom casting is barely any better than the top casting ingot.

Metal injection casting

When anti-gravity casting is done well, with cleaned metal free of dense populations of bifilms, and when transferred uphill, against gravity, carefully controlled by a pump, the resulting castings can be spectacularly excellent. Eventually, however, it was found that with counter-gravity it was difficult to make a bad casting, while with gravity casting it was difficult to make a good casting.

Vacuum casting

The steel casing is immersed in a massive steel holder, which is held closed during the impact of the filling process by hydraulic rams that develop hundreds or thousands of tons of force. Turbulence during the injection process, in which the metal velocity typically exceeds 50 to 100 m/s, is so great that defects are inevitably created, but are accepted as a feature of the process.

Vacuum induction melting (VIM)

The vacuum casting has a lower oxygen content, and is assumed to be cleaner, which in a way it is.

Secondary remelting

Vacuum arc remelting (VAR)

It is demonstrated by the cracking of the ingots during forging (unlike ESR ingots, which forge like butter). Since the ingots are forged better after removing 5 mm, most of the cracks are definitely removed.

Electroslag remelting (ESR)

The manufacturers machine approximately 5 mm depth from the outer surface as a sign gesture to remove cracks. The intrusion of the 'crown' of spatter and vaporized metal (Figure 7) into the forming rod can introduce additional macroscopic bifilms.

Metal processing

However, it is of course unlikely, given the variability of conditions during arc melting, that all were removed. A bifilm occupying a significant cross-sectional area of ​​the electrode can cause a large portion of the electrode to detach and fall into the melt.

Metal properties

  • Ductility
  • Fatigue
  • Creep
  • Pitting corrosion
  • Stress corrosion cracking (SCC)
  • Hydrogen embrittlement (HE)

In addition, the bifilm could be extensive, for example, it may have extended over most of the shaft. It is clear that bifilms inside the metal will also experience hydrogen gas pressure.

Figure 8 shows a typical etch pit. Although the conventional explanation of the  image would be that the etch pit has initiated the formation of cracks, the reverse  is true
Figure 8 shows a typical etch pit. Although the conventional explanation of the image would be that the etch pit has initiated the formation of cracks, the reverse is true

Conclusions

The blisters are the observation of bifilms, inflated by hydrogen, near the surface of the metal. Here the feeding of the solidifying casting is easiest, by the general lowering of the liquid metal surface in the mould.

Introduction

Casting, the final operation in production

As seen in Figure 1, the dendritic arm spacing (λ2) is measured from the surface of the casting in terms of 'd'. Such high solidification rates are seen as or within a short distance from the surface of the mold.

Castings with heavy mechanical working

This leads to the resulting variations in the properties of the casting, such as its strength ' 'σ and elongation ' 'ε. As the distance from the surface of the mold to the inside of the mold increases, the solidification rate decreases, λ2 increases and grain size of the casting increases, yielding a poor combination of mechanical properties.

Concept of nucleation

Homogeneous nucleation

Change of free energy (volume and interface) as a consequence of the creation of solid phase. The radius of the embryonic crystal must be greater than ' 'rc so that the free energy changes ∆G.

Heterogeneous nucleation

This free energy gained is proportional to the surface area of ​​the solid particle created. As seen in Figure 2, for small values ​​of 'r, the sum of free energy changes is positive.

Growth processes

  • Plane-front growth
  • Thermal super-cooling
  • Constitutional super cooling
  • Freezing of eutectic alloys
  • Other growth modes
  • The structure of the casting
  • The temperature gradient (G) and rate of cooling (R) ratio (G/R)
  • Further factors influencing the cast structure

Figure 2 also shows the overall change in free energy as a consequence of both components as a volume of solid is created in the melt. Schematic representation of solute rejection at the boundary (7(a)) and equilibrium temperature change (7(b)) as a consequence of solute accumulation.

Figure 8 clearly illustrates, before the actual (existing) temperature falls consid- consid-erably for growth to occur, there, is a pool of melt where considerable supercooling  can be witnessed at points farther within the melt
Figure 8 clearly illustrates, before the actual (existing) temperature falls consid- consid-erably for growth to occur, there, is a pool of melt where considerable supercooling can be witnessed at points farther within the melt

Mould feeding issues

Stage I

In general, the fragmented dendrules in the melt tend to settle to the bottom of the melt due to density differences between the solid dendrules and the surrounding liquid melt. Transport of crystallites by gravity or mass motion in the interior of the melt.

Stage II

Crystal multiplication is a consequence of fragmentation of dendritic arms in the column area due to local factors such as thermal fluctuations and change in growth rates, etc. Also, cores formed on the inside of the mold wall can be washed away when other metals are poured into the mold.

Stage III

Thus, any contraction can be easily compensated by a supply head with the general reduction in free liquid surface. This fine-grained structure can improve the ability of the casting to inhibit the sliding of the dislocations.

Freezing characteristics of alloys

The cooling rate on the other hand can be controlled by controlling the casting temperature of the metal, casting rate, promotion of differential cooling by use of chill, differential heating by addition of exothermic materials, use of filling, etc. A fine grain structure can therefore be obtained by proper selection of the casting rate and temperature.

Effect of temperature gradient on the feeding range of the alloys As mentioned earlier the temperature gradient in a casting system can be

These measures stiffen the temperature gradient helping to establish a path fed by the riser to the shrinkage locations in the mold. In these joints, solidification occurs simultaneously throughout most of the casting, and even throughout the casting.

Concluding remarks

The liquid solidifies in the mold and the solidified liquid, known as the casting, is finally removed from the mold. In the entire process of making a casting, solidification processes play an important role in deciding the structure of the casting, which dictates the structural properties of the casting and decides its final use.

Anna Gowsalya and Mahboob E. Afshan

Heat transfer mechanism in solidification

In general, the heat transfer behavior between the mold and the sand mold is used and all three modes of heat transfer are studied. The heat transfer characteristics of the mold are at a faster rate for a die mold than for the sand mold.

Shrinkage behavior of casting

  • Liquid shrinkage
  • Liquid- solid shrinkage
  • Solid shrinkage

Interfacial heat transfer coefficient (IHTC)

  • Air gap measurement technique
  • Numerical approaches (inverse method)
  • Behavior of IHTC for the given Al 6061

This leads to the sudden drop in heat flow and the formation of a firm skin on the outer casting surface [3]. Due to the induced thermal resistance, as the metal solidifies and contracts, a drop in IHTC is vividly observed.

Conclusion

Understanding the characteristics of heat transfer during solidification will help to relate the various developments in the microstructure of the materials and the displacements present. Determination of the interfacial heat transfer coefficient at the metal-sand mold interface in low-pressure sand casting Experimental Thermal and Fluid Science.

Application of casting simulation software

  • Casting Troubleshooting
  • Method optimization
  • Part design improvement

The simulation software can be used for the development of any new casting or it can be used to standardize any existing casting for any design changes to improve casting performance without floor testing. It is readily understood that simulation software will perform well if and only if the input parameters are close to real-world values.

Operational Methodology of simulation software This section has been discussed in following three subsections

  • Inputs
  • Outputs
  • Analysis

Casting troubleshooting, method optimization, and part design improvement are the three most important applications of casting simulation software. The casting simulation software can also be used to calculate the cost of the job in an indirect manner.

Intelligent design assistant

The conditions for ending the analysis are, for example, the flow rate and the time to be specified. Then the type of riser material, whether exothermic or not, must be specified as input.

Case study 1

It depends on three parameters, Geometry complexity, Minimum wall thickness and Weight of the component. To achieve the graphical representation of simulation behavior, some virtual thermocouples must be set at some strategic locations.

Case study 2

  • Iteration

The flow simulation of the product shows filling percentage with respective temperature scales as shown in Figure 4. Failure analysis of the knuckle and real cross section of critical location indicating zero defect.

Figure 9 indicates that major shrinkage defects have formed in the coupler  body and these are to be removed by adopting proper casting methodology
Figure 9 indicates that major shrinkage defects have formed in the coupler body and these are to be removed by adopting proper casting methodology

Conclusions

Finally, the effectiveness of the residue trap was verified by actual full-casting experiments. The authors also optimized the shapes of the runners in die castings by using CFD simulation and the shape optimization method for flowing molten metal [2].

Parameter identification for CFD simulation

In full mold casting, the heat of the metal breaks down the foam model and generates gaseous pyrolysis products. Therefore, the thickness of the gas layer between the metal and foam model is reduced due to the pyrolysis products.

CFD analysis and new gating system

  • Design of gating system based on CFD analysis
  • New gating system for full mold casting foam residue traps
  • Optimal design of residue traps

The optimum tails trap design is used for the capstan drum shown in Figure 2. The basic shape of the tails trap and the locations where the design variables are set are shown in Figure 6.

Verification of effectiveness by casting experiments

The part of the rim that does not come into contact with the residue trap suppresses the backflow of metal-containing residue. The experimental results of the conventional plan and the corresponding simulation results are shown in Figure 12.

Non-equilibrium thermodynamics

  • Nucleation and growth rates of oxide inclusions
  • Alumina morphology
  • Further growth of inclusions
  • Bond strength among particles

The free energy balance for the nucleation of an oxide that precipitates in the homogeneous melt includes the volumetric free energy and the surface energy that opposes the stabilization and growth of the nucleus. The nucleation process consumes short times of the order of microseconds as shown schematically by Figure 2.

Figure 4a and b show the effect of the supersaturation on the nucleation kinetics on the nucleation rates of different oxides recalculated from reference [26]
Figure 4a and b show the effect of the supersaturation on the nucleation kinetics on the nucleation rates of different oxides recalculated from reference [26]

Adherence of alumina particles on refractory surfaces

  • Adherence force

The contact angle 1 (between the inclusion and the melt) is greater than the contact angle 2 (between the refractory material and the melt). Therefore, the refractory material repels the metal and there is the adhesion of the recording to the wall.

Figure 17a shows the effects of the surface roughness on the contact angle or Wenzel angle
Figure 17a shows the effects of the surface roughness on the contact angle or Wenzel angle

Boundary conditions of wall adhesion

9]Zhang L., Thomas B.G., State of the art in inclusion control during steel casting. The majority of the studies on porosity formation in aluminum alloys have been carried out on aluminum silicon cast alloys [3–6].

Experimental procedure

19] investigated the role of iron in the formation of porosity in Al-Si-Cu based casting alloys. It should be mentioned here that the production of the grain refiner produces Al2O3 which will increase in the amount of porosity.

Table 1 lists the chemical composition of the as received ingots. The ingots of  each alloy were cut, cleaned and melted in an electrical heated furnace using 6 kg  SiC crucibles
Table 1 lists the chemical composition of the as received ingots. The ingots of each alloy were cut, cleaned and melted in an electrical heated furnace using 6 kg SiC crucibles

Results and discussion 1 Grain size

  • Porosity

The black arrows highlight the presence of (Al.Si)3Ti platelets near the oxide films. Figure 15(b) and (c) confirm the presence of the oxide films interacting with the β-Al5FeSi platelets.

Conclusions

Change in hardness of alloy A319.0 as a function of aging temperature and applied melt treatment. Roy, Porosity Formation in Al-Si-Cu Alloys: The Role of Intermetallics, in Proceedings of the Light Metals Symposium, CIM 35th Annual Conference of Metallurgists, Montreal, Quebec, August, p.

Feeder System Design for Solidification Contraction

The latter effectively means that the thermal center of the entire casting must eventually migrate to the feeder/s, where high porosity will form due to hot spots or in the form of tube shrinkage. However, this is not necessary in power system design, since substituting Eq. where module m was introduced.

Interdendritic feeding

  • Solidification Characterisation of Steels
  • Mushy zone feeding

1 For a real steel, the phase diagram will differ slightly due to the influence of the alloying elements. The nucleation and growth of the solid phase in the mushy zone is accompanied by very complex phenomena, not all of which can be adequately dealt with in this chapter.

Classification of Shrinkage Porosity Types

In the previous sections, the mechanisms for the formation of shrinkage porosity were discussed from a thermal point of view - that is, during solidification of the pulpy zone. Therefore, the length scales of microporosity in shrinkage can be only a few microns and increase to multiple SDAS values ​​in the case of an interconnected interdendritic melt.

Porosity inspection

In this chapter, reference will be limited to ASTM Standard E2868 (Standard Digital Reference Radiographs for Steel Castings up to 2 inches (50.8 mm) in Thickness). Reference radiographs can be created to a comparable resolution (pixel size) to that of production radiographs.

Summary

Shrinkage Porosity Reduction in High Performance Steel Castings: The Case of an ASME B16.34 Gate Valve Body: Part 2 - Simulation and Experimental. Shrinkage Porosity Reduction in High Performance Steel Castings: The Case of an ASME B16.34 Gate Valve Body: Part 1 - Analysis, Techniques and Experimental.

Hình ảnh

Figure 8 shows a typical etch pit. Although the conventional explanation of the  image would be that the etch pit has initiated the formation of cracks, the reverse  is true
Figure 8 clearly illustrates, before the actual (existing) temperature falls consid- consid-erably for growth to occur, there, is a pool of melt where considerable supercooling  can be witnessed at points farther within the melt
Figure 9 indicates that major shrinkage defects have formed in the coupler  body and these are to be removed by adopting proper casting methodology
Figure 9 indicates that major shrinkage defects have formed in the coupler  body and these are to be removed by adopting proper casting methodology
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