Casting Process Research Articles

The temperature field characteristics and amorphous formation ability during the continuous casting process of Zr-based bulk metallic glass

This study utilized FLUENT dynamic mesh simulation technology to simulate the temperature field distribution characteristics during the continuous casting (CC) process of 5 mm thick Zr41.2Ti13.8Cu12.5Ni10.0Be22.5 (Vit1) bulk metallic glass (BMG), analyzed and discussed the amorphous forming ability of the Vit1 BMG plate prepared through CC. The results indicate that during the CC process, the temperature gradient and cooling rate of Vit1 BMG plate decrease with increasing distance from the cooling copper block surface and prolonged solidification time. Even at the lowest cooling rate, it still remains significantly higher than the critical cooling rate (Rc) of Vit1 bulk amorphous alloy. The temperature variations recorded by the thermocouple during the alloy melt solidification process are in basic agreement with the simulation data. The experimental test and simulation results show that 5 mm thick Vit1 BMG slab can be prepared theoretically by continuous casting technology. Finally, XRD, DSC and TEM were used to analyze the amorphous formation ability and microstructure of the Vit1 BMG slab.

Stress state of billet – mandrel system during production of hollow steel billet in a unit of continuous casting and deformation. Part 2

The paper presents the results of theoretical research of stress-strain state of a billet – mandrel system when producing steel hollow billets in a unit of combined continuous casting and deformation, in which the working surface of the calibrated anvils are made with a variable radius. The necessity of making the working surface of the calibrated anvils with a variable radius is substantiated and initial data for the calculations is given. The calculation results are considered along the lines of the volumetric model passing through the characteristic points of deformation centers. The authors determined the forces when the anvils compress the wall of a hollow billet and the force of pulling the hollow billet from the mold. The laws of metal axial displacements and stresses in the deformation centers during compressing the wall of a hollow billet was established at the combined process of continuous casting and deformation in the unit. Nature of the stressed state of the metal wall of a hollow billet is considered from the perspective of improving its quality. The technique studied allows to determine the stress-strain state of a mandrel when producing a hollow steel billet using such a unit. The authors provided the recommendations for reliable gripping and compression with calibrated anvils of a hollow steel billet coming from a water-cooled copper mold of the unit of combined continuous casting and deformation.

Defect prediction and performance optimization of A413 vertical centrifugal castings through FEA-based simulation

This study benefits from advanced simulation based on finite element analysis, where finite element analysis possesses robust numerical algorithms to confront critical industrial challenges, including prediction and optimization techniques. The primary goal is to predict the location and quantity of shrinkage porosity and air entrainment, and to mitigate them by optimizing key casting process factors while considering the geometric effects. Virtual experiments designed through the Taguchi method, with three parameters (aspect ratio, pouring temperature, and mold rotation speed) at five levels each, were conducted using the finite element analysis software ProCAST. Post-experimentation, comprehensive data analyses, including signal-to-noise ratio and response surface methods, were employed to determine optimal conditions. Additionally, a sophisticated regression model was developed to clarify the complex relationship between key parameters and defect aspects. Optimal conditions to reduce shrinkage porosity were identified within parameter ranges of (50–75) rpm, (750–800) °C, and (1.75–2) aspect ratio. Similarly, optimal parameters to reduce air entrainment were identified as 150 rpm, 800 °C, and (1) aspect ratio.

Separation of Used Coolants From High-Pressure Aluminium Alloys Die-Casting Via Turbidimetric Method

Abstract The growth of the automotive industry and increased efforts to reduce the environmental impact of transportation require the use of more and more aluminium components in the production of new cars. The process of high-pressure die casting of aluminium makes it possible to meet the goals, but it requires the use of coolants based on oil and wax emulsions that are difficult to dispose of. A method for demulsification of real wastewater samples from the high pressure die casting process was developed and evaluated. The optimal parameters for conducting the separation process were determined, and the changes occurring in the emulsion being separated were analysed.

Study of Some Physical and Antibacterial Properties of Bio-based (PLA)/(PCL) Blend reinforced with ZrO2 Nanoparticles

The aim of this study was to produce flexible films by combining polylactic acid (PLA) and poly(ε-caprolactone) (PCL), and enhance their strength by reinforcing them with different weight percentages (0.75, 1.5, and 2.25%) of zirconium oxide (ZrO2) nanoparticles (NPs) using a solvent casting process. The physical and antibacterial properties of the films were analysed to determine their suitability for use in food packaging. X-ray diffraction (XRD) patterns of the PLA/PCL films containing 2.25% by weight ZrO2 nanoparticles have a peak at an angle of 2θ = 17.18°, accompanied by smaller peaks. This confirms that these thin films have a semi-crystalline structure and that the molecules in the thin films are well dispersed. Scanning electron microscopy (SEM) analysis of the film surfaces reveals that the pure PLA/PCL films exhibit a smooth surface, while the (PLA/PCL/ZrO2NPs) films have a rough surface. The thermal behaviour of the blends through differential scanning calorimetry (DSC) showed fluctuations due to variations in the reinforcement ratio, resulting in changes in the glass transition and melting temperatures. These oscillations indicate changes in the level of crystallinity. ZnO2 has antibacterial properties that promote growth inhibition, making these films more effective in food packaging.

Optimizing hot tearing susceptibility of Al-5.5Zn-2.4 Mg-1.3Cu alloys by grain refinement, increasing mold and casting temperature

The Al-Zn-Mg-Cu alloy is widely used in automotive lightweighting and other applications due to its excellent mechanical properties. However, when this alloy is cast using metal molds, it exhibits high hot tearing susceptibility (HTS), increasing the risk of use. Volumetric shrinkage due to density differences during the transition from liquid to solid metal produces shrinkage stresses. At the same time, lacks feeding of the remaining liquid phase in the late solidification stage can also lead to hot tearing. The purpose of this paper is to present a device for quantitatively determining and optimizing HTS. The relationship between solidification shrinkage displacement and stress was tested in a quantitative way using a Self-designed T-tester equipped with stress and displacement sensors. The test results show that the reduction of grain size shifts the solidification shrinkage of the alloy and reduces the solidification shrinkage stress, which avoids hot tearing caused by higher solidification shrinkage stress and local stress inhomogeneity. Secondly, the grain size reduction increases the number of feeding channels in the solidification vulnerable stage, and more liquid phase is available for crack healing. In addition, the influence of casting process parameters on the HTS was studied.

A Study of the Influence of Engineering Support on the Quality of the Molding Process of Basalt–Plastics Using Vacuum Infusion

A Study of the Influence of Engineering Support on the Quality of the Molding Process of Basalt–Plastics Using Vacuum Infusion

Epoxy Composites with Post-Production Gray Cast-Iron Powders.

Processing of cast-iron castings by machining is associated with a large amount of post-production waste in the form of cast-iron chips, which constitute up to about 5% of the weight of the entire casting. In the case of serial production, this generates large amounts of post-production waste, constituting a constantly growing scale of environmental problems. The aim of this research was to develop a simple and cheap method of utilizing post-production waste of gray cast-iron chips from the machining process for the production of small structural elements of water supply fittings. The analysis of the state of knowledge indicates that the simplest method of managing waste chips is to use them as a starting material in the process of manufacturing polymer composites. The most frequently chosen material for the matrix of polymer composites reinforced with metal powders is epoxy resin. The epoxy composite was produced by the vacuum-assisted casting method. This paper presents the results of tests of morphological, mechanical, and corrosion properties of epoxy composites filled with grey cast-iron powder with a grain size below 0.075 mm and a mass content in the composite of 65%. The composite cured at 130 °C for 90 min had the best mechanical properties. The sample cured at 130 °C for 90 min was observed to have the optimum effect, with a tensile strength of 28.35 MPa, a flexural strength of 55.4 MPa, and a compressive strength of 53.8 MPa. All tested composites were characterized by very good thermal resistance and, in comparison to gray cast iron, over 2.5 times lower weight and an over three times lower corrosion rate in the tap water environment.

Formation mechanism of edge crack during hot rolling process of high-grade non-oriented electrical steel

Edge crack formed during the hot rolling process significantly affected the quality of high-grade non-oriented electrical steel (NOES), posing substantial challenges to production. This study investigated the formation mechanism of serrated edge cracks in hot rolled strip, characterized by unusually coarse strip-like grains with typical thicknesses ranging from 0.5 to 0.8 mm and lengths ranging from 10 to 15 mm. These coarse strip-like grains evolved from abnormal columnar grains at the edges of reheating slab. During the continuous casting process, the bulge phenomenon occurred easily in high-grade NOES slabs, due to its lower yield strength at high temperatures. This bulge induced high internal stress at the slab edge, leading to abnormal growth of the columnar grains during the slab reheating process at high temperature. The orientation of coarse grains gradually changed to a rotated cube texture ({100}<011>) throughout the hot rolling process. These grains with rotated cube texture exhibited fewer slip systems and lower deformation storage energy, which is not conducive to the plastic deformation in thickness direction. Consequently, coarse grains at the slab edge deformed along TD direction and overflowed towards the lower surface of hot rolled strip, resulting in the original edge boundary enveloped by the overflowed metal to generate crack source. Finally, the serrated edge crack was formed from crack source under tensile stress during finish hot rolling.

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

Effect of the brass waste recycling process on mechanical properties with investment casting for gear materials

This study is an experimental research to analyze the characteristics and mechanical properties of the casting process of recycled brass alloy, which will be used as a material for gears. Currently, the remaining production and waste from brass alloys continue to increase. Another thing is the increase in the need for brass gears, so environmentally friendly material engineering is needed to provide good quality and efficient energy use, especially during the casting process. The casting process uses an electric furnace that melts brass alloys at 526 up to 900 °C within 1 hour and molds to make test specimens. The results of microstructural testing for grain size in recycled brass alloys range from 74.63 μm to 84.57 μm. The maximum tensile strength produced is up to 225.2 MPa, the maximum yield strength is up to 179.8 MPa, and the maximum elongation is up to 7.3 %. The roughness of recycled brass alloys has a maximum Ra value (average roughness) of up to 0.836 μm. Validation was carried out by comparing the mechanical properties of CAC 302 brass products and the study results. The data shows that recycled brass's maximum yield strength value is 179.8 MPa and CAC 302 brass material is 175 MPa, but for the ultimate tensile strength value, the value of recycled brass is far below CAC 302 products. These results can be a consideration for the industry to be able to use recycled brass alloys for gear products because the yield strength value is not far from CAC 302 brass products. The impact result of this study produces recycled brass alloys that are environmentally friendly, efficient in smelting energy consumption, and have good yield strength. The results of this research can benefit the manufacture of gear components made of brass alloys.

A Research on Fresh and Hardened Concrete Residences with Partial Replacement of Recycled Coarse Aggregates Obtained from Demolition and Construction Waste

The modern world is witnessing the development of extremely demanding structures right now. Concrete is an extremely important and widely used material. However, the reuse of construction waste is crucial when considering life cycle assessment (LCA) and the efficient recycling of construction materials. Given its potential to address sustainability and environmental challenges, using recycled materials in construction has attracted much attention. This study aims to examine what happens to concrete's compressive strength when recycled coarse aggregates (RCA) replace some of the conventional coarse aggregates. The aim is to study the impact of RCA content on the mechanical characteristics of concrete and determine its appropriateness for use in structural applications. The main objectives of this work is to determine and compare the Density, Workability, Compressive strength, split tensile strength, and Flexural strength of Recycled aggregate in relation to conventional aggregate also to ascertain the ideal percentage of aggregate replacement with recycled aggregate and to calculate the percentage change in strength for recycled aggregate at different levels of replacement. The research methodology involves carrying out laboratory experiments to examine the compressive strength, split tensile strength, and flexural strength of concrete specimens with different proportions of recycled concrete aggregate (RCA) substitutions. The typical coarse aggregates are substituted by recycled aggregates in various proportions (5%, 10%, 15%, 20%, 25%, and 30%) by weight in M25 grade concrete. The formulation of the concrete mix design is meticulously done to provide a consistent water-cement ratio and other crucial criteria. The study involves the process of casting and curing concrete specimens that contain varying amounts of recycled concrete aggregate (RCA). At certain curing ages (e.g., 7 days and 28 days), the specimens are tested for compressive strength, split tensile strength, and flexural strength in order to assess their mechanical capabilities. After that, the outcomes are contrasted with control samples made entirely of conventional coarse aggregates. Primary finding shows workability declines as the proportion of recycled trash rises, but it is kept stable with mixing.

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.

Exploring optimal Li composite electrode anodes for lithium metal batteries through in situ X-ray computed tomography

The uncontrolled Li dissolution/deposition dynamics and rapid Li pulverizations hinder the widespread deployment of Li metal batteries (LMB). Designing a Li composite electrode possessing a mechanically robust and lithiophilic three-dimensional (3D) framework represents a promising strategy to address these challenges. This study involves the preparation of three uniquely tailored Li-B-Mg composites using a combined metallurgical process of melting, casting, and rolling, along with the synergistic application of in situ X-ray computed tomography (CT) and post-mortem failure analysis to explore the most promising composite electrode candidate for LMBs. During the in-depth investigation, the optimal 70Li-B-Mg composite electrode stands out due to its robust skeleton fiber structure, uniform Li dissolution/deposition characteristics and high capacity of free-Li. Its promising prospects for enabling high-performance LMBs are showcased by the superior performance of the built Li||O2, Li||LiFePO4, Li||NCM622 and Li||NCM811 battery systems. This work offers a novel approach for exploring universally applicable and robust Li composite electrodes to realize high-performance LMBs using in situ CT analysis.

Implementation of Lean Construction to Reduce Waste with the Value Stream Analysis Tools (VALSAT) Method in the Project Casting Process

This study aims to identify waste that occurs in the casting process of the project carried out by CV. Wishitama using value stream analysis tools (VALSAT) and provide suggestions for improvements with fishbone diagrams for the casting process of the project carried out by CV. Wishitama. This study uses a qualitative approach and case study with value stream analysis tools (VALSAT) and fishbone diagram analysis. The results of this study are that there are four types of waste that are prioritized for elimination, namely, overprocessing, defective products, queues, and motion. This study will provide new contributions to knowledge in the field of lean construction, with a focus on the construction industry. The results of this study will complement existing knowledge and provide new insights into how the application of lean construction can eliminate waste in the construction industry. Companies can eliminate and be effective in waiting for heavy equipment (readymix and concrete pumps) and vibrating equipment during casting. In addition, companies can increase direct supervision, conduct additional training, conduct evaluations, implement a reward or punishment system according to employee performance, plan efficient schedules, assign employees according to needs, and conduct outreach on current employee performance as a form of effort to improve human resources.

Optimization and Evaluation of Alkali Activated Fly Ash for Lightweight Aggregate Production

This study investigates the utilization of solid waste, specifically fly ash, and other materials to produce aggregates through geopolymerisation. The research aims to explore the properties of fly ash aggregates and assess their viability in concrete production. The objectives of the study encompass the preparation of aggregates using different proportions of fly ash and alkali activator such as sodium hydroxide and sodium silicate, alongside the casting of concrete cubes utilizing the artificial aggregate. The methodology employed involves the preparation of alkali activator, mix proportioning, and the subsequent processes of mixing, casting, crushing, and curing. Various ratios of fly ash to activator (2.5:1, 3:1, and 3.5:1) were investigated, with corresponding results obtained for properties such as abrasion value, impact value, bulk specific gravity, and water absorption. The findings reveal that the properties of the fly ash aggregates vary with different ratios, with notable differences observed in abrasion value, impact value, bulk specific gravity, and water absorption. For 2.5:1 abrasion value is 26.02%, impact value is 19.32%, bulk specific gravity 1.821 and water absorption 9.61%.For 3:1 abrasion value is 37.14%, impact value is 25.15%, bulk specific gravity 1.78 and water absorption 10.58%.For 3.5:1 abrasion value is 46.5%, imapct value is 32.87%, bulk specific gravity 1.648 and water absorption 12.83%. Casting cude using ratio 2.5:1, 28 day strength is 20.46 N/mm2.. This research project offers an eco-friendly solution for utilizing fly ash in the production of high-performance aggregates, contributing to sustainable construction practices. The implications of the findings include reduced environmental impact, enhanced resource efficiency, and the potential for resilient and environmentally conscious built environments. Further research and development in this area could lead to broader adoption of geopolymerized fly ash aggregates in the construction industry, paving the way for a more sustainable and Greener future.

Experimental investigation and fluid-structure interaction modelling of the casting of self-compacting concrete for CRTS III slab track in the curved segments

Ensuring the casting quality of self-compacting concrete (SCC) is crucial for the operational safety and durability of China railway track system (CRTS) III slab track. However, the mechanisms of key factors influencing flow behaviors of SCC and structural responses remain insufficiently understood, nor is the relationship between flow behaviors and structural responses during casting. In this study, fluid-structure interaction (FSI) models of SCC casting were developed and verified by full-scale physical tests, comprising slump flow, L-box flow and casting of SCC in an actual track at the field of Laixi-Rongcheng high-speed railway. Through in-depth analysis on the casting process of SCC in curved segments with a super elevation of 80 mm, the relationship between flow behaviors and structural responses was established. Furthermore, the influence mechanisms of key factors on flow behaviors and structural responses were investigated systematically. Results show that during gravity-fed SCC casting, its flow velocity diminishes, thus increasing the static pressure and the forces exerted on the slab by SCC. These vertical and lateral forces increase to 147.16 and 7.83 kN through three stages of development, acceleration and stabilization, resulting in commensurate structural responses. At the end of casting process, the central region of the slab exhibits maximum vertical deformation of 0.95 mm and tensile stress of 1.07 MPa. The tension rods at the side with lower elevation bear greater vertical and lateral forces than the ones at the side with higher elevation. The rise of funnel height from 1.05 to 1.35 m accelerates the casting process but increases the forces exerted by SCC by up to 26 % and augments the associated response of entire structures, whereas the funnel diameter shows little effect. Increasing yield stress of SCC from 9.3 to 49.3 Pa produces a more uniform flow morphology and thus higher static pressure and force by SCC in the middle region of the slab, impacting the structural responses by up to 15 %. The growth of plastic viscosity from 59 to 99 Pa⋅s significantly affects the volume rate and casting time by up to 66 % but has little effect on the flow morphology, fluid pressure and structural responses. In order to ensure high quality casting of SCC, five clamping beams are suggested with two beams positioned at either side of the slab and the other three evenly placed along the middle region of the slab.

Triple solutions for unsteady stagnation flow of tri-hybrid nanofluid with heat generation/absorption in a porous medium

The present theoretical study focuses on enhancing the performance and efficiency of casting and extrusion processes. Thus, this work examines the flow characteristics and heat transfer of unsteady tri-hybrid nanofluid flow in porous media while also considering the heat source/sink effect. The governing boundary layer equations are solved via a built-in collocation method available in MATLAB software. Three distinct numerical solutions which convey the fluid flow characteristics have been identified. Notably, nanofluid composition influences boundary layer separation, with tri-hybrid nanofluid showing enhanced heat transfer when the stretching/shrinking parameter exceeds −10.53. When the sheet shrunk at −10.8, ternary and hybrid nanofluids improved thermal efficiency by 15.22 % and 20.38 %, respectively, compared to mono nanofluids.

Warpage evaluation and mechanical characterisation of modified polyamide-6 specimens produced by Arburg plastic freeformer

AbstractIn injection moulding and additive manufacturing processes, it is common for the final product to exhibit warpage induced by a non-uniform cooling rate after material deposition. Residual stresses can be generated in the built parts, with a volume shrinkage that leads to dimensional inaccuracy and reduced usability. This phenomenon is even amplified in the presence of semi-crystalline polymers, which still need to be more widespread among additive manufacturing processes despite their capacity to show better mechanical properties when compared to amorphous ones. This study evaluates the degree of deformation and subsequently characterises the mechanical properties of a novel modified Polyamide 6 formulation (i.e., RADILON® S X21351 NT) printed through the Arburg Plastic Freeforming process. This new proprietary formulation modified the crystallisation behaviour during cooling. The whole exothermic crystallisation peak was shifted to lower temperatures, allowing the processing envelope of the modified formulation to widen. More specifically, after preliminary polymer characterisation analyses and after evaluating the warpage, a mechanical characterisation was performed using tensile tests on specimens (dry-as-moulded and conditioned) printed with different filling strategies on the build platform (XY-0°; XY- ± 45°; XY-90°; ZX-0°). Measured mechanical properties were ultimately compared to those achieved by applying the injection moulding technique on the same non-modified material. The specimens produced through the Arburg Plastic Freeforming process showed brittle behaviour that was more marked than those obtained by injection moulding. Moreover, the infill direction and water content significantly influenced the mechanical properties of specimens.

Revealing ancient technology: a high-energy X-ray computed tomography examination of a Mesopotamian copper alloy head

Although the origins of lost wax casting extend back into the 5th millennium BCE, it was not until the development of hollow core casting that life-sized metal sculptures could be produced. Based on existing evidence, the earliest adoption of this technique, which involves the inclusion of a clay core within a wax model, occurred in Iraq (Mesopotamia) during the Early Dynastic III period (ca. 2600–2350 BCE). To date, only one hollow core casting from the succeeding Akkadian period (ca. 2350–2150 BCE)—the Sargon Head in the collection of the Iraq Museum—has been studied from a technical point of view. The recent attribution of The Metropolitan Museum of Art's Head of a ruler to this formative period of hollow core lost wax casting provided the impetus for its examination by high-energy X-ray computed tomography—the most practical technique for an object that is continuously on display that could image in 3D the interior morphology of this sculpture given the considerable thickness of its metal walls. This scan revealed a markedly different style of production than the Sargon Head. Although further research on early castings is required to determine the chronological implications of the differences observed and to elucidate more generally the early development of hollow casting technology, the scan of the Head of a ruler provides evidence of some of the challenges encountered and problem-solving strategies used in the casting process.