scholarly journals Validation Tests of Prediction Modules of Shrinkage Defects in Cast Iron Sample

2017 ◽  
Vol 17 (1) ◽  
pp. 57-66 ◽  
Author(s):  
J. Hajkowski ◽  
P. Roquet ◽  
M. Khamashta ◽  
E. Codina ◽  
Z. Ignaszak
Keyword(s):  
Cast Iron ◽  
Cast Alloy ◽  
Processing Parameters ◽  
Standard Test ◽  
Experimental Simulation ◽  
Simulation Code ◽  
Iron Castings ◽  
Shrinkage Defects ◽  
Iron Sample ◽  
Validation Tests

Abstract The paper presents the results of experimental-simulation tests of expansion-shrinkage phenomena occurring in cast iron castings. The tests were based on the standard test for inspecting the tendency of steel-carbon alloys to create compacted discontinuities of the pipe shrinkage type. The cast alloy was a high-silicone ductile iron of GJS - 600 - 10 grade. The validation regarding correctness of prognoses of the shrinkage defects was applied mostly to the simulation code (system) NovaFlow & Solid CV (NFS CV). The obtained results were referred to the results obtained using the Procast system (macro- and micromodel). The analysis of sensitivity of the modules responsible for predicting the shrinkage discontinuities on selected pre-processing parameters was performed, focusing mostly on critical fractions concerning the feeding flows (mass and capillary) and variation of initial temperature of the alloy in the mould and heat transfer coefficient (HTC) on the casting - chill interface.

Study on Data Base of Modeling Concerning Casting Phenomena in Cast-Iron-Mould Simulation Systems

2010 ◽  
Vol 457 ◽  
pp. 305-311 ◽  
Author(s):  
Zenon Ignaszak
Keyword(s):  
Cast Iron ◽  
Model Validation ◽  
Thermomechanical Properties ◽  
Experimental Simulation ◽  
Knowledge Level ◽  
Simulation Studies ◽  
Simulation Code ◽  
Iron Castings ◽  
Chunky Graphite ◽  
Simulation Systems

In the foundry processes the hard modeling based on physical-mathematical formula is burdened with simplifications resulting from both: knowledge level on description of particular phenomena and level of theirs complexity. Trends observed in modeling of foundry processes and expectations of users compared with creators’ up-grades propositions are discussed. The author presents real possibilities of efficient modeling validation considering that limits of multiphysics/multiscale modeling exist for massive cast-iron castings, including the zones infected by degenerated structure (e.g. chunky graphite, dross inclusions). The model validation demands experimental-simulation studies. In the paper also the stress grid castings made of lamellar cast-iron are presented as an example of experimental model validation including the thermomechanical properties of cast-iron and furan mould and applying special Hot Distortion (HDplus®) tests of this sand. The validation of thermo-mechanical model was carried out with the use of Comsol system and chosen foundry simulation code.

scholarly journals Cellular Automaton Modeling of Ductile Iron Density Changes at the Solidification Time

2013 ◽  
Vol 13 (4) ◽  
pp. 9-14 ◽  
Author(s):  
A.A. Burbelko ◽  
D. Gurgul ◽  
M. Królikowski ◽  
M. Wróbel
Keyword(s):  
Cast Iron ◽  
Ductile Iron ◽  
Liquidus Temperature ◽  
Temperature Phase ◽  
Casting Alloys ◽  
Iron Castings ◽  
Shrinkage Defects ◽  
Maximum Value ◽  
Three Stages

Abstract Formation of the shrinkage defects in ductile iron castings is far more complicated phenomenon than in other casting alloys. In the paper one of the aspects of formation of porosity in this alloy was considered - changes in cast iron's density during crystallization caused by varying temperature, phase fractions and phase's composition. Computer model, using cellular automata method, for determination of changes in density of ductile iron during crystallization was applied. Simulation of solidification was conducted for 5 Fe-C binarie alloys with ES from 0.9 to 1.1 for the estimation of the eutectic saturation influence on the ductile iron shrinkage and expansion. As a result of calculations it was stated that after undercooling ductile iron below liquidus temperature volumetric changes proceed in three stages: preeutectic shrinkage (minimal in eutectic cast iron), eutectic expansion (maximum value equals to about 1.5% for ES = 1.05) and last shrinkage (about 0.4% in all alloys regardless of ES).

Modelling of the Density Changes of Nodular Cast Iron During Solidification by CA-FD Method

2014 ◽  
Vol 790-791 ◽  
pp. 140-145
Author(s):  
Andriy A. Burbelko ◽  
Daniel Gurgul ◽  
Wojciech Kapturkiewicz ◽  
Edward Guzik
Keyword(s):  
Cast Iron ◽  
Ductile Iron ◽  
Liquidus Temperature ◽  
Nodular Cast Iron ◽  
Solidification Path ◽  
Temperature Phase ◽  
Casting Alloys ◽  
Iron Castings ◽  
Shrinkage Defects ◽  
Three Stages

Formation of the shrinkage defects in ductile iron castings is far more complicated phenomenon than in other casting alloys. In the presented paper changes the ductile iron density during solidification is analyzed. During the solidification path the influence of the temperature, phase fractions and phase composition is taking into account. Computer model, using cellular automata method, for estimation of changes in density of ductile iron during its solidification is applied. Results of the solidification modeling for Fe-C binary alloys with different composition in the castings with a different wall thickness are presented. As a result of calculations it was stated that after undercooling ductile iron below liquidus temperature volumetric changes proceed in three stages: pre-eutectic shrinkage (minimal in eutectic cast iron), eutectic expansion and the last shrinkage.

The Influence of the Cooler Material on the Structure and Hardeness Gradient of a Grey Pearlitic Cast Iron

2015 ◽  
Vol 1128 ◽  
pp. 18-25 ◽  
Author(s):  
Sorin Ion Munteanu ◽  
Ioan Ciobanu ◽  
Aurel Crisan ◽  
Tibor Bedo ◽  
Daniel Feraru
Keyword(s):  
Cast Iron ◽  
Cooling Rate ◽  
Hardened Layer ◽  
Superficial Layer ◽  
Physical Characteristics ◽  
Grey Cast Iron ◽  
Industrial Practice ◽  
Iron Castings ◽  
Iron Sample ◽  
Grey Cast

The structure and properties of grey cast iron castings are considerably influenced by the cooling rate during solidification. In order to obtain grey cast iron parts with a hard superficial layer (wear resistant), external metallic coolers are placed on those surfaces during casting. This is the case of cam pushers, camshafts, driving shafts, metalworking rolls, etc. Cast iron coolers or steel coolers are mostly used in practice. The cooling rate during solidification is influenced by the thermo-physical characteristics of the coolers. This paper presents the results obtained by simulation and experimental research on coolers material influence on the structure and hardness of the surface layer of a pearlitic cast iron sample. It was studied the solidification of samples with dimensions 20 x 20 x 60 mm, cast of pearlitic cast iron in six variants: without a cooler and in the presence of some metallic coolers of different thermo-physical characteristics (iron, steel, copper, titanium and aluminum coated with a thin layer of steel). It was studied the influence of cooler material on structure of the superficial layer, on thickness of the hardened layer, on superficial hardness, on the temperature field and cooling rates. Conclusions are drawn regarding these influences and the possibility of using external coolers in industrial practice.

Study of Feeding Parameters for the Production of Sound High-Alloyed Ductile Iron Castings with Aluminum

2010 ◽  
Vol 457 ◽  
pp. 261-266
Author(s):  
Vladimir D. Belov ◽  
Edis B. Ten ◽  
Alexander S. Drokin
Keyword(s):  
Cast Iron ◽  
Combustion Engine ◽  
High Heat ◽  
Gray Iron ◽  
High Tendency ◽  
Iron Castings ◽  
Shrinkage Defects ◽  
Feeding Parameters ◽  
Casting Production ◽  
High Aluminum

This work deals with the problem of casting production from high-aluminum cast iron Al22D. This cast iron is characterized by unique combination of properties [1-3]: high heat-resistance in corrosive gases medium especially containing sulfurous gases; relatively low density in comparison with gray iron and satisfactory mechanical properties. In addition, castings made from high aluminum cast iron Al22D are required in many areas of mechanical engineering. However, obtaining high-quality products from this cast iron is a particular problem due to its low-casting properties, especially its high tendency to gas saturation, oxidization and forming scabs, shrinkage and gas-shrinkage defects. Therefore, the aim of this work is the study of the castings feeding parameters. In addition, the technology of "exhaust manifold" casting of internal combustion engine designed to work in forced mode was developed on the basis of the obtained results.

scholarly journals Management of the activity of quality assurance of cast iron castings in foundries

2021 ◽  
Vol 1781 (1) ◽  
pp. 012050
Author(s):  
A Josan ◽  
E Ardelean ◽  
M Ardelean ◽  
V Puţan
Keyword(s):  
Quality Assurance ◽  
Cast Iron ◽  
Iron Castings

scholarly journals Optimisation of Shrinkage and Strength on Thick Plate Part Using Recycled LDPE Materials

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1795
Author(s):  
Norshahira Roslan ◽  
Shayfull Zamree Abd Rahim ◽  
Abdellah El-hadj Abdellah ◽  
Mohd Mustafa Al Bakri Abdullah ◽  
Katarzyna Błoch ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Thick Plate ◽  
Processing Parameters ◽  
Processing Parameter ◽  
Plastic Injection Moulding ◽  
Optimal Setting ◽  
Quality Of Products ◽  
Validation Tests ◽  
Plastic Injection

Achieving good quality of products from plastic injection moulding processes is very challenging, since the process comprises many affecting parameters. Common defects such as warpage are hard to avoid, and the defective parts will eventually go to waste, leading to unnecessary costs to the manufacturer. The use of recycled material from postindustrial waste has been studied by a few researchers. However, the application of an optimisation method by which to optimise processing parameters to mould parts using recycled materials remains lacking. In this study, Response Surface Methodology (RSM) and Particle Swarm Optimisation (PSO) methods were conducted on thick plate parts moulded using virgin and recycled low-density polyethylene (LDPE) materials (100:0, 70:30, 60:40 and 50:50; virgin to recycle material ratios) to find the optimal input parameters for each of the material ratios. Shrinkage in the x and y directions increased in correlation with the recycled ratio, compared to virgin material. Meanwhile, the tensile strength of the thick plate part continued to decrease when the recycled ratio increased. R30 (70:30) had the optimum shrinkage in the x direction with respect to R0 (100:0) material where the shrinkage increased by 24.49% (RSM) and 33.20% (PSO). On the other hand, the shrinkage in the y direction for R30 material increased by 4.48% (RSM) and decreased by 2.67% (PSO), while the tensile strength of R30 (70:30) material decreased by 0.51% (RSM) and 2.68% (PSO) as compared to R0 (100:0) material. Validation tests indicated that the optimal setting of processing parameter suggested by PSO and RSM for R0 (100:0), R30 (70:30), R40 (60:40) and R50 (50:50) was less than 10%.

scholarly journals Influence of Technological Parameters of Furane Mixtures on Shrinkage Creation in Ductile Cast Iron Castings

2014 ◽  
Vol 59 (3) ◽  
pp. 1037-1040 ◽  
Author(s):  
I. Vasková ◽  
M. Hrubovčáková ◽  
J. Malik ◽  
Š. Eperješi
Keyword(s):  
Cast Iron ◽  
Ductile Iron ◽  
Ductile Cast Iron ◽  
Gating System ◽  
Technological Parameters ◽  
Iron Castings ◽  
Steel Castings ◽  
The Impact ◽  
Very High ◽  
Great Development

Abstract Ductile cast iron (GS) has noticed great development in last decades and its boom has no analogue in history humankind. Ductile iron has broaden the use of castings from cast iron into areas, which where exclusively domains for steel castings. Mainly by castings, which weight is very high, is the propensity to shrinkage creation even higher. Shrinkage creation influences mainly material, construction of casting, gating system and mould. Therefore, the main realized experiment was to ascertain the influence of technological parameters of furane mixture on shrinkage creation in castings from ductile iron. Together was poured 12 testing items in 3 moulds forto determine and compare the impact of various technological parameters forms the propensity for shrinkage in the casting of LGG.

Formation of the Cast Iron Coatings Plasma-Sprayed at Different Substrate Temperatures

2010 ◽  
Vol 44-47 ◽  
pp. 2144-2147
Author(s):  
Ya Zhe Xing ◽  
Chao Ping Jiang ◽  
Hong Chen ◽  
Jian Min Hao
Keyword(s):  
Cast Iron ◽  
Substrate Temperature ◽  
Phase Structure ◽  
Processing Parameters ◽  
Optical Microscope ◽  
Atmospheric Plasma ◽  
Cross Sectional ◽  
The Cross ◽  
Plasma Sprayed ◽  
Iron Coatings

In this work, three cast iron coatings were produced by atmospheric plasma spraying. During spraying, the surface temperature of three coatings (substrate temperature) was controlled to be averagely 50oC, 180oC and 240oC by changing the processing parameters. X-ray diffraction (XRD) was employed to analyze the phase structure of the starting powder and the coatings. The results showed that the powder was mainly composed of (Fe,Cr)7C3 and martensite and both the spraying processing and the substrate temperature exerted no influence on coating phase structure. An optical microscope (OM) was used to characterize the microstructure of the cross-section and surface of the coatings. It was found that the cross sectional hardness increased with the increase of the substrate temperature due to the improvement in interlamellar bonding.

scholarly journals Opening Material as the Possibility of Elimination Veining in Foundries

2016 ◽  
Vol 16 (3) ◽  
pp. 157-161 ◽  
Author(s):  
M. Hrubovčáková ◽  
I. Vasková ◽  
M. Benková ◽  
M. Conev
Keyword(s):  
Thermal Conductivity ◽  
Particle Size ◽  
Thermal Expansion ◽  
Cast Iron ◽  
Granular Material ◽  
Surface Defects ◽  
Silica Sand ◽  
Iron Castings ◽  
Thermal Dilatation

Abstract The main bulk density representation in the molding material is opening material, refractory granular material with a particle size of 0.02 mm. It forms a shell molds and cores, and therefore in addition to activating the surface of the grain is one of the most important features angularity and particle size of grains. These last two features specify the porosity and therefore the permeability of the mixture, and thermal dilatation of tension from braking dilation, the thermal conductivity of the mixture and even largely affect the strength of molds and cores, and thus the surface quality of castings. [1] Today foundries, which use the cast iron for produce of casts, are struggling with surface defects on the casts. One of these defects are veining. They can be eliminated in several ways. Veining are foundry defects, which arise as a result of tensions generated at the interface of the mold and metal. This tension also arises due to abrupt thermal expansion of silica sand and is therefore in the development of veining on the surface of casts deal primarily influences and characteristics of the filler material – opening material in the production of iron castings.

Sign in / Sign up

Export Citation Format

Share Document