Casting of Titanium Alloys in Centrifugal Induction Furnaces

2014 ◽  
Vol 59 (1) ◽  
pp. 403-406 ◽  
Author(s):  
A. Karwiński ◽  
W. Lesniewski ◽  
P. Wieliczko ◽  
M. Małysza
Keyword(s):  
Titanium Alloys ◽  
Ceramic Material ◽  
Centrifugal Casting ◽  
Metal Flow ◽  
Casting Process ◽  
Material Strength ◽  
Vacuum Furnace ◽  
Technical Problems ◽  
Different Temperatures ◽  
Metal Pressure

Abstract This paper discusses technical problems related with casting of titanium alloys in centrifugal vacuum furnaces. The potentials of an analysis of the centrifugal casting process carried out in the Flow3D software CFD (Computational Fluid Dynamics) were presented. Simulations were carried out on a model set, which enables casting of two connecting rods for an I.C. engine. Changes in the mould filling process were examined for the three selected spinning velocities of the casting arm. The ranges of the metal flow velocity in mould were calculated as well as metal pressure in mould after reaching a predetermined spinning velocity. The results and the adopted mould geometry enabled determination of the magnitude of stress occurring in mould at the time of filling it with liquid titanium alloy. The paper presents a methodology for testing of the ceramic material strength using a four-point loading arrangement. The strength of the ceramic material was determined on samples heated at different temperatures. The obtained results enabled a thesis to be formulated that for pouring of moulds in a centrifugal vacuum furnace, the layered foundry ceramic moulds can be safely used, and the use of moulds that will provide the directional solidification of metal should be possible as well.

Effect of Heat Treatment on Mechanical and Tribological Properties of Centrifugally Cast Functionally Graded Cu/Al2O3 Composite

2017 ◽  
Vol 140 (2) ◽  
Author(s):  
Manu Sam ◽  
N. Radhika
Keyword(s):  
Heat Treatment ◽  
Wear Resistance ◽  
Centrifugal Casting ◽  
Casting Process ◽  
Sem Analysis ◽  
Functionally Graded ◽  
Dry Sliding Wear ◽  
Centrifugally Cast ◽  
Mechanical And Tribological Properties ◽  
Different Temperatures

A functionally graded Cu–10Sn–5Ni metal matrix composite (MMC) reinforced with 10 wt % of Al2O3 particles was fabricated using the centrifugal casting process with dimension Φout100 × Φin85 × 100 mm. The mechanical and wear resistance of the composite has been enhanced through heat treatment. Samples from of the inner zone (9–15 mm) were considered for heat treatment, as this zone has higher concentration of less dense hard reinforcement particles. The samples were solutionized (620 °C/60 min) and water quenched followed by aging at different temperatures (400, 450, and 550 °C) and time (1–3 h). Optimum parametric combination (450 °C, 3 h) with maximum hardness (269 HV) was considered for further analysis. Dry sliding wear experiments were conducted based on Taguchi's L27 array using parameters such as applied loads (10, 20, and 30 N), sliding distances (500, 1000, and 1500 m), and sliding velocities (1, 2, and 3 m/s). Results revealed that the wear rate increased with load and distance whereas it decreased initially and then increased with velocity. Optimum condition for maximum wear resistance was determined using signal-to-noise (S/N) ratio. Analysis of variance (ANOVA) predicted the major influential parameter as load, followed by velocity and distance. Scanning electron microscope (SEM) analysis of worn surfaces predicted the wear mechanism, observing more delamination due to increase in contact patch when applied load increased. Results infer 8% increase in hardness after heat treatment, making it suitable for load bearing applications.

scholarly journals Induction Brazing for Rapid Localized Repair of Inconel 718

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1096
Author(s):  
Aprilia Aprilia ◽  
Jin Lee Tan ◽  
Yongjing Yang ◽  
Sung Chyn Tan ◽  
Wei Zhou
Keyword(s):  
Adverse Effects ◽  
Grain Growth ◽  
Inconel 718 ◽  
Vacuum Furnace ◽  
Slow Process ◽  
Prolonged Heating ◽  
Induction Brazing ◽  
Heating And Cooling ◽  
Short Period ◽  
Different Temperatures

Vacuum furnace has been used for brazing repair of aerospace components, but it is a slow process which typically takes a few hours. The prolonged heating and cooling cycles could cause some adverse effects on the components such as excessive grain growth. A rapid brazing technique using induction coil was studied to evaluate its suitability for localized repair. Induction brazing of Inconel 718 was carried out using AMS 4777 brazing paste at different temperatures (950 °C, 1050 °C and 1150 °C ) for various durations (2 min, 10 min and 20 min). Microstructure and microhardness were evaluated. The experimental results show that brazing at 1050 °C leads to desirable microstructures in a short period of merely 2 min. The study demonstrates the potential application of induction brazing for rapid localized aerospace repair.

Investigation of Functionally Graded Aluminium A356 Alloy and A356-10%SiCp Composite for Hydro Turbine Bucket Application

2016 ◽  
Vol 26 ◽  
pp. 30-46 ◽  
Author(s):  
Williams S. Ebhota ◽  
Akhil S. Karun ◽  
Freddie L. Inambao
Keyword(s):  
Heat Treatment ◽  
Tensile Stress ◽  
Centrifugal Casting ◽  
A356 Alloy ◽  
Casting Process ◽  
Ultimate Tensile Stress ◽  
Functionally Graded ◽  
Cnc Machining ◽  
Mould Material ◽  
Turbine Bucket

The study investigates the application of centrifugal casting process in the production of a complex shape component, Pelton turbine bucket. The bucket materials examined were functionally graded aluminium A356 alloy and A356-10%SiCp composite. A permanent mould for the casting of the bucket was designed with a Solidworks software and fabricated by the combination of CNC machining and welding. Oil hardening non-shrinking die steel (OHNS) was chosen for the mould material. The OHNS was heat treated and a hardness of 432 BHN was obtained. The mould was put into use, the buckets of A356 Alloy and A356-10%SiCp composite were cast, cut and machined into specimens. Some of the specimens were given T6 heat treatment and the specimens were prepared according to the designed investigations. The micrographs of A356-10%SiCp composite shows more concentration of SiCp particles at the inner periphery of the bucket. The maximum hardness of As-Cast A356 and A356-10%SiCp composite were 60 BRN and 95BRN respectively, recorded at the inner periphery of the bucket. And these values appreciated to 98BRN and 122BRN for A356 alloy and A356-10%SiCp composite respectively after heat treatment. The prediction curves of the ultimate tensile stress and yield tensile stress show the same trend as the hardness curves.

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.

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.

scholarly journals Effect of the Filling Ratio on the Solidified Structure in Horizontal Centrifugal Casting Process

2015 ◽  
Vol 101 (9) ◽  
pp. 488-493 ◽  
Author(s):  
Hisao Esaka ◽  
Yoshimasa Kataoka ◽  
Kei Shinozuka
Keyword(s):  
Centrifugal Casting ◽  
Casting Process ◽  
Filling Ratio

Properties and CA4GE-Engine Test of TiAl-Based Alloy Valves by Permanent Mold Casting

2010 ◽  
Vol 139-141 ◽  
pp. 557-560
Author(s):  
Wen Bin Sheng ◽  
Chun Xue Ma ◽  
Wan Li Gu
Keyword(s):  
Tial Alloy ◽  
Centrifugal Casting ◽  
Casting Process ◽  
Vacuum Arc ◽  
Permanent Mold ◽  
Casting Method ◽  
Arc Melting ◽  
Vacuum Arc Melting ◽  
Mold Casting ◽  
Induction Skull Melting

TiAl-based alloy valves were manufactured by combining charges compressed /vacuum arc melting (VA)/ induction skull melting (ISM) procedure with permanent mold centrifugal casting method. Microstructures, compositions and mechanical properties of as-cast and hot isostatical pressed (HIPed) valves are detected. Results show that the permanent mold centrifugal casting process obviously refines the size of grain in TiAl alloy and the tensile strength of as-cast and HIPed valves are 550MPa and 580MPa at 20°C, 370MPa and 470MPa at 815°C, respectively. As-cast specimens show ~0% elongation at 20°C and 1~2% at 815°C, while HIPed ones show an elongation of 1~2% at room temperature and about 10% at 815°C. Furthermore, a 200-hour test was carried out with CA4GE-engine, which demonstrated the possibility of as-cast TiAl alloy valves for the substitution of present steel ones.

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.

A Preliminary Study of Fabrication Technology for Dynamic Compression Plates Using Centrifugal Casting Process

2021 ◽  
Vol 18 (2) ◽  
Author(s):  
A.K. Nasution ◽  
D. Gustiani ◽  
A. Handoko ◽  
Mukhtar ◽  
Zulkarnain ◽  
...  
Keyword(s):  
Low Income ◽  
Dynamic Compression ◽  
Centrifugal Casting ◽  
Casting Machine ◽  
Casting Process ◽  
Low Income Countries ◽  
Silicon Alloy ◽  
Horizontal Type ◽  
Preliminary Study ◽  
Cast Pipe

The high cost of health services in low-income countries has caused them to produce implants and medical devices at low cost. This research highlights a preliminary study of the design concept, mould design, and fabrication of horizontal type centrifugal casting machines for the manufacture of dynamic compression plates materials. Normally, dynamic compression plate is produced from materials such as 316L stainless steel, cobalt, and titanium alloys. In this work, aluminium-silicon alloy was used in this preliminary study. Aluminium-silicon alloy was melted at a temperature of 730 °C and poured into a mould with a rotational speed of 1500 rpm. Tensile, hardness and microstructure investigation were carried out to discern the mechanical properties of the cast product from the horizontal type centrifugal casting machine. Results showed the measured value of tensile strength is not significantly different in the two zones of cast pipe, the butt zone of fall of molten metal (specimen A) was 147 MPa, and the butt-end zone (specimen B) was 142 MPa. The hardness value for the as-cast pipe obtained from the outside, middle, and inside, was 104.0, 92.9, and 80.3 HV, respectively. Evaluation of microporosity in fractures (from tensile test) results from horizontal type centrifugal castings showed a small distribution. Meanwhile, the calculation of the contour hole processing time for DCP with eight holes is 38 minutes per implant.

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