Abstract
Defects in investment casting will inevitably reduce the lifetime, degrade the quality of the casting, and increase the manufacturing costs. In this paper, the potential for shrinkage porosity was numerically determined and a retained melt modulus (RMM) model was implemented to analyze highly probable regions. The proposed casting schemes of gating designs are compared by the quality of casting (shrinkage porosity) and practical feasibility in terms of small hole drilling machinability. The purpose of this study was to determine the feasible plan with the lowest PES (percentage of elements with shrinkage porosity) while promoting near-net shape casting with minimum machining cost and increasing material usage. Virtual thermo-dynamical sensors (VTDSs) were adopted in the simulations to indicate the impacts of different pattern assembly gating systems on the cooling gradient and direction of solidification. VTDSs were used in simulating and virtually monitoring the casting systems, with the aim of characterizing the rates and directions of solidification in various regions of the cast. The best-case scenario of investment casting conditions was chosen to fabricate valve housing in an investment casting foundry. The experimental results of the X-ray image differentiated nearly none of the pernicious defects that typically occurred with the proposed casting, confirming the efficacy of the proposed scheme accordingly.
Highlights
Industrial meters are widely used in various sectors to measure velocities, flow, pressure, etc., such as liquid valve and gas valve
The numerical simulations based on the modulus method were used to predict where and how shrinkage defects can form in stainless steel (316L) industrial meter housing for the valve
Our simulation results illustrate that the gating system (Case D) extended could reduce most casting defects
Summary
Industrial meters are widely used in various sectors to measure velocities, flow, pressure, etc., such as liquid valve and gas valve. These systems are subject to high pressure or even corrosive environments and must maintain perfect sealing performance, which means that the parts have an increased risk of corrosion and leakage and require regular maintenance. The casting processes of 316L valve housing have been simulated with the numerical method. A closer casting pattern assembly method is used, and there is some shrinkage porosity found on the surface of the simulation result and trial casting. The feeding system is a structure for storing the molten material to compensate for the possible shrinkage in the solidification phase during the casting process [15,16,17]
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