Properties Of Castings Research Articles

Optimization of Aluminium Casting with Alumina Reinforcement via Stir Casting: Impact on Physical and Mechanical Properties

Aluminum casting using the stir casting method is a common practice in the industrial sector. This study aims to optimize the effect of stirring speed on the physical and mechanical properties of aluminum casting reinforced with alumina powder (Al2O3). The material used in this study is derived from discarded vehicle rim waste. The stir casting method was performed at varying speeds of 500, 600, and 700 rpm, with a mold temperature of 250°C and a pouring temperature of 700°C. Physical testing to examine the microstructure was conducted using optical metallography, hardness testing was performed using the Rockwell hardness scale B, and tensile strength was measured using a Universal Testing Machine. The microstructure observations showed that a stirring speed of 500 rpm yielded the best results, with minimal porosity. The highest hardness value recorded was 65 HRB at 500 rpm, consistent with the microstructure observations. The highest tensile strength was also recorded at 500 rpm, reaching 262 MPa.

Enhancing microstructural properties of copper-based composite castings through microwave-assisted reinforcement with MWCNT

An emerging advancement in the field of metallic materials casting is the in-situ microwave casting of metallic materials. To achieve this, the microwave heating process is applied within the applicator cavity, working on the principles of hybrid microwave heating (MHH). This process involves melting the charge, pouring it into an in-situ container, and subsequently solidifying the melted charge. The electromagnetic and thermal properties of the charge influence the interactions between the microwave energy and the material, as well as the melting behavior induced by the microwaves. As for the solidification process, this is also controlled by a cooling condition within the applicator. The present study aims to outline an in-situ casting process for copper-based composite castings fabricated within a multimode cavity, utilizing 900 W at 2.45 GHz. The quality of the developed in-situ cast was assessed by analyzing its characteristics. A microstructural examination revealed that the composite castings exhibited a homogeneous and dense structure. Scanning electron microscopy (SEM) and Energy-dispersive spectroscopy (EDS) analysis was conducted across the casting. The XRD pattern confirmed the presence of major peaks of copper in the composite castings, along with the presence of oxide phases such as Cu64O. Also, the micro indentation hardness of the Cu + 1.5%MWCNT casts was found to be 1.23 times higher than that of microwave-processed pure copper.

The Effect of TiC-TiB2 Dual-Phase Nanoparticles on the Microstructure and Mechanical Properties of Cast Ni-Fe-Based Superalloys.

TiC-TiB2 dual-phase nanoparticles were added into a Ni-Fe-based cast superalloy and their effects on the microstructure and mechanical properties were compared to those of a Ni-Fe-based superalloy with the addition of TiC nanoparticles. The addition of TiC nanoparticles led to the precipitation of a higher volume fraction of carbides. Compared to the addition of TiC, the addition of TiC-TiB2 nanoparticles not only led to the precipitation of carbides but also promoted the formation of flaky borides and a reduction in the precipitation of the Laves phase. The strengthening effect of TiC-TiB2 nanoparticles on the mechanical properties of Ni-Fe-based superalloys was stronger than that of TiC nanoparticles due to more secondary γ' precipitates. This study provides valuable insights for selecting ceramic nanoparticles to increase the mechanical properties of cast Ni-Fe-based superalloys.

Effect of the refining process on porosity and selected mechanical properties of AlSi7Mg alloy pressure castings

Effect of the refining process on porosity and selected mechanical properties of AlSi7Mg alloy pressure castings

Temperature gradient mechanism in the heterogeneous nucleation of inoculated alloy: A quantitative phase-field study

The grain size of solidification microstructure has a significant influence on the mechanical properties of castings. Generally, smaller grain size makes the strength of castings higher. Therefore, inoculation is an effective strategy to reduce grain size and improve casting performance. In this work, the phase-field method combined with the free growth model is employed to simulate the solidification of inoculated aluminum alloy with temperature gradient. The simulations indicate that a higher temperature gradient slows the progression of already nucleated grains into impingement growth and enhances the undercooling of the melt ahead of the solid-liquid interface. Hence, more inoculants have chance to get the corresponding nucleation undercooling, promoting grain nucleated sequentially along the gradient direction. These results are consistent with previous real-time observed experiments. This work may provide guidance on improvement of the theoretical models for predicting grain size of inoculated alloys and the optimization of casting process to obtain refined grains in inoculated ingots.

Studies on the Influence of Methane Gas Bubbling of Metal Alloys on the Casting Properties

Abstract The purpose of using bubbling in the case of metal alloys was to increase the mechanical resistance, to improve the casting properties as well as to observe the changes brought by gases on the structure. During bubbling, especially hydrogen and oxygen are removed, which obviously leads to the improvement of metal alloys. The influence of bubbling on the casting properties is explained by the structural changes that occur in the cast alloys. Therefore, bubbling with methane gas is a safe means of improving the quality of cast parts, ensuring at the same time the increase of casting properties of alloys.

The effect of pre-dehydrated magnesium-silicate-hydrate on the properties of the castables bonded with hydrable magnesium carboxylate

This study investigates the effect of pre-dehydrated magnesium-silicate-hydrate (PMSH) on the properties of HMC-bonded castables (HMCC), aiming to enhance the medium-temperature mechanical performance of HMCC through the structural memory characteristics of PMSH. The results indicate that adding M-S-H-300 (PMSH treated at 300 °C) improves the mid-temperature mechanical properties of HMCC. Specifically, the cold modulus of rupture (CMOR) for the samples 300MSH increases by 605.9 % at 500 °C and 582.6 % at 800 °C compared to control samples due to the excellent thermal stability of M-S-H-300 and a 38.3 % improvement in castable sintering performance. Additionally, M-S-H-300 improves the thermal shock resistance and setting properties of HMCC, extending the castable's setting time by 19 %. The conductivity test results indicate that the addition of M-S-H-300 inhibits the ionization of HMC, thereby delaying its hydration process. Castables with M-S-H-300 demonstrate higher CMOR and residual strength ratio before and after thermal shock. Further testing reveals that adding M-S-H-300 increased the castable's elastic modulus by 482.6 % and fracture toughness by 35.6 % after sintering at 1500 °C, enhancing resistance to microcrack propagation during thermal shock. Furthermore, adding M-S-H-300 reduces the aspect ratio of HMC hydration products, optimizing microstructure and reducing porosity. However, this modification slightly decreases the mechanical properties of the green body.

Effect of rotational speed on friction stir welding microstructure and properties of cast and rolled (ZrB2 + Al3Zr) particle-reinforced aluminum matrix composites

Effect of rotational speed on friction stir welding microstructure and properties of cast and rolled (ZrB2 + Al3Zr) particle-reinforced aluminum matrix composites

An experimentally validated thermomechanical model for a parametric study on reducing residual stress in cast iron repair welding

Remarkable casting properties and superior mechanical characteristics of cast iron make it an ideal material for a wide range of industrial applications. However, the production of cast iron components may result in the formation of cracks and defects, posing a significant threat to their structural integrity. Repair welding is a promising solution to resolve cast iron production defects. However, repair welding cast iron components poses unique challenges that stem from residual stress (RS) formation and the possibility of cracking during the repair process. Moreover, research on cast iron repair is scarce. To overcome these challenges, this paper presents a thermo-mechanical model validated by experiments to reduce RS in cast iron repair welding through the optimization of welding parameters and weld sequences as well as the geometry of the repair area. An experimental bead-on-plate weld is set up in order to validate the developed thermo-mechanical model. The temperature distribution in the weld is measured using thermocouples placed around the weld line. An X-ray diffraction technique is used to measure the axial and transverse RS at different points around the weld line. The developed finite element model is employed to simulate the repair welding process and analyze the effect of inter-pass temperature, the number of welding passes, welding sequences, and groove geometry on the RS. The numerical approach applied in this study provides a framework for repair welding optimization of cast iron and other materials, fostering the development of more efficient and reliable repair methods for industrial applications.

Effects of carbon content and heat treatment on wear-resistance and impact properties of novel cast steels with bainitic and martensitic structure

Abstract The traditional material for caterpillar boards is mainly Hadfield steel. The wear resistance of the Hadfield steel cannot be fully exerted due to insufficient work hardening during the operation of the caterpillar board. The effects of carbon content and heat treatment on the wear-resistant and impact properties of a novel caterpillar board cast steels with bainitic and martensitic structures have been investigated. The microstructural observation of worn surface topography was performed by scanning an electronic microscope, and the impact toughness was carried out by an impact tester, in a bid to improve the wear-resistant properties and its impact toughness. The results demonstrate that the hardness and wear-resistant properties of cast steels increase with the increase of carbon content, whereas the impact properties reduce because the brittle phases, such as the carbide precipitation and the martensite, are more. The heat treatment temperature of steels can change the relative ratio of bainitic and martensitic structures, thus affecting the wear-resistant properties of the steels. By controlling the carbon content and heat treatment processing of the steels, the optimal combination of toughness and wear-resistant properties can be achieved. The wear mechanism of dual-phase cast steel was analyzed through wear resistance tests, and it also shows that dual-phase cast steel with bainitic and martensitic structures had better wear-resistance properties compared to the Hadfield steel at low-impact wear conditions.

Effect of hot rolling process on the microstructure and mechanical properties of a high-strength strip casting microalloyed steel

A novel Nb–V–Mo microalloyed steel with 1 GPa yield strength and high ductility was developed by strip casting. The effects of hot rolling on the microstructure and mechanical properties of the Nb–V–Mo microalloyed steel were investigated using scanning electron microscopy, electron backscatter diffraction, transmission electron microscopy, atom probe tomography and tensile tests. Both the as-cast and hot-rolled specimens exhibit a microstructure characterized by lath-like bainite and (Nb, V, Mo)C clusters, while the bainite lath was refined after hot rolling. Tensile test results show obvious improvements in the yield strength, tensile strength, and elongation of the hot-rolled specimen (1008 MPa, 1075 MPa, 20.1 %, respectively), compared to that of the as-cast ones (879 MPa, 978 MPa, 19.0 %, respectively). Additionally, the hot-rolled specimen displays a similar dislocation multiplication and storage capacity to the as-cast specimen, resulting in a comparable work-hardening capability during plastic deformation.

Effect of La on the Microstructures and Mechanical Properties of Al-5.4Cu-0.7Mg-0.6Ag Alloys.

The effects of the rare earth element La on the microstructure and mechanical properties of cast Al-5.4Cu-0.7Mg-0.6Ag alloys have been investigated through metallographic observation, scanning electron microscopy analysis, transmission electron microscopy, X-ray diffraction, and tensile testing. The present form and action mechanism of La have been analyzed. The findings indicate that the inclusion of trace amounts of La markedly diminishes the grain size in the Al-Cu-Mg-Ag alloy. Furthermore, as the La content increases, the alloy's strength is significantly improved. When the La concentration reaches 0.4 wt.%, the mechanical properties of the alloy, both at room temperature and at 350 °C, surpass those of the alloy lacking rare earth elements. When the added rare earth La content exceeds 0.2 wt.%, the emergence of the Al6Cu6La phase causes the alloy structure to exhibit a skeletal morphology, altering the morphology and distribution of excess second phases along grain boundaries, thereby impacting the alloy's overall performance. Incorporating La leads to a reduction in the size of the strengthening precipitate phase Ω while also enhancing its precipitation density, but an excess of La leads to the emergence of Al6Cu6La, depleting the available Cu and suppressing the precipitation of the Ω phase, ultimately affecting the mechanical properties of the alloy.

The impact of small Zr addition to Al–Ni cast alloy for elevated temperature applications

Most aluminium casting alloys are based on the eutectic system Al–Si, which has weak thermal properties. Alloys from the eutectic Al–Ni system on the other hand have higher thermal stability and good casting properties and are therefore promising for casting applications. Using casting simulations, a copper mold was designed to achieve cooling rates above 100 K/s with the aim of producing a Zr-rich supersaturated solid solution. Microstructural analysis revealed that the addition of Zr leads to notable changes in the microstructure characterised by the formation of primary Al3Zr and αAl dendrites. Subsequent heat treatment revealed that Zr-enriched alloys undergo significant age hardening, which showed an improvement in microhardness due to effective Al3Zr precipitation.

Adaptive neuro-fuzzy inference system approach for tensile properties prediction of LPDC A357 aluminum alloy

This study is based on the desire of aluminum casting foundries to understand the influence of minor changes, within the specification limits, in the alloy chemistry. In order to ensure the casting of A357 Al alloys within the framework of the casting standards and to minimize the quality problems that may arise during casting; the estimation of ultimate tensile strength (UTS), yield strength (YS) and elongation (ε) due to very small changes among the alloying elements, although they are in the standard range, by using machine learning method (ML), were studied. The dataset of chemical composition and tensile properties of Low-Pressure Die Cast (LPDC) A357 Al alloy were experimentally established. The relationship between five input variables in the A357 alloy, namely the main alloying elements Si and Mg together with the most common impurity contents Fe, Ti and Cu were selected and three outputs (i.e UTS, YS and ε) were linked by Adaptive Neuro Fuzzy Inference System (ANFIS). The ANFIS model predicted that the most detrimental element affecting tensile properties was Fe content. According to this model, the order of the relative importance on UTS, YS and ε revealed as Si, Mg and Ti content respectively after the Fe content of the alloy.

Effect of Al or Cu Content on Microstructure and Mechanical Properties of Zn Alloys Fabricated Using Continuous Casting and Extrusion

The effect of Al or Cu content on the microstructure and mechanical properties of continuous casting and extrusion Zn alloys has been studied by a room temperature tensile test, X-ray diffraction, and scanning electron microscope. With the increase in Al content, the microstructure of continuous casting and extrusion Zn alloys slightly coarsens, and the lamellar eutectic structure increases. The changes in the above structural factors result in a slight decrease in strength and a significant increase in the elongation of Zn-Al alloys. The strength of Zn alloys increases as the Cu content increases due to the increased content and size of the second phase in the Zn alloys. This means that the mechanical properties of Zn alloys can be adjusted by a continuous casting and extrusion process, and the improvement of equipment capacity can improve the structure and morphology of the alloys.

Revisiting class: A feminist political analysis of the Indian Time Use Survey

AbstractThe literature on agrarian change in India has largely employed class categories based upon data on land, assets and occupational status, which collapse women's class relations into those of (mostly male) households heads. In this paper, we interrogate this understanding of class building on the work of Carmen Diana Deere. Employing the first ever national time use survey conducted in India in 2019, we interrogate class as a labour process that intersects with caste and gender. Our analysis of the data using a Marxist‐feminist framework suggests the following. First, there exist intra‐household gendered differences in class locations. This calls to question theoretical frameworks that assign a cohesive class location to all household members that underlie data collection in India and elsewhere. Second, individuals participate in multiple labour processes depending on their caste and gender. Hence, they may be subsumed to capital in varied and sometimes contradictory ways. Finally, we find that both men and women engage in reproductive labour in addition to other forms of labour, which varies by caste categories. This finding further underscores and supports previous research on the importance of an expanded conception of work that includes reproductive labour. In sum, we argue for a more complex understanding of class in India, one that incorporates its caste and gender dimensions.

Effects of Alumina Bubble Addition on the Properties of Corundum-Spinel Castables Containing Cr2O3.

Purging plugs made of corundum-spinel castables containing Cr2O3 have been widely utilized in secondary refining process. However, their poor thermal shock resistance has greatly limited the improvement of their service life. Aiming to enhance their properties, we introduced alumina bubbles (ABs) to corundum-spinel castables, and the effects of the AB addition on the properties of the castables are studied in this manuscript. The results indicate that the apparent porosity, permanent linear change, cold strength, and hot strength all increased with an increasing AB amount. The thermal shock resistance of the samples with the AB addition was improved; the residual strength and residual strength ratio of the sample with 4 wt% ABs was the best. The effects of ABs on the tabular alumina aggregate distribution and relationship between the cold strength of the samples and the AB content was evaluated via the box dimension method. With the increments of AB content, the box dimension value of the tabular alumina within the samples significantly decreased, indicating that the tabular alumina aggregate distribution was related to the amount of ABs. In addition, the relationship between the box dimension and the strength was also established.

Properties of tape cast (Na, K, Li) (Nb, Sb, Ta)O3 -based ceramics sintered in reduced atmosphere and its application in triaxial piezoelectric accelerometer

In this study, we utilized the tape-casting method to produce Pb-free (Na0·52K0·4425Li0.0375) (Nb0·8925Sb0·07Ta0.0375)O3 + 2 mol% MnCO3 + y mol% LiF (y = 0 to 3) piezoelectric ceramics. We investigated the impact of LiF sintering in a reduced atmosphere on microstructure, dielectric properties, impedance spectroscopy, and piezoelectric performance. By analyzing the degree of diffuse phase transition, we observed increased density and enhanced long-range order in the sample doped with 1 mol% LiF, which exhibited optimal piezoelectric properties (d33 = 265 pC/N and kp = 0.437) and a minimal diffusion parameter. Moreover, LiF doping enabled sintering at 1020 °C under low PO2, facilitating potential co-firing with Cu inner electrodes to further enhance the piezoelectric performance. Using the optimized parameters, we fabricated a cross-type triaxial piezoelectric accelerometer, demonstrating sensitivities of 2.33, 2.44, and 10.6 mV/g along the X, Y, and Z axes, respectively, with a resonance frequency of ∼2600 Hz and frequency range of ∼1300 Hz. This accelerometer holds promise for vibration measurements in low-frequency mechanical systems.

The effect of ultra-fast surface hardening and strengthening on microstructure and mechanical properties of cast (9Cr–3Co–3W) heat-resistant steel

The effect of ultra-fast surface hardening and strengthening on microstructure and mechanical properties of cast (9Cr–3Co–3W) heat-resistant steel

Influence of Plastic Deformation and Hydroxyapatite Coating on Structure, Mechanical, Corrosion, Antibacterial and Cell Viability Properties of Zinc Based Biodegradable Alloys

Zinc (Zn)-based biodegradable alloys have been at the forefront of absorbable biomaterial research in recent years due to their high biocompatibility and corrosion rates. The arc melting process was used to produce the Zn–1Cu–1Ag biodegradable alloy. The influence of different plastic deformation rates on the microstructure of the material was examined after the cold rolling at deformation rates of 47% and 61%. The undeformed and deformed alloys have been hydroxyapatite-coated using the electrophoretic deposition process to improve its surface, corrosion, and bioactivity properties. Optical, XRD, SEM, and EDS examinations were used to analyze the samples’ uncoated, coated, and rolled-unrolled forms. The nucleation of the (Ag, Cu)Zn4 secondary phase was formed during the rolling process. Hardness and compression tests were used to determine the mechanical properties of cast and rolled alloys, and in vitro corrosion tests were carried out in simulated body fluid. Antimicrobial and cell viability tests are executed to demonstrate the biocompatibility of the deformed and HA-coated Zn–1Cu–1Ag alloy. The mechanical properties were improved after the rolling process, with the highest results found in 47% of the rolled samples exhibiting a compressive strength of 412.65 ± 0.5 MPa and 61% of the rolled samples exhibiting a hardness value of 88.1 ± 0.5 HV. The samples that were rolled (61%) and coated with hydroxyapatite (HA) exhibited the highest level of corrosion resistance. The antimicrobial tests revealed that the rolled and HA coated Zn1Cu1Ag groups exhibited greater inhibition rates (47 and 61%) compared to the other groups when tested against E. coli. The HA-coated groups exhibited good cell viability ratios, with the maximum viability seen in the rolled and HA-coated group at 47%.Graphical