Pouring Temperature Research Articles

The effect of pure temperature and pressure on alloy hardness of Al-6.7% Cu using squeeze casting method

Squeeze casting is done by combining the casting and forging processes. The metal solidification process is carried out in a metal mold by pressing it with hydraulic pressure. This study aims to determine the effect of pouring temperature and pressure on the hardness value of the squeeze casting of Al-6.7% Cu alloy material. The process is that the material is melted using a crucible furnace until it melts then poured with a temperature variation of 710 ° C, 730 ° C and 750 ° C. Then it is poured into a metal mold that is heated to a temperature of 250 ° C and then pressed for 60 seconds with variations of 0 MPa, 2.5 MPa, 5 MPa and 7.5 MPa. The test results show that; (1) the higher the pouring temperature, the lower the hardness value, (2) the higher the pressure, the higher the hardness value. (3) The highest hardness value was at pouring temperature of 710 ° C with a pressure of 7.5 Mpa (59 HB) while the lowest hardness value was at pouring temperature of 750 ° C with a pressure of 0 Mpa (34 HB)

Low pressure casting effect to tensile strength of aluminium

The air in the mould cavity is pushed out by liquid metal when the liquid metal entered mould cavity. In green sand-casting process, the air passes through the pores in the mould. Permanent mould doesn’t have pores and the air released from the mould cavity only through air outlet. Low pressure on mould cavity make liquid metal easier and faster filling the mould cavity, and make casting process can be done at lower temperature, the main focus of this research is about effect of pouring temperature on the low-pressure casting process to tensile strength and porosity of the aluminium. The casting process carried out at 750, 800 and 850°C. Aluminium smelting uses electric furnace and the mould used is a metal mould with a pressure of 0.33 atm. The casting process on aluminium at low pressure (-0.33 atm) and at a temperature of 750 °C produces the highest tensile strength compared to aluminium casting at 800 and 850 °C. The increasing pouring temperature increasing porosity of aluminium is from 1.86% at 750 °C to 4.03% at 850 °C.

Effect of pouring temperature on hot tearing susceptibility of Al-Cu cast Alloy: Casting simulation

Al-Cu alloy more prone to hot tear in the foundry metals in casting process. It is widely using in structural, aerospace, marine and automotive industry. Defect-free casting is being challenge in the foundry. In the present investigation, the hot tearing of the molten Al-Cu cast alloy is reported by varying the pouring temperature at 700 °C, 750 °C and 780 °C by means of casting simulation. It has a direct impact on production cycle time, casting internal quality, material utilization, and gating design optimization. Simulation was performed by AutoCAST-X software; it enables directional solidification and feed metal paths. In the simulation set up have been considered green sand mould system with the wooden pattern, and the steel metallic cores are facilitated in the cavity to contrast the temperature while solidification process; as a result pouring temperature is subject to crack susceptibility. The results revealed that the dependence on pouring temperature is a key factor for the prediction of hot tearing susceptibility. The microscopic cracks were observed in casted part by simulation. The Casting simulation forecast the hot spot zone in casting solidification process to facilitate the riser for compensation of shrinkage allowance of molten metal. Simulation enhances the material utilization, quality of casting, productivity and optimization of gating design. The relation of pouring temperature was developed with solidification time.

Microstructure and mechanical properties of AZ91D magnesium alloy by expendable pattern shell casting with different mechanical vibration amplitudes and pouring temperatures

To refine the microstructure and improve the mechanical properties of AZ91D alloy by expendable pattern shell casting (EPSC), the mechanical vibration method was applied in the solidification process of the alloy. The effects of amplitude and pouring temperature on microstructure and mechanical properties of AZ91D magnesium alloy were studied. The results indicated that the mechanical vibration remarkably improved the sizes, morphologies and distributions of the primary α-Mg phase and β-Mg17Al12 phase, and the densification and tensile properties of the AZ91D alloy. With an increase in amplitude, the microstructures were gradually refined, resulting in a continuous increase in mechanical properties of the AZ91D alloy. While, with the increase of pouring temperature, the microstructures were continuously coarsened, leading to an obvious decrease of the mechanical properties. The tensile strength and yield strength of the AZ91D alloy with a vibration amplitude of 1.0 mm and a pouring temperature of 730 °C were 60% and 38% higher than those of the alloy without vibration, respectively.

A New Method for Sensing Pouring Temperature of Molten Steel in Tundish

Pouring temperature of molten steel at the outlet of the tundish is the key parameter to control the solidification accurately. However, the stopper occupies the top of the outlet, leading to that the existing sensor cannot measure the molten steel temperature at the outlet. To solve the problem, this work develops a new small sensor installed at the bottom of the stopper, which combines the stopper and the temperature sensor into one. Mo-W-ZrO <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sub> cermet that has excellent corrosion resistance has been used to make a small sensor with a thin-walled structure of 5 mm thickness. To sense the pouring temperature independently, fast and accurately, the length/radius ratio of the small sensor should reach 13 to form a blackbody cavity approximately. According to the industrial test, the pouring temperature of molten steel is measured for the first time in the field of metallurgy. Meanwhile, a deviation (e.g., 8.2 °C or 1.4 °C) between the pouring temperature and the temperature measured by the existing sensor is found. As a result, based on the temperature measured by the existing sensor, the superheat of molten steel and the cooling water flow usually have enough margin for ensuring the safe operation of continuous casting, reducing the control accuracy of the solidification and increasing the risk of quality problems. Therefore, this work will be helpful to control the solidification more accurately, improving the product quality.

Influence of Ni interlayer on interfacial microstructure and mechanical properties of Ti-6Al-4V/AZ91D bimetals fabricated by a solid–liquid compound casting process

Abstract The solid–liquid compound casting of Mg-AZ91D and Ti-TC4 alloys was developed by using pure Ni electro-deposited coating. The pouring temperatures of 660 ℃, 690 ℃, 720 ℃ and 750 ℃ were chosen to investigated the effects of casting temperatures on microstructural evolution, properties, and fracture behaviors of Ni-coated TC4/AZ91D bimetals by the solid–liquid compound casting (SLCC). The scanning electron microscopy (SEM) and the energy dispersive spectroscopy (EDS) results showed that the interfacial zone mainly composed of nickel, Mg2Ni and Mg-Al-Ni in the bimetals cast at 660 ℃. As the pouring temperature was increased to 750 ℃, the width of the interface zone, which mainly composed of δ(Mg), Mg2Ni, Mg-Al-Ni, Mg3TiNi2 and Al3Ni, gradually increased. The microhardness tests showed that the micro-hardness of the interface zone was smaller than that of TC4 substrate but larger than that of the cast AZ91D matrix. At the pouring temperature of 720 ℃, the Ni-coated TC4/AZ91D bimetals had the most typical homogeneous interface, which had granular Mg-Al-Ni ternary phase but no ribbon-like Al3Ni binary phase, and achieved the highest shear strength of 97.35 Mpa. Meanwhile, further fracture behavior analysis showed that most fracture failure of Ni-coated TC4/AZ91D bimetals occurred at the Mg2Ni + δ(Mg) eutectic structure and Al3Ni hard intermetallic.

Experimental study of foundry defects in aluminium castings for quality improvement of casting

Every industry objective is to improve quality as well as productivity of manufacturing product. Casting defects is one and the only limitation in any casting process. Sand casting process too suffers from the same problem. Finding out the optimum condition towards acquiring minimum casting defects is very critical. The normal method that most of the companies use is the trial and error method. But due to limitations like error prone results, expensive and time consuming, this method causes too much cost to company. In this paper, an attempt has been made to minimize the casting defects by following right practices in the sand casting process. It was found from Casting defects and their remedies that defects can be minimised by controlling the quality of moulding sand such as sand grain size, clay content and moisture percentage. From sand testing, it was found that the clay content in the moulding sand was very high and the size of sand particles was coarse. It resulted in various sand casting defects such as blow holes, shrinkage, sand inclusions, etc. It is very important to provide preventive action to improve quality as well as productivity an industrial level. By following right practices such as proper melt treatment, optimum sand quality, right pouring temperature the sand casting defects can be reduced successfully.

Improved interface bonding of Mg/aluminized steel bimetallic castings prepared by solid–liquid compound casting process

ABSTRACT The effect of pouring temperature on microstructure and bonding properties of the Mg/aluminised steel bimetallic castings prepared by the solid–liquid compound casting process was investigated in this paper in order to improve the interface bonding of the Mg/aluminised steel bimetallic castings. The results show that the Mg/aluminised steel bimetallic castings produced with different pouring temperatures obtained a uniform interface layer that was mainly composed of the Fe2Al5, τ10-Al9Fe4Si3, FeAl3 and Al12Mg17 phases. When the pouring temperature was low, the cracks were formed between the Mg and the interface layer. With increasing pouring temperature, a compact interface bonding was achieved. The bonding properties of the Mg/aluminised steel bimetallic castings increased with increasing pouring temperature. An optimised bonding of the Mg/aluminised steel bimetallic castings was obtained with a pouring temperature of 780°C.

Experimental Investigation on the Effect Due to Mould Vibrations on Mechanical and Metallurgical Properties of Aluminum Alloy (A-1050)

In the current research work performed, the consequences caused in the casting aluminum alloy specimen due to mechanical mould vibrations are examined. Mould vibration throughout the casting provides decreased rate of shrinkage, good morphology, surface finish and lesser probability of hot tear. In this research work, the effect of mould vibration during solidification of Aluminum A-1050 alloys for dissimilar values of wavelengths at a permanent pouring temperature has been investigated to understand the modification in microstructure and mechanical properties after casting. The Al A-1050 casting has been made in a metal mould with different vibrations. The frequencies are varied from 15Hz to 50 Hz during the casting process. A casting has been made with different vibration as well to compare the results of castings with vibration frequencies. The experimental outcomes exhibited substantial grain refinement and significant increase in tensile strength and hardness of the castings with mechanical mould vibration during the duration and after solidification.

Fabrication and performance analyses of 45# steel supports using liquid forging

In this paper, 45# steel supports prepared by liquid forging showed excellent performances and the effects of processing techniques on the development of microstructures and mechanical properties of these steel supports were researched. The liquid forging process was simulated and technological parameters were optimized via a ProCAST simulation software. The solidification time, temperature distribution, first principal stress distribution of the 45# steel supports varied with time, temperatures, and position. Two principal parameters, pouring temperature and dwell time, were assessed for their effects on microstructures, mechanical properties, and wear resistance properties of 45# steel supports. Results showed that the optimal pouring temperature of the molten metal and the pressure-holding time were between 1540 °C and 1560 °C and between 35 s and 40 s, respectively. The microstructure, mechanical properties, and fracture behavior of different positions in the support were also discussed, and the central position performed better than the edge because of plastic deformation. Finally, the dynamic solidification process was also investigated and the liquid forging process of 45# steel supports was complex and contained some special metal liquid convection and several plastic deformation stages.

Improving the wear resistance of cast aluminum alloys by the melt thermal-rate treatment

The method of the melt thermal-rate treatment has been successfully tested to increase the macrohardness and abrasive wear resistance of a low-alloy cast aluminum alloy of the Al-Mg-Si system. It was found that an increase in the melt superheating temperature to 900 °C with subsequent isothermal holding and fast cooling to the pouring temperature leads to a decrease in weight loss from 0.359 to 0.324 in comparison with the initial state, which corresponds to an increase in the coefficient of relative wear resistance to 1.11. A good correlation has been found between wear resistance and macrohardness of treated alloys. Application of the proposed approach will increase the service life of aluminum parts exposed to various abrasive effects, however, to further increase the wear resistance, it is recommended to obtain a reinforced composite structure in the Al-Mg-Si system using the melt thermal-rate treatment.

Inhibition of interface reaction of DZ22B alloy and high purity Al 2 O 3 mould surface by changing directional solidification process parameters

The effect of casting temperature and withdrawal rate on the interfacial reaction between DZ22B nickel-base superalloy and high-purity Al2O3 ceramic shell facecoat material was studied by changing the parameters of directional solidification process.The SLM was used to observe the different characteristic regions of the macroscopic reaction. The SEM analysis equipped with EDS was used to study the microstructure of the alloy-formed shell interface and the qualitative analysis of the interfacial reaction product elements. The phase and element valence of the interfacial reaction product were identified by XRD and XPS.The results show that the interface reaction products are mainly HfO2 and Al1.98Cr0.02O3 and exhibit a sub-regional distribution along the direction of directional solidification.Under the premise of ensuring the directionally solidified alloy structure, lowering the pouring temperature and increasing the withdrawal rate can inhibit the occurrence of delayed interface reaction.

Effects of process parameters on semi-solid squeeze casting performance of aluminum alloy scrolls for scroll compressors

The aluminum alloy scroll is one of the key parts of the scroll compressors widely used in the air-conditioning, refrigeration, and heat pump systems. In this work, the semi-solid squeeze casting (SSSC) process was used to fabricate the aluminum alloy scroll. The effects of process parameters including the pouring temperature, mold temperature, and squeezing velocity on the filling and solidification behaviors of the alloys were investigated through simulations based on the power law cut-off (PLCO) material model. Results show that there is a significant increase in the flow velocity of the slurry, and the area of the high-speed region enlarges with the increase of the pouring temperature. The homogeneity of the temperature and velocity fields in the slurry is improved with an increase in mold temperature. Both the filling time and its variation rate decrease with an increase in squeezing velocity. The maximum solidification time exhibits a linear variation with the increase in pouring temperature. The shrinkage area is decreased by increasing the mold temperature. The optimal process parameters of the SSSC process were obtained from simulation analysis, which are the pouring temperature of 595 °C, mold temperature of 350 °C, and squeezing velocity of 0.3 m·s−1. Moreover, the qualified scroll casting was fabricated using the SSSC process under the optimal process parameters.

Effects of Pouring and Mold Temperatures on the Fluidity and Hot Tearing Susceptibility of Al–3.5Si–0.5Mg–0.4Cu Alloy

The effects of pouring and mold temperatures on the fluidity and hot tearing susceptibility (HTS) of Al–3.5Si–0.5Mg–0.4Cu alloy were investigated by the spiral mold test and the constrained-rod casting mold test, respectively. Optical microscope (OM) and scanning electron microscope (SEM) were carried out for microstructure observation. The results showed that the flow length (Lf) of Al–3.5Si–0.5Mg–0.4Cu alloy increased with increasing pouring temperature (T) and mold temperature (T0). Moreover, the functional relationship between the fluidity and casting parameters was obtained by fitting the fluidity data as: $$ L_{f} \, = \, 60.9 \, + \, 1082.4\text{[}\Delta T/T - T_{0} \text{]} $$ . The hot tearing mechanism was analyzed by observing the microstructure of the hot crack, and the HTS of the alloy with the mold and pouring temperatures was discussed in detail. According to the research, to achieve a lower hot tearing susceptibility under better fluidity, the suggested pouring and mold temperatures are 740 °C and 200 °C, respectively.

A Statistical Analysis of Evaporative Pattern Casting Process Parameters for the Production of Aluminum Alloy Components

Four process parameters were investigated with the aim of determining their influence on the mechanical properties of some test castings, bars, cylinders and plates. The influence was quantified in terms of percentage contribution. Analysis of variance (ANOVA), regression, main effects and interaction effects plots were employed to carry out the statistical analysis. As regards the tensile strength of the test castings, the geometry of components (GOC) dominated, contributing 90.83% and the pouring temperature (PT) contributed 91.90% influence on the hardness property. These dominating potentials of these twoparameters limited the interaction of the parameters studied in the research.

Effect of Pouring and Mold Temperatures on Hot Tearing Susceptibility of WE43 Magnesium Alloy

The effects of different pouring temperature and mold temperature on the hot tearing susceptibility of WE43 magnesium alloy were studied using computer numerical simulation, hot tearing test and differential thermal analysis experiment. The microstructure of the hot tearing zone of the casting was observed using SEM, and the phase composition was analyzed using EDS. Numerical simulation results show that the change in pouring temperature and mold temperature could affect the hot tearing susceptibility (HTS) of WE43 alloy, and the influence of mold temperature was more significant with the conditions of pouring temperature (Tp) of 710–730 °C and mold temperature (Tm) of 240–320 °C. The experimental results are in good agreement with the simulation results. At the lower pouring temperature, the dendrite coherency began at a higher solids fraction, which could enhance the resistance to hot tearing at the end of solidification and reduce HTS of WE43 alloy. At the same pouring temperature, with the increase in the mold temperature, the number of dispersed eutectic phases in the alloy increased obviously, so that hot tearing could be well filled with the eutectic phase to reduce the HTS of WE43 alloy. In experimental conditions, the WE43 magnesium alloy had the lowest HTS at a pouring temperature of 710 °C and a mold temperature of 320 °C.

Uji ketahanan fatik aluminium hasil remelting piston bekas menggunakan metode pengecoran centrifugal casting

Aluminum is one of the non-ferrous metals that are most widely used in the engineering field due to it has mild properties and is resistant to corrosion, but aluminum waste such as used pistons that are damaged or not utilized as an proper resource, on the other hand, that this process is very potential due to it uses a used piston that is not used, and is expected to have a better economic value by doing remelting and centrifugal casting to the used piston. This study aims to determine the value of the fatigue cycle of the used piston which is remelting and printed using the centrifugal casting method by using variations in the pouring temperature and die temperature and rotation variations. Based on the tests conducted using pouring temperature variations and rotation speed are as follows: best cycle value at 250 rpm variation is at pouring temperature 600oC with a value of 76000 N, and the lowest is at room temperature of 750oC with a value of 32000 N, best cycle at a variation of 500 rpm is at a pouring temperature of 700oC with a value of 40000 N, and the lowest is at a room temperature of 660oC with a value of 12000 N. The best cycle value at a variation of 750 rpm is at a pouring temperature of 750oC with a value of 16000 N, and the lowest is at room temperature 660oC with a value of 10000 N. While the results of subsequent tests conducted using variations in die temperature and rotation speed are as follows: the best cycle value at 250 rpm variation is at a print temperature of 350oC with a value of 17400 N, and the lowest is at room temperature of 250oC with a value of 8370 N. The best cycle value at a variation of 500 rpm is at a print temperature of 350oC with a value of 67760 N, and the lowest is at a room temperature of 250oC with a value of 22850 N. The best cycle value at a variation of 750 rpm is at a print temperature of 350oC with a value of 75170oC. and the lowest is at room temperature of 250oC with a value of 28940 N.Keywords: Centrifugal casting, fatigue test, remelting, used piston, aluminum, cycle value.

An Integrated Analysis Method of Service Life Based on the 3D Heterogeneous Material Model with Casting Defects

Based on the heterogeneous material model, an integrated analysis method was introduced to predict the service life of propeller. The morphology and distribution characteristic of non-continuous defects (porosity & inclusion) were calculated and mapped into the finite element model by 3D-mapping algorithm, and the fatigue life was predicted based on the heterogeneous material model. In this paper, the coupling analysis of casting process and fatigue prediction of marine propeller was done. The results show that porosity and mass inclusions in blade roots of propeller form serious heterogeneous characteristics in those parts, which increased the maximum stress of the propeller and decreased its theoretical fatigue life by 1/2, indicating that the effect of non-continuous defects on the service performance of casting is notable and cannot be ignored. Based on the integrated analysis method, the inference of the pouring temperature and gating system on the service life of propeller was studied further. The integrated analysis method brings the influence of the casting defects into structural analysis and fatigue analysis, which can improve the accuracy of the fatigue life prediction significantly.

Effect of Ultrasonic Treatment on the Microstructure and Mechanical Properties of Hypereutectic Al-Si Alloy) A392(

Hypereutectic Al–Si alloy (A392) was treated with ultrasonic vibration (UV) induced to the melt through a cylindrical resin–bonded sand mold. This work aims at studying the influence of UV at the different pouring temperatures of A392 alloy during solidification process on the microstructures and mechanical properties. The microstructures of as-cast samples were examined by using optical microscopy (OM) and scanning electron microscopy (SEM). The mechanical properties were investigated by tensile and hardness tests. The results showed clearly that with applied UV at optimum pouring temperature (640 oC), nearly fine uniform and polyhedral shape of the primary Si were obtained. Improvement of tensile properties and hardness of the investigated alloy modified with UV is related to the modification and refinement of primary Si particles. The fracture surfaces of prepared alloy without and with UV were also investigated.

Atomistic Simulations and Experimental Investigations of the Diffusion Behavior of Steel/ZCuPb20Sn5 Bimetals

A hybrid verification method consisting of experiments and molecular dynamics simulations was implemented to investigate the diffusion behaviour of steel/ZCuPb20Sn5 bimetals. The effects of different carbon steels (Q235 steel, 45 steel, and T8 steel), pouring temperatures, and holding times on their microstructures and mechanical properties were studied to obtain the optimum process parameters. The experimental results indicated that the pouring temperature and holding time played an imperative role in improving the shear strength of the steel/copper bimetallic composite. The highest bonding strength of all the steel/copper bimetallic composites was obtained at 1523 K and the holding time of 40 min. Moreover, the carbon steel of 45 steel with a ZCuPb20Sn5 interface exhibited the highest bonding strength because of the appropriate pearlite content along with the preferable structure and micro-hardness for the considered diffusion width and bonding strength. Meanwhile, the diffusion distance of copper atoms in the carbon steel matrix was smaller than that of iron atoms in the ZCuPb20Sn5 matrix. In the simulation results, the diffusion coefficient of Cu atoms was smaller than that of Fe atoms, but the diffusion distance of Fe atoms in the Cu bulk was larger than that of Cu atoms in the Fe bulk; this showed a significant agreement with the experimental result.