Improving Casting Integrity Through the Use of Simulation Software and Advanced Inspection Methods

2012 ◽  
Author(s):  
Ike Sowden ◽  
George Currier
Keyword(s):  
Metal Flow ◽  
Casting Process ◽  
Simulation Software ◽  
Destructive Testing ◽  
Material Density ◽  
Fraction Solid ◽  
Engineering Team ◽  
Trial And Error Method ◽  
Shrinkage Cavities ◽  
Inspection Techniques

Casting integrity is essential for providing components that meet design criteria for strength and fatigue performance. As the leading method of manufacturing metal components in the rail industry, maintaining quality and consistency is a continuing struggle for car owners and builders. Internal shrinkage and voids due to insufficient metal flow are issues commonly found in casting molds which are not designed or utilized properly. Using casting simulation software, potential issues can be discovered upfront and robust mold designs can be created that offer a tolerance for the variance or variations in casting conditions that are present in the real world. Strato, Inc. has extensively studied the effectiveness of these simulations in foundries through advanced inspection techniques. It is evident that casting simulations can not only locate, but also explain shrinkage cavities and voids through material density plots and inspection of directional solidification via critical fraction solid time plots. This approach is markedly more efficient than the traditional trial and error method, where mold makers rely on experience and destructive testing to develop acceptable mold designs. With recent advances in simulation software, the labor and time-intensive ways of the past have been supplanted by a more scientific approach to the problem. Understanding the fluid dynamics and thermodynamics of the casting process provides a means of creating a stable, repeatable final product. This higher quality final product can be delivered faster to the customer and at a far less expense by identifying problem areas prior to the tooling and sampling processes. Case-studies explored by the Strato engineering team suggest that using this software decreases the fallout rate.

scholarly journals Feeding and Gating System Design and Simulation of Flange Roller of Hydrators for Yield Melioration

10.29007/fs9r ◽  
2018 ◽  
Author(s):  
Purvi Chauhan ◽  
Mohit Anuvadiya ◽  
Vivek Chauhan
Keyword(s):  
System Design ◽  
Metal Flow ◽  
Casting Process ◽  
Simulation Software ◽  
Casting Simulation ◽  
Gating System ◽  
Methods And Techniques ◽  
Mould Cavity ◽  
Effectiveness And Efficiency ◽  
Molten Metal Flow

The aim of this paper is showing the advantage of simulation technology in Casting. Casting simulation technique is widely used in foundries and casting industries. Casting simulation simulates the real casting phenomenon and gives a virtual casting process as molten metal flow in mould cavity with respect to time and direction. This paper explains the methods and techniques of feeding & gating system uses to increase the yield of casting in the company. On the basis of the own research it can be stated, that introducing the simulation software bring the great changes in the company, for example: product improvement by prevention of defects, increasing of effectiveness and efficiency in the processes, reduction in timing, proper utilization of material, grater quality, less cost to fulfill defects.

Automatic Control of Molten Metal Flow for Improving Casting Performance

2011 ◽  
Vol 693 ◽  
pp. 179-184
Author(s):  
Thomas Jarlsmark ◽  
Jan Strömbeck ◽  
Mikael Terner ◽  
Jerry Wilkins
Keyword(s):  
Molten Metal ◽  
Metal Flow ◽  
Casting Process ◽  
Direct Chill ◽  
Level Control ◽  
Level Measurement ◽  
Cost Efficient ◽  
Molten Metal Flow ◽  
Automatic Level ◽  
Rolling Ingot

The ways to gain better quality and higher casting performance is an urgent topic among aluminium producers today. This issue is also often on the agenda at conferences like this and the subjects and technologies to achieve this varies. Controlling the molten metal flow by maintaining predefined levels or level patterns is one of many powerful tools to reach this goal. Precimeter Control specializes in applications for non-ferrous molten metal level measurement and molten metal flow control. By integration, or retrofitting, any new or existing casting line can easily be automatically controlled and gain improved casting performance in a cost efficient way. This paper will focus on the main benefits from automatic level control and how some plants have achieved improvements in their casting process of DC (Direct Chill) slab (or rolling ingot) casting after implementing such technology.

Casting Process Solutions Optimization of LFC Forklift Box

2014 ◽  
Vol 571-572 ◽  
pp. 1091-1096
Author(s):  
Guang Sheng Zhang ◽  
Fei Zhang
Keyword(s):  
Orthogonal Experiment ◽  
Casting Process ◽  
Shrinkage Porosity ◽  
Simulation Software ◽  
Technology Program ◽  
Original Process ◽  
Porosity Defects ◽  
Process Solutions ◽  
Technology Solution ◽  
Casting Simulation Software

There are many advantages in producing forklift box through the LFC. However, we found shrinkage porosity defects in the interior of castings through simulating the original process by ProCAST casting simulation software. Therefore, we analyzed the defects and improved the technology program. firstly, increased riser in position of shrinkage, Secondly, changed the filling’s way, lastly, selected the best temperature and vacuum by the orthogonal experiment and determined the best technology solution. we found the shrinkage porosity defects have been removed by the improved process. We found the production consistent with the simulation results through verification. Therefore we verify the accuracy of the ProCAST.

scholarly journals Multi-Method END Study in the Search for 'Defects' in an Aeronautical Radar Element

2020 ◽  
Vol 14 (11) ◽  
pp. 19
Author(s):  
Gaston Sanglier ◽  
Jose Miguel ◽  
Jose Antonio Penaranda ◽  
y Gabriel Del Ojo
Keyword(s):  
Partial Information ◽  
Non Destructive Testing ◽  
Destructive Testing ◽  
The Past ◽  
New Methods ◽  
New Concepts ◽  
Indispensable Tool ◽  
Inspection Techniques ◽  
Non Destructive

Non-Destructive Testing (NDT) has gone from being a simple laboratory curiosity to an indispensable tool in the industry to determine the level of quality achieved in its products. The new concepts of Integrated Manufacturing (CIM) bring a more universal concept of quality compared to the past philosophy based on Quality Control as a group specialized in checking whether production works within certain specifications. Even so, NDTs have not lost interest, but have seen their interest increased due to automated inspection techniques. It has become a contribution to the structuring of quality as it allows to move from purely empirical criteria to other more objective and that constitute the link between design and evaluation (Ramirez et al, 1996). The work presented, although it does not propose new methods or techniques of NDT, has the interest of converging into a single object five conventional methods each of which provides partial information about their quality of manufacture and must synthesize the results in order to evaluate it. Furthermore, it shows a situation of the application of NDT in which these must be applied in the absence of reference standards, as they do not exist. This peculiar situation is completely different from the usual situation in the use of NDT in the industry, both in manufacturing processes and in maintenance inspections.

Understanding T-Ingot Horizontal DC Casting Using Process Modelling

2006 ◽  
Vol 519-521 ◽  
pp. 1461-1466 ◽  
Author(s):  
André Larouche ◽  
Malcom Lane ◽  
Massimo DiCiano ◽  
Daan M. Maijer ◽  
Steve CockCroft ◽  
...  
Keyword(s):  
Process Model ◽  
Defect Formation ◽  
Metal Flow ◽  
Casting Process ◽  
Production Costs ◽  
Process Characteristics ◽  
Powerful Approach ◽  
Foundry Alloys ◽  
Dc Casting

Horizontal continuous casting process has been successfully implemented in Alcan for the production of T-ingots of primary aluminium and foundry alloys. Ability to achieve increased productivity targets and reduce production costs relies on a fundamental understanding of key process characteristics and operating parameters. Thanks to the long-standing experience in vertical DC Casting, numerical modelling appeared as a powerful approach to understand phenomena related to metal flow, solidification and ultimately defect formation. As part of a collaborative R&D program, a global model of horizontal casting process, integrating specialized sub-models on critical aspects of the process such as meniscus dynamics, is being developed. Experimental characterization of primary and secondary cooling is performed in parallel with modelling work to provide the information necessary to properly characterize mould heat transfer. This paper will present the development of a 3D process model of T-ingot casting along with its application to solve specific process challenges that have emerged during the first years of production in the plant.

Analysis of the Common Causes of Papermaking Cast Iron Dryer's Defects and the Study of Test On-Line

2014 ◽  
Vol 936 ◽  
pp. 1851-1856
Author(s):  
Wen Wei Li ◽  
Qing Du ◽  
Wei Zhong Li
Keyword(s):  
Cast Iron ◽  
Longitudinal Wave ◽  
Transition Zone ◽  
Safety Assessment ◽  
Large Angle ◽  
Online Testing ◽  
Destructive Testing ◽  
Double Crystal ◽  
Testing Technology ◽  
Shrinkage Cavities

The existing researches only put forward the stress concentration portion and design improvements from the perspective of stress analysis, or conducts safety assessment on dryers with the methodology of fracture mechanics, without non-destructive testing methods. Based on over 3,400 tests on cast iron dryers in Hangzhou, an ultrasonic testing technology with longitudinal wave double crystal probe is developed in the present investigation. This study illustrates how to identify the volume defects through testing on the air holes, shrinkage cavities and inclusions in the dryer cylinder and small R transition zone with longitudinal wave double crystal probe at a small angle (5°), as well as plane defects with deep cracks through testing on the dryer cylinder and small R transition zone with longitudinal wave double crystal probe at a large angle (42°). It addresses the issues of how to measure the thickness in regular online testing for cast iron dryers, to calculate the intensity or compare with the design value, to identify low hardness value, to determine the key parts in online testing, and how to conduct safety assessment on the cast iron dryers with small cracks. This technique may resolve various problems in cast iron dryer testing.

scholarly journals Microstructure Examinations in Corners of the Low-Carbon Steel Slabs from Continuos Caster Machine

2016 ◽  
Vol 61 (4) ◽  
pp. 2051-2056 ◽  
Author(s):  
G. Kwinta ◽  
S. Kara ◽  
B. Kalandyk ◽  
R. Zapała ◽  
P. Pałka
Keyword(s):  
Surface Defects ◽  
Cast Steel ◽  
Continuous Process ◽  
Low Carbon Steel ◽  
Casting Process ◽  
American Petroleum Institute ◽  
Test Material ◽  
Low Carbon ◽  
Destructive Testing ◽  
Gaseous Fuels

Abstract The exposed selvedge layers in slabs cast by the continuous process should be free from surface defects, which in most cases appear in the form of cracks on the casting surface and run to its interior. In addition to the parameters of the casting process, the occurrence of such defects depends on the chemical composition of cast steel, on the segregation of surface active elements and formation of the precipitates of carbides, nitrides and other phases. Due to the frequent occurrence of defects in corners of the slabs, non-destructive testing was performed on the mechanically cleaned surfaces of slabs. The test material was low-carbon API(American Petroleum Institute API 5L standard) steel micro alloyed with Nb and Ti designed for the production of pipes to handle gas, oil and other liquid and gaseous fuels. Despite the use of different methods of inspection, i.e. ultrasonic, magnetic particle and penetrant, cracks were not traced in the examined material. Then, from the corners of the examined slabs, specimens were cut out for metallographic examinations. The main purpose of these examinations was to disclose the presence of possible cracks and micro cracks on the surfaces transversal and longitudinal to the direction of casting. At the same time, studies were conducted to establish the number and morphology of non-metallic inclusions in selvedge layers of the slab corners and axis. Additionally, hardness of the slabs was measured. The conducted studies revealed only some minor differences in the slab hardness along its axis (130 ÷ 135 HB) and in selvedge layers (120 ÷ 123 HB).

Numerical Simulation on the Liquid Metal Flow of the Acceleration Phase in the Shot Sleeve of Cold Chamber Die Casting Process

2007 ◽  
Vol 561-565 ◽  
pp. 1801-1804
Author(s):  
Jie Yang ◽  
Lang Yuan ◽  
Shou Mei Xiong ◽  
Bai Cheng Liu
Keyword(s):  
Numerical Simulation ◽  
Liquid Metal ◽  
Metal Flow ◽  
Three Dimensional ◽  
Great Influence ◽  
Casting Process ◽  
Shot Sleeve ◽  
Three Dimensional Model ◽  
Acceleration Phase ◽  
Fill Ratio

Slow shot velocity and its acceleration phase in the shot sleeve have great influence on the flow pattern of the liquid metal in the shot sleeve. In this paper, a three-dimensional model based on the SOLA-VOF algorithm was developed and used to simulate the flow of melt in the shot sleeve. The mathematical model was verified by water analog experiments with constant plunger velocities. Based on numerical simulation results, the influences of the plunger acceleration on the wave profile of the liquid metal in the shot sleeve under different fill ratios and sleeve diameters were investigated. The results indicated that in order to avoid air entrapment in the shot sleeve, the optimal acceleration value to the critical slow shot velocity increases with the increase of the fill ratio, and the range of suitable acceleration becomes wider as well. With the same fill ratio, the value of suitable acceleration rises as the plunger diameter increases.

scholarly journals Theoretic and Experimental Studies on the Casting of Large Die-Type Parts Made of Lamellar Graphite Grey Pig Irons by Using the Technology of Polystyrene Moulds Casting from Two Sprue Cups

2012 ◽  
Vol 2012 ◽  
pp. 1-7
Author(s):  
Constantin Marta ◽  
Ioan Ruja ◽  
Cinca Ionel Lupinca ◽  
Monica Rosu
Keyword(s):  
Heat Treatment ◽  
Comparative Analysis ◽  
Research Method ◽  
Experimental Studies ◽  
Casting Process ◽  
Simulation Software ◽  
Casting Defects ◽  
Pig Iron ◽  
Cast Part ◽  
Lamellar Graphite

This paper presents a comparative analysis between the practical results of pig iron die-type part casting and the results reached by simulation. The insert was made of polystyrene, and the casting was downward vertical. As after the part casting and heat treatment cracks were observed in the part, it became necessary to locate and identify these fissures and to establish some measures for eliminating the casting defects and for locating them. The research method was the comparisons of defects identified through verifications, measurements, and metallographic analyses applied to the cast part with the results of some criteria specific to simulation after simulating the casting process. In order to verify the compatibility between reality and simulation, we then simulated the part casting respecting the real conditions in which it was cast. By visualising certain sections of the cast part during solidification, relevant details occur about the possible evolution of defects. The simulation software was AnyCasting, the measurements were done through nondestructive methods.

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