Casting Defects Research Articles

An innovative thermal simulation study of microstructure improvement by delay forging during solidification

The solid fraction at the beginning of the forging process is an important factor affecting the performance of the casting-forging integrated forming, which is an innovative and efficient process. The solid fraction depends on the delayed forging time during the casting-forging integrated forming. This paper investigates the effect of delayed forging time on the microstructure of aluminum alloy forged during solidification using an innovative physical simulation method. In this work, a solidification-forging device compatible with the Gleeble system has been developed. Then, experiments were conducted at various delayed forging time. Temperature and force data were collected using the Gleeble system for analysis. Microstructural evolution was investigated using methods including Optical Microscopy (OM), Scanning Electron Microscopy (SEM), Electron Backscattered Diffraction (EBSD), and Three Dimensional Computed Tomography (3D-CT). The results demonstrate that with the extension of the delayed forging time, the grain size of the alloy decreases gradually, and the coarse dendrite structure changes to the rose-shaped grains, and the local misorientation in the grain increases. Moreover, the effect of forging under different forging time on the casting defects of the alloy is studied. When the forging delay is extended to 8 s, the forging promotes the porosity caused by the liquid phase convection. However, with further extension of forging delay, the reduction of the liquid phase and the fracture of dendrites lead to the complexity of liquid phase channels, resulting in the increase of porosity. Additionally, forging near solidification can close shrinkage porosity.

A Strain Integrated Gas Infusion Process (SIGI) for Magnesium Alloy Castings

This study presents a Strain Integrated Gas Infusion Process (SIGI) to manufacture high-performance cast AZ91 magnesium alloys without the addition of secondary alloying elements/reinforcements or secondary processing. The current SIGI process involves a combination of agitation and localized rapid heat extraction via strain integration and high-energy gas infiltration. The SIGI casting process has been compared systematically with conventional techniques. The critical process parameters, including hole diameter, bubble diameter, and flow rate, have been optimized through numerical calculations, simulations, extensive experiments, and comprehensive analysis. The study also focused on investigating the effect of gas bubbles on the molten metal and established the mechanisms involved in improved solidification. Gas infusion combined with strain integration impacts the solidification process, ensuring uniform alloying element distribution and reducing segregation and microporosity. This manufacturing strategy eliminates casting defects such as segregation and microporosity, resulting in a non-dendritic homogeneous microstructure. The significant refinement in morphologies of both primary (α-Mg dendrites) and secondary (β-Mg17Al12 phase) phases highlights the success of the current SIGI process. Compared to the conventional casting processes, a remarkable improvement in strength-ductility synergy is achieved in the current SIGI process. The scientific know-how and efficiency of the current SIGI process are established and discussed in detail, providing a promising solution to address the existing challenges encountered in magnesium alloy billet castings. The SIGI process improves the mechanical properties and corrosion resistance of billet-cast magnesium alloys. The SIGI process is suitable for the billet casting, offering significantly improved properties but faces limitations in complex mold casting applications. The billets casted by SIGI process can be used as a high-quality precursors for downstream processes to create industrial components.

Modelling freckles and spurious grain formation in directionally solidified superalloy castings

Segregation channels with misoriented spurious grains, known as freckles, are an unacceptable casting defect in superalloy turbine blades. A digital-twin method to predict segregation channels was proposed in our previous studies; however, the formation of spurious grains was ignored. Here, we extend the digital twin methodology by incorporating dendrite fragmentation, which is recognized as the predominant mechanism in the formation of spurious grains. The flow-induced fragmentation process has been refined to account for the timing of dendrite pinch-off. A three-phase mixed columnar-equiaxed solidification model was used to track the motion of the crystal fragments. Directional solidification experiments for superalloy casting were conducted in an industrial-scale Bridgman furnace, and the distribution of spurious grains in the freckles was metallographically analysed. Excellent simulation-experiment-agreement was achieved. Based on this study, the formation of spurious grains within the segregation channels is mainly caused by the flow-driven fragmentation mechanism. Experimentally measured freckles can be reproduced only if the timing of the dendrite pinch-off is considered.

Surface defect detection method of aluminium alloy castings based on data enhancement and CRT‐DETR

AbstractThe surface quality of aluminium alloy castings is crucial to quality control. Aiming to address the challenges of limited samples and extensive computation in deep learning‐based surface defect detection for aluminium alloy castings, this paper proposes a surface defect detection method based on data enhancement and the Casting Real‐Time DEtection TRansformer. First, to tackle the issue of small sample sizes and uneven distribution in surface defect data sets of aluminium alloy castings, ECA‐MetaAconC Deep Convolution Generative Adversarial Networks is proposed for generating defects with fewer samples and employ the image augmentation (IMGAUG) library for sample enhancement. Second, building upon the Real‐Time DEtection TRansformer (RT‐DETR), a lightweight partial‐rep convolution is designed to decrease the network's parameter count. Simultaneously, the Deformable attention module and the DRBC3 module are introduced to enhance the neck network, thereby improving the model's capability to capture information and enhancing its detection performance. Compared to RT‐DETR, this method reduces the number of model parameters by 38.7%, increases mAP by 1.5%, and achieves a frame rate that is 1.58 times higher than the original model. The experimental results demonstrate that this method can effectively and accurately detect surface defects in aluminium alloy castings, satisfying industrial requirements.

Attention Pyramid Dilated Region-based Model for Metallurgical Defect Detection

Abstract Defect recognition is the key to realizing automatic visual inspection and quality control in intelligent manufacturing. Deep learning (DL) has been widely applied to locate damaged areas in images, characterize impurities of materials and further analyze the quality of products. However, automatic defect detection by DL in practical industrial applications is still a challenge due to the lack of sufficient datasets and appropriate recognition methods. Here, a novel Attention Pyramid Dilated Region-based Convolutional Neural Network (ADRCNN) is proposed to realize the multi-scale defect recognition and pixel-level instance segmentation of metallographic images. We also collected a dataset containing 900 images of commercial A356 aluminum alloy with different casting defects. The ADRCNN model is evaluated on our dataset with an average detection accuracy of 87.2% and 93.3% on validation and test sets respectively. To address the overfitting problem, a pretraining fine-tuning strategy is implemented by using the pretraining weights from large-scale datasets and temporarily freezing the weights of the backbone network during the training process. The experimental results show that the proposed model can achieve satisfactory defect segmentation in metallographic images, promoting the development of intelligent manufacturing in alloy industries.

Comparison of the hardness value and microstructure of Al6061 in horizontal centrifugal casting with and without mold cooling

The object of this research is the horizontal centrifugal casting process of the Al6061 alloy. Usually, cast products experience some casting defects, so the horizontal centrifugal casting process is applied to reduce the possibility of casting defects arising. In some casting processes, especially in the production of cylindrical specimens, casting defects such as porosity are encountered. Therefore, horizontal centrifugal casting was applied to overcome this problem. The test results show that the average hardness value for aluminum 6061 specimens resulting from centrifugal casting products with water cooling was 73.3 HRE, while the average hardness value for aluminum 6061 specimens resulting from centrifugal casting products without water cooling was 86.4 HRE. The microstructure results show that the grain size of centrifugal casting products with water cooling was 82.5 µm, whereas without water cooling it was 75 µm. Higher hardness values were obtained in specimens without mold cooling, this is because the conductivity in molds without cooling was higher compared to molds that experienced water cooling. The higher the heat conductivity of the mold, the faster the cooling process of the cast product. The casting process using the horizontal centrifugal method can be carried out to produce cylindrical spare parts

Silicon carbide-embedded AZ91E alloy nanocomposite hybridised with chopped basalt fibre: performance measures

ABSTRACT This study uses vacuum stir casting to manufacture magnesium alloy hybrid nanocomposites of silicon carbide nanoparticles (50 nm) and chopped basalt fibre. The different weight percentages (0 wt%, 3 wt%, 6 wt% and 9 wt%) of chopped basalt fibres with a constant weight percentage of 7.5 wt.% silicon carbide nanoparticles were added into molten AZ91E magnesium alloy at 600 rpm constant stirring speed. During the final casting process, 0.1 MPa vacuum pressure was applied to all the composites to reduce the casting defects. The prepared hybrid composite was characterised by physical, mechanical, microstructural and wear properties. The Quanta FEG model SEM apparatus was used to examine the distribution of silicon carbide nanoparticles and basalt fibre. The mechanical characteristics, such as ultimate tensile strength (UTS), yield strength and impact strength, were obtained for 7.5 wt% SiCnp/9 wt% basalt fibre reinforced AZ91E magnesium alloy matrix hybrid nanocomposite. Adding chopped basalt fibre enhanced the wear properties of conventional AZ91E magnesium alloy.

A novel framework for low-contrast and random multi-scale blade casting defect detection by an adaptive global dynamic detection transformer

The radiographic inspection plays a crucial role in ensuring the casting quality for improving the service life under harsh environments. However, due to the low-contrast between the defects and the image background, the random spatial position distribution, random shapes and aspect ratios of the defects, the development of an accurate defect automatic detection system is still challenging. To address these issues, this paper proposes a novel framework for low-contrast and random multi-scale casting defect detection, which is referred to as adaptive global dynamic detection transformer (AGD-DETR). A novel defect-aware data augmentation method is first proposed to adaptively highlight the feature of the low-contrast defect boundary. A multi-attentional pyramid feature refinement (MPFR) module is then established to refine and fuse the multi-scale defect features of random sizes. Afterwards, a novel global dynamic receptive fusion-transformer (GDRF-Transformer) detection scheme is designed to perform the global perception and feature dynamic extraction of complex internal casting defects. It includes 4D-anchor query and cross-layer box update strategy, query rectification by prior information of defect aspect ratio, and global adaptive-feed forward network (GA-FFN). A dataset comprising turbine blade casting defect radiographic (TBCDR) images, is used to demonstrate the high efficiency of the proposed AGD-DETR. The obtained results show that the proposed method can accurately capture the spatial position distributions and complex defect shapes. Furthermore, it outperforms existing state-of-the-art defect detection methods.

Assessment of biodegradability and biocompatibility: An experimental and comparative analysis of magnesium and magnesium-(zinc-tin)/hydroxyapatite composites

This study presents the fabrication and comparative assessment of biodegradation and biocompatibility behaviors of pure Mg, Mg/HA (Hydroxyapatite), Mg-Zn/HA, and Mg-Sn/HA composites with fixed 5 wt% HA and 1 wt% each of Zn and Sn, using novel ultrasonic-assisted rheo casting technology. Characterization techniques, including X-ray diffractometry and scanning electron microscopy integrated with energy dispersive spectroscopy, were employed to analyze phase formation, surface morphology, and elemental composition. Microhardness tests were conducted to assess indentation resistance, while in vitro corrosion performance was evaluated in simulated bodily fluid to compare degradation behavior. Results indicate a uniform distribution of reinforced particles within the matrix with minimal casting defects. Intermetallic phases MgZn and Mg2Sn precipitated along grain boundaries in Mg-Zn/HA and Mg-Sn/HA composites. The Mg-Sn/HA composite exhibited peak microhardness (94.8 HV) due to precipitation strengthening. In contrast, Mg-Zn/HA samples showed a low degradation rate (0.19 mm/yr) and H2 gas evolution rate (0.035 ml/mm2), attributed to uniform distribution of secondary phases and fine grains that mitigate galvanic cell formation and control degradation. Cell viability assay results demonstrated that Mg-Zn/HA composite outperformed all other samples, showing a 94% relative cell growth rate of osteosarcoma MG-63 cells after 2 h of incubation, attributed to strong apatite formation (rich in Ca and P) on the surface post-immersion, promoting cell proliferation.

Corrosion properties of submerged friction stir modified as-cast nickel-aluminum bronze (NAB) compositions

This study aimed to analyze the effects of adding alloying elements and cooling medium during friction stirring on the electrochemical and immersion corrosion properties. The results showed that the addition of nickel and iron prevented the formation of an unfavorable phase γ2 and instead produced intermetallic compounds κ in the microstructure. Friction stir processing (FSP) helped refine and homogenize the coarse and inhomogeneous structure of the casting, and also eliminated casting defects, whether performed in air or underwater conditions. The polarization and electrochemical impedance tests revealed that, in most cases, FSP led to a decrease in electrochemical and short-term corrosion behaviors as compared to the as-cast specimens, under the impact of alloy composition and active cooling. However, the weight loss immersion tests indicated that the friction stir processed alloys, particularly those processed underwater, demonstrated the best long-term corrosion properties. It was observed that the corrosion product film created on all models after immersion had a similar composition.

Effect of annealing treatment on the mechanical properties and corrosion behaviour of Co40Cr20Ni30Al4.5Ti5Mo0.5 high-entropy alloy

Cast high-entropy alloys are frequently found to have large internal tensions, compositional segregation, and shrinkage defects, which can directly prevent them from performing as intended. Proper heat treatment can modify the internal structure of an alloy and enhance its overall performance. This study describes a new nonequiatomic proportional cast Co40Cr20Ni30Al4.5Ti5Mo0.5 high-entropy alloy prepared by a vacuum induction melting technique. The impacts of different annealing temperatures (700, 800, 900, and 1000 °C) on the microstructure evolution mechanism, mechanical properties and corrosion behaviour of the alloy are systematically examined. The results show that the heat treatment can successfully improve the overall mechanical properties and corrosion resistance of high-entropy alloys while suppressing casting defects. The alloy exhibits the best overall mechanical properties after annealing at 700 °C, with a yield strength of 923 MPa and a tensile strength of 1090 MPa. After annealing at a temperature of 800 °C, the alloy demonstrates excellent corrosion resistance, characterized by a low passivation current density, a large passivation range, and a high corrosion potential. Specifically, ipass is measured to be 4.59 × 10−7A/cm2, and Ecorr is −319 mV. Furthermore, the maximum Cr2O3 oxide content in the alloy passivation film formed at 800 °C contributes to the passivation film stability.

On the application of reduced pressure test for the prediction of ductility of 46000 alloy: Role of pore's morphology and distribution

Bifilms have been proposed to be critical for forming casting defects. The reduced pressure test (RPT) and bifilm index (BI) have been widely studied and used in industry for melt quality assessment. However, the BI remains challenged in predicting the mechanical properties. This work investigated the usage of RPT for elongation prediction by analyzing the melt in two foundries. The results showed that the BI could be valid when the bifilms exist as fully inflated pores. In reality, bifilms present as pores with various morphology and distribution, generating local stress concentrations under tension. Consequently, the parameter areaeff, which considers the pores’ morphology and distribution, was proposed, and the resultant feff showed a good correlation with the elongation of the castings. These results guide the foundry to predict the elongation of the final castings and give directions for further research on the bifilm defects.

Design and Development of LM24 plate Casting using Solid Cast Simulation Technique

Abstract: This research deals with the elimination of defects in aluminium alloy castings and enhancement in the casting yield and quality. The main intention of the work is to improve the quality of a cast component using Computer Aided Casting Simulation Software. SOLID Cast simulation software is used for simulating the solidification process of casting and visualizing outputs showing possible problematic areas or defects which may occur in the cast product. Plate Castings of aluminium alloy - LM 24 are produced with different designs of gating systems and tested for defects like porosity using Archimedes immersion Technique and also Radiographic testing is used to check the quality of the castings. The produced castings are observed to be sound, and the results obtained are in agreement with the simulation results. Hence it is verified that solidification simulation helps in improving the quality of castings without any shop-floor trails. Casting yield and percentage porosity values are determined for 12 castings produced with different gating systems. The best results are observed to be produced by the castings having a 1-Ingate system in horizontal or lateral positions.

High mechanical properties of CNTs/Al composites achieved by second phase refinement and reinforcement dispersion via hot extrusion

The carbon nanotubes (CNTs) reinforced 2A70 alloy by the coating of ZrO2 (ZrO2@CNTs/2A70) are processed by a hot extrusion process. The microstructure and mechanical properties of ZrO2@CNTs/2A70 composites were investigated in this study. The results show that the second phase of the composites is broken and uniformly dispersed under the action of shear force and the second phase as well as the ZrO2@CNTs reinforcement is uniformly distributed along the extrusion direction. The hot extrusion process eliminates the cast defects and improves the reinforcing phase's dispersion and the material's mechanical properties are significantly improved. At the extrusion ratio of 25, the composites exhibited notable enhancements in their mechanical properties, as evidenced by a significant increase in hardness, yield strength (YS), ultimate tensile strength (UTS), and elongation (EL), with respective values of 141.7 HV, 237.4 MPa, 309.7 MPa and 13.9%. These values were higher than those obtained from cast composites by 17.5%, 20.0%, 20.9% and 152.7%, respectively. The fracture characteristics of the composite are mainly ductile fractures. Besides, the extruded composites are strengthened mainly by grain refinement and load transfer mechanism.

Homogenization Path Based on 250 mm × 280 mm Bloom under Mixed Light and Heavy Presses: Simulation and Industrial Studies

This study proposed a new method for homogenizing continuous casting blooms based on solidification simulation calculations and industrial tests. The text describes a theoretical analysis of the solidification route of a cast billet of high-carbon alloy steel (B300A) under different process conditions. It summarizes the changing law of different under-pressure process parameters and under-pressure efficiency. The text also presents a solution to the seriousness of center shrinkage defects in the continuous casting of a large square billet of high-carbon alloy steel with the synergistic control technology of mixed light and heavy mixing under pressure. The study indicates that the center carbon segregation index of a high carbon steel continuous casting billet is 1.05, with a carbon extreme difference of not more than 0.08% and a proportion of 98.4%. Additionally, the center shrinkage is not more than a 0.5 level with a proportion of 99.5%. Meanwhile, the internal quality of cast billets has been improved, allowing for the rolling of large-size bars with a low consolidation ratio. The pass rate for internal ultrasonic flaw detection using the GB/T4162A grade is now higher than 99.95%, significantly reducing process costs and improving production efficiency for continuous casting and rolling.

Numerical Simulation of Lost-Foam Casting for Key Components of A356 Aluminum Alloy in New Energy Vehicles.

The intricate geometry and thin walls of the motor housing in new energy vehicles render it susceptible to casting defects during conventional casting processes. However, the lost-foam casting process holds a unique advantage in eliminating casting defects and ensuring the strength and air-tightness of thin-walled castings. In this paper, the lost-foam casting process of thin-walled A356 alloy motor housing was simulated using ProCAST software (2016.0). The results indicate that the filling process is stable and exhibits characteristics of diffusive filling. Solidification occurs gradually from thin to thick. Defect positions are accurately predicted. Through analysis of the defect volume range, the optimal process parameter combination is determined to be a pouring temperature of 700 °C, an interfacial heat transfer coefficient of 50, and a sand thermal conductivity coefficient of 0.5. Microscopic analysis of the motor housing fabricated using the process optimized through numerical simulations reveals the absence of defects such as shrinkage at critical locations.

Detection method of micro and macro scale defects in silicon carbide castings

Aiming at challenges such as low efficiency, high missing rate, difficulty in identifying contour defects, and difficulty in extracting tiny defects, a defect detection method for extracting micro and macro scale defects is proposed in this paper. After preprocessing the image, contour detection is performed to identify the contours. Subsequently, a contour complementation algorithm is employed to complement the unclosed contours. Finally, the detection of micro scale defects is conducted based on the grayscale variation of the center of the micro scale defects. The experimental results show that compared with the traditional method, the proposed algorithm can accurately detect the bubble defects of different scales in silicon carbide castings and can identify the complex defects better.

Optimizing Factors affecting gas porosity in GDC of Al-Si (A356) Alloy using Taguchi’s DOE

Aluminium alloys find extensive use in various applications because of its advantage of strength-to-weight ratio,. However, the casting process introduces susceptibility to defects, and managing all parameters proves to be a complex task. Casting rejections often stem from one or more defects, with mold parameters, filling, and solidification processes being key contributors. When the molten metal of the Al-Si (A356) alloy is exposed to the atmosphere in a holding furnace, it develops an oxide layer on its surface. Turbulence in the molten metal leads to the formation of a double oxide layer, also known as bifilms. Gas entrainment occurs due to the turbulent movement of metal, resulting in the entrapment of gas in the molten metal and ultimately causing gas porosity in the final casting. Gas entrapment during the filling process leads to gas porosities during the solidification phase.This study aims to comprehend the factors influencing the formation of gas entrapment during the casting of the aluminium alloy Al-Si (A356). The experimental investigation utilizes Taguchi’s Design of Experiments (DOE) to explore the impacts of parameters such as pouring temperature (PoT), degassing time (DgT), and volume in the holding furnace (VoH) on the formation of gas porosity in casting [8].An experimental setup was created to produce tensile test rods and reduced pressure test (RPT) samples. The results were validated using the mechanical properties of the tensile test samples and the density of the Reduced Pressure Test (RPT) samples. Better the mechanical properties, fewer will be the defects in castings. Taguchi’s DOE is applied to analyse the results. The experimental findings indicate that a pouring temperature at level 1 (710°C), degassing time at level 1 (10 minutes), and volume in the holding furnace at level 1 (>450 kg) yield favourable castings. Confirmatory tests were conducted to validate the results, and they aligned with the experimental data.

Thermo-Mechanical Optimization of Die Casting Molds Using Topology Optimization and Numerical Simulations.

Conventional cooling channels used in die casting molds exhibit significant drawbacks, resulting in extended cooling times for cast parts. Issues such as the formation of dirt, limescale, and corrosion substantially diminish the thermal efficiency of these channels, leading to challenges in achieving uniform cooling and potential quality issues. In response to these challenges, this study proposes Topology Optimization as a novel approach. It involves designing cooling structures through Topology Optimization to replace traditional cooling channels, incorporating both Discrete and Gaussian boundary conditions to optimize thermal efficiency. Additionally, Structural Topology Optimization is employed to ensure structural integrity, preventing deformation or yielding under high loads during the die casting process. Numerical analysis revealed superior thermal performance compared to conventional channels, particularly when subjected to Discrete and Gaussian boundary conditions. Furthermore, the application of the latter establishes conformal cooling and minimizes temperature gradients in the casting, reducing casting defects such as shrinkage porosity. These findings highlight the efficacy of Topology Optimization in addressing the challenges of traditional cooling methods, with wide-ranging implications for manufacturing processes utilizing permanent molds for shaping materials.

The influence of hot isostatic pressing on precipitates, mechanical properties of Mg-12Gd-0.8Zn-0.4Zr (wt.%) alloy manufactured by sand casting

Microstructures and mechanical properties of Mg-12Gd-0.8Zn-0.4Zr (GZ1208K, wt.%) alloy under different treatments (as-cast: signed as nonHIP-GZ1208K, hot isostatic pressing (HIP): signed as HIP-GZ1208K) were characterized. Based on microstructure characterization, two prismatic precipitates, β′ and β1 precipitates, and one basal precipitate, γ′ precipitate, formed in both of nonHIP-GZ1208K and HIP-GZ1208K alloy. According to analysis, the area number density and the size of β′ precipitate could be adjusted through HIP treatment. The area number density of β′ precipitate increased after HIP treatment when aged at 32 h, and the size of β′ precipitate refined in both of the HIP-GZ1208K alloy aged at 8 h and 32 h. Except the influence of HIP treatment on microstructures, the ultimate tensile strength (UTS) and elongation of nonHIP-GZ1208K alloy also improved after HIP treatment. The UTS of the GZ1208K alloy aged at 8 h increased from 348 MPa (nonHIP-) to 371 MPa (HIP-) and the elongation increased from 2.6% to 4.7%. The density of the nonHIP-GZ1208K alloy increased after HIP treatment, that is to say the casting defects could be eliminated and the compactness of microstructures could be increased under the high pressure of HIP treatment.