Direct Observation of Effects of Foam Density, Gating Design and Pouring Temperature on Mold Filling Process in Lost Foam Casting of A356 Alloy

2015 ◽  
pp. 109-118
Author(s):  
A. Sharifi ◽  
M. Mansouri Hasan Abadi ◽  
R. Ashiri
Keyword(s):  
Direct Observation ◽  
A356 Alloy ◽  
Mold Filling ◽  
Lost Foam Casting ◽  
Foam Density ◽  
Filling Process ◽  
Pouring Temperature ◽  
Lost Foam

scholarly journals Investigation of temperature, degree of vacuum, pattern coating thickness effects on mold filling in lost foam casting (LFC) process of A356 alloy

2015 ◽  
Vol 18 (2) ◽  
pp. 94-103
Author(s):  
Ha Ngoc Nguyen ◽  
Phong Quoc Le ◽  
Tri Nhat Nguyen ◽  
Hoai Dinh Lai
Keyword(s):  
Coating Thickness ◽  
A356 Alloy ◽  
Mold Filling ◽  
Complex Model ◽  
Production Costs ◽  
Lost Foam Casting ◽  
Pouring Temperature ◽  
Casting Technique ◽  
Lost Foam ◽  
Dipping Time

Lost foam casting (LFC) process with outstanding advantages has been known as a new casting technique in foundry engineering. Especially, the operation restricts errors of a mould because of using expanded patterns without parting line being appropriate for the complex model. Great interest in this technology of the casting manufacturers is mainly lower, compared with the traditional process, investment outlays and production costs. The use of unbounded sand also reduces its treatment cost, more friendly and simple with the environment. The study examines the simultaneous effects of pouring temperature, degree of vacuum, coating thickness (through dipping time) on mold filling in LFC. A356 aluminum alloy is used in this study. By using a full two-level factorial design of experimental technique to identify the significant manufacturing factors affecting the mold filling. Results of this investigation indicated that increasing pouring temperature, degree of vacuum and decreasing dipping time obtain casting with higher filling rate.

Numerical Modeling of EPS Foam Decomposition in the Lost Foam Casting Process

2005 ◽  
Author(s):  
X. J. Liu ◽  
S. H. Bhavnani ◽  
R. A. Overfelt
Keyword(s):  
Heat Transfer ◽  
Process Parameters ◽  
Experimental Studies ◽  
Casting Process ◽  
Mold Filling ◽  
Lost Foam Casting ◽  
Interfacial Heat Transfer Coefficient ◽  
Filling Process ◽  
Foam Pattern ◽  
Lost Foam

The importance of smooth mold filling in the lost foam casting process has been recognized for a long time. The more uniform the filling process, the better the quality of the casting products that are produced. Successful computer simulations can help reduce the number of trials and cut down the lead time in the design of new casting products by better understanding the complex mechanisms and interplay of different process parameters in the mold filling process. In this study, a computational fluid dynamics (CFD) model has been developed to simulate the fluid flow of molten aluminum and the heat transfer involved at the interfacial gap between the metal and the expanded polystyrene (EPS) foam pattern. The commercial code FLOW-3D was used because it can track the front of the molten metal by a Volume of Fluid (VOF) method and allow complicated parts to be modeled by the Fractional Area/Volume Ratios (FAVOR) method. The code was modified to include the effects of varying interfacial heat transfer coefficient based on gaseous gap pressure which is related to foam degradation and coating permeability. The modification was validated against experimental studies and the comparison showed better agreement than the basic model. Process parameters such as initial metal temperature, foam pattern property, and gating system were investigated. The defect prediction model was also used to study the dependence of defect formation on the process variables.

Determination of Optimal Temperature for Defect-Free Casting of Aluminium in the LP-LFC Process

2011 ◽  
Vol 101-102 ◽  
pp. 934-937
Author(s):  
Ji Qiang Li ◽  
Zhong Zhao ◽  
Zi Tian Fan ◽  
Zhi Xin Jia ◽  
Wen Liu ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Aluminium Alloys ◽  
Low Pressure ◽  
Experimental Results ◽  
Metal Temperature ◽  
Lost Foam Casting ◽  
Optimal Temperature ◽  
Pouring Temperature ◽  
Lost Foam

Fluidity of ZL101 aluminium alloys in the low-pressure lost foam casting (LP-LFC) process has been investigated by altering various temperature variables. The experimental results indicate that the LP-LFC process had fine fluidity, and the pouring temperature was lower than conventional lost foam casting. The effect of the metal temperature on the fluidity is marginal in the LP-LFC process. Excessive pouring temperature not only aggrandizes energy consumption but also deteriorates porosity defect. The success of casting cooling fin demonstrates the advantages of LP-EPC process in producing high-complicated castings.

Lost Foam Casting of Hydroturbine Blades Based on CAE

2011 ◽  
Vol 71-78 ◽  
pp. 694-697
Author(s):  
Jian Zhou ◽  
Li Jun Li ◽  
Jian Wen Yi ◽  
Ming Yang
Keyword(s):  
Model Material ◽  
Raw Material ◽  
Lost Foam Casting ◽  
Polystyrene Foam ◽  
Pouring Temperature ◽  
Fireproof Coating ◽  
Lost Foam ◽  
Foam Plastics ◽  
Lower Carbon ◽  
Carbon Martensite

The article studies the method which hydroturbine part is manufactured by lost foam casting for obtaining higher quality product.The lost model material is polystyrene foam plastics,the EPS diameters are selected in 0.5-0.76mm,the casting raw material is lower carbon martensite stainless steel(ZG06Cr13Ni4Mo).The style of open pouring system is adopted, ∑Fin-gate：∑Fcross-gate：∑Fdown-sprue=1：1.1：1.2, fireproof coating is mixed and coated,square sand box is used. The pouring temperature of liquid is 1600-1650°C.If the technology is strictly according to the design,good quality casting can be gotten.

Functions of Step Gating System in the Lost Foam Casting Process

2012 ◽  
Vol 591-593 ◽  
pp. 940-944 ◽  
Author(s):  
Hong Zhou ◽  
Li Heng Luo
Keyword(s):  
Mass Flux ◽  
Flux Ratio ◽  
Casting Process ◽  
Mold Filling ◽  
Lost Foam Casting ◽  
Gating System ◽  
Bottom Side ◽  
Total Mass Flux ◽  
Filling Characteristics ◽  
Lost Foam

In order to explore whether the step gating system played a role in lost foam casting (LFC) process, this paper simulated the mold filling process of a step gating system with an auxiliary sprue and three side ingates by using the gravity LFC model of the code FLOW-3D, and analyzed its mold filling characteristics in LFC. It is found the mass flux ratio through the bottom-side ingate exceed 82% the total mass flux, much more than through the others. And it is also found the metal temperature of the middle region in the height direction is lower than the upper region or bottom region. The results show that the step gating system is not able to achieve its main roles in LFC. Our results can be used to design gating system in LFC.

Experimental study on the filling process of the lost foam casting process of a cast iron plate

2013 ◽  
Vol 47 (1/2/3/4) ◽  
pp. 188 ◽  
Author(s):  
Jinwu Kang ◽  
Xiaokun Hao ◽  
Gang Nie ◽  
Haimin Long ◽  
Tianjiao Wang ◽  
...  
Keyword(s):  
Experimental Study ◽  
Cast Iron ◽  
Casting Process ◽  
Lost Foam Casting ◽  
Filling Process ◽  
Iron Plate ◽  
Lost Foam
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