scholarly journals Mechanisms of gas and shrinkage porosity formation in solidifying shear bands

Author(s):  
Shishira Bhagavath ◽  
Zhixuan Gong ◽  
Tim Wigger ◽  
Saurabh Shah ◽  
Bita Ghaffari ◽  
...  
2014 ◽  
Vol 790-791 ◽  
pp. 429-434 ◽  
Author(s):  
Sadaf Vazehrad ◽  
Jessica Elfsberg ◽  
Attila Diószegi

The purpose of this work is to investigate the relation between macro shrinkage porosity level and the level of graphite nodularity, gaseous elements and the size of eutectic colonies in compacted graphite iron. Also, the internal shrinkage-pore surfaces were analyzed by SEM and EDS techniques. It was found that samples with higher shrinkage porosity level, contained higher level of graphite nodularity and number of eutectic colonies. Also, samples with higher level of gaseous elements (Hydrogen and Nitrogen) showed higher tendency to shrinkage porosity formation. Austenite dendrites with different morphologies were observed inside the pores, indicating that were formed at different times during solidification, and the surface of the pores were covered with a layer of carbon film indicating that the pores were internal, with no contact to the atmosphere at elevated temperatures.


2016 ◽  
Vol 256 ◽  
pp. 222-227 ◽  
Author(s):  
Jorge Santos ◽  
Anders E.W. Jarfors ◽  
Arne K. Dahle

Aluminium semi-solid castings have gained increased attention due to their superior mechanical properties, lower porosity compared to conventional high pressure die cast material. These characteristics suggests that semi-solid casting should be suitable to produce thick-walled structural components, yet most successful applications of semisolid casting have been for thin-walled components. There is a lack of understanding on filling and feeding related defect formation for semi-solid castings with thick-walled cross-sections. In the current study an AlSi7Mg0.3 aluminium alloy was used to produce semi-solid castings with a wall thickness of 10mm using a Vertical High Pressure Die Casting machine. The RheoMetalTM process was used for slurry preparation. The primary solid α-Al fraction in the slurry was varied together with die temperature. The evaluation of the filling related events was made through interrupted shots, stopping the plunger at different positions. Microscopy of full castings and interrupted test samples were performed identifying the presence of surface segregation layer, shear bands, gas entrapment, shrinkage porosity as well as burst feeding.


2013 ◽  
Vol 336 ◽  
pp. 135-146 ◽  
Author(s):  
Zenon Ignaszak ◽  
Paweł Popielarski ◽  
Jakub Hajkowski

This paper highlights permanent development of process virtualization in the mechanical engineering industry, especially in the area of foundry. Virtualization is increasingly developed on the stage of product design and materials technologies optimization. Simultaneously, increasing expectations of design and process engineers regarding the practical effectiveness of applied simulation systems is observed. To enhance the knowledge in the scope of modelling and simulation in the foundry processes, one should be acquainted with the hard modelling based on physical-mathematical formula and also the soft modelling, burdened with simplifications resulting from both knowledge level on description of particular phenomena and level of theirs complexity. The trends observed in modelling of foundry processes and expectations of users compared with creators upgraded propositions new, additional modules based mostly on poorly tested theory are discussed. In such cases, each new module should be tested on sensitivity of additional parameters, which appear in these new modules. If needed and possible, these tests ought to be related to validation of the whole complex model containing such new modules. The purpose is to obtain simulation tools allowing the most possible realistic prognosis of the casting structure, including indication, with the highest possible probability, places in the casting that are endangered with the possibility of a gas and shrinkage porosity formation. These problems with elements of model validation are presented in the paper.


2017 ◽  
Vol 2017 ◽  
pp. 1-19 ◽  
Author(s):  
M. G. Mahmoud ◽  
A. M. Samuel ◽  
H. W. Doty ◽  
S. Valtierra ◽  
F. H. Samuel

The present study was performed on A356 alloy with the main aim of investigating the effects of La and Ce additions to 356 alloys (with and without 100 ppm Sr) on the microstructure and porosity formation in these alloys. Measured amounts of La, Ce, and Sr were added to the molten alloy. The results showed that, in the absence of Sr, addition of La and Ce leads to an increase in the nucleation temperature of the α-Al dendritic network with a decrease in the temperature of the eutectic Si precipitation, resulting in increasing the freezing range. Addition of 100 ppm Sr results in neutralizing these effects. The presence of La or Ce in the casting has a minor effect on eutectic Si modification, in spite of the observed depression in the eutectic temperature. It should be noted that Ce is more effective than La as an alternate modifying agent. According to the atomic radius ratio, rLa/rSi is 1.604 and rCe/rSi is 1.559, theoretically, which shows that Ce is relatively more effective than La. The present findings confirm that Sr is the most dominating modification agent. Interaction between rare earth (RE) metals and Sr would reduce the effectiveness of Sr. Although modification with Sr causes the formation of shrinkage porosity, it also reacts with RE-rich intermetallics, resulting in their fragmentation.


2000 ◽  
Vol 627 ◽  
Author(s):  
Prabhu R. Nott ◽  
K. Kesava Rao ◽  
L. Srinivasa Mohan

ABSTRACTThe slow flow of granular materials is often marked by the existence of narrow shear layers, adjacent to large regions that suffer little or no deformation. This behaviour, in the regime where shear stress is generated primarily by the frictional interactions between grains, has so far eluded theoretical description. In this paper, we present a rigid-plastic frictional Cosserat model that captures thin shear layers by incorporating a microscopic length scale. We treat the granular medium as a Cosserat continuum, which allows the existence of localised couple stresses and, therefore, the possibility of an asymmetric stress tensor. In addition, the local rotation is an independent field variable and is not necessarily equal to the vorticity. The angular momentum balance, which is implicitly satisfied for a classical continuum, must now be solved in conjunction with the linear momentum balances. We extend the critical state model, used in soil plasticity, for a Cosserat continuum and obtain predictions for flow in plane and cylindrical Couette devices. The velocity profile predicted by our model is in qualitative agreement with available experimental data. In addition, our model can predict scaling laws for the shear layer thickness as a function of the Couette gap, which must be verified in future experiments. Most significantly, our model can determine the velocity field in viscometric flows, which classical plasticity-based model cannot.


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