scholarly journals The Research of Properties of Experimental Ceramic Layers

2014 ◽  
Vol 59 (2) ◽  
pp. 703-705
Author(s):  
A. Karwiński ◽  
Z. Żółkiewicz
Keyword(s):  
Molten Metal ◽  
Casting Process ◽  
Ceramic Layer ◽  
Physiochemical Properties ◽  
Research Results ◽  
Evaporative Pattern Casting

Abstract In the evaporative pattern casting process, the surface of a polystyrene pattern (Styrofoam) is coated with a ceramic layer. This ceramic layer, which coats the evaporative pattern, should have specific physiochemical properties including: resistance to thermal, chemical, and erosive activity of molten metal and proper permeability for gases which are produced by the evaporative polystyrene pattern. The article presents the research results of properties of experimentally selected ceramic layers applied on a polystyrene pattern in the evaporative pattern casting process.

scholarly journals Reinforcing cast iron with composite insert

2017 ◽  
Vol 62 (1) ◽  
pp. 355-357 ◽  
Author(s):  
A. Dulska ◽  
A. Studnicki ◽  
J. Szajnar
Keyword(s):  
Wear Resistance ◽  
Cast Iron ◽  
Abrasive Wear ◽  
Molten Metal ◽  
Abrasive Wear Resistance ◽  
Ceramic Layer ◽  
Research Results ◽  
Ceramic Preform ◽  
Ceramic Insert

Abstract The paper presents a proprietary method of making composite cast iron (eutectic) locally reinforced with ceramics. The research included making casts with a ceramic layer, its percentage of the surface was 30%. The research included abrasive wear resistance according to ASTM G 65-00. As a result of the research it has been found that the infiltration of the molten metal into the ceramic preform mainly affects the correct production of the cast with local reinforcement. The research results also have proven that the application of a lattice ceramic insert placed in the mould is the most appropriate option, due to the even distribution of the particles in the cast and obtaining a sound cast.

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 Pre-Detecting Method for Molten Metal Leakage in Casting Process by Using Air Leakage Through Molds

DENKI-SEIKO ◽  
2008 ◽  
Vol 79 (4) ◽  
pp. 329-335
Author(s):  
Naoki Fuse ◽  
Kenichi Tate ◽  
Atsushi Komori
Keyword(s):  
Molten Metal ◽  
Casting Process ◽  
Air Leakage ◽  
Detecting Method

Numerical Simulation of Molten Metal-Polymeric Foam Interface Velocity During Lost Foam Casting

2001 ◽  
Author(s):  
Sayavur I. Bakhtiyarov ◽  
Ruel A. Overfelt
Keyword(s):  
Molten Metal ◽  
Flow Model ◽  
Interface Velocity ◽  
Casting Process ◽  
Lost Foam Casting ◽  
Foam Material ◽  
Polymeric Foam ◽  
Gaseous Products ◽  
3D Software ◽  
Lost Foam

Abstract A novel multiphase flow model is presented for describing the pyrolisis of polymeric foam material in a lost foam casting process. FLOW-3D software (Flow Science, Inc.) has been used to simulate liquid metal filling dynamics and the molten metal-polymeric foam interface velocity in foam patterns of rectangular shape. The effect of the degradation gaseous products on the molten metal-polymeric foam interface velocity was taken into consideration through specially written sub-routing program. The results of the simulations are compared with the previously obtained experimental data for the lost foam iron casting.

scholarly journals Pressing Control Design Based on Analysis of Metal Temperature and Flow in Sand Mold Press Casting

2018 ◽  
Vol 925 ◽  
pp. 491-498
Author(s):  
Ryosuke Tasaki ◽  
Hideto Seno ◽  
Kunihiro Hashimoto ◽  
Kazuhiko Terashima
Keyword(s):  
Molten Metal ◽  
Casting Process ◽  
Metal Temperature ◽  
Sand Mold ◽  
High Yield ◽  
Necessary Condition ◽  
Temperature Decrease ◽  
Velocity Control ◽  
Complex Shapes ◽  
Optimum Velocity

The sand mold press casting method is a novel iron casting process, which has developed by our group in recent years. The proposed method can cast iron into complex shapes with a high yield over 90% and produces high-quality products by filling control of molten metal during pressing motion. However, molten metal inside mold is cooled down by heat transfer to the molds and atmosphere, and often causes solidification before the end of press. Then, the pressing movement of the upper mold is blocked by the solidified metal. Therefore, to avoid the solidification during pressing sand mold, metal temperature must be heated properly to estimate the filling temperature decrease behavior based on analysis results of CFD simulator, FLOW-3D. The necessary condition not to solidify molten metal before the end of press has been found. It was made clear that the mold must be heated up to the necessary temperature beforehand in the pressing process. Furthermore, optimum velocity reference with specified pressure constraints has been designed to prevent casting defect such as penetration and also to minimize the temperature decrease. In this paper, optimum velocity control of servo cylinder considering the both of allowable pressure of molten metal and starting time of solidification is proposed by using a theoretical approach of Model Predictive Control: MPC method. The effectiveness of the proposed control system has been demonstrated by computer simulation and experiments using a laboratory scale machine with molten metal of casting iron.

Aluminum Foam, “Alporas”: The Production Process, Properties and Applications

1998 ◽  
Vol 521 ◽  
Author(s):  
T. Miyoshi ◽  
M. Itoh ◽  
S. Akiyama ◽  
A. Kitahara
Keyword(s):  
Physical Properties ◽  
Production Process ◽  
Molten Metal ◽  
Manufacturing Process ◽  
Aluminum Foam ◽  
Casting Process ◽  
Cellular Structures ◽  
Solidification Shrinkage

ABSTRACTThe production of foamed aluminum has long been considered difficult to realize because of such problems as the low foamability of molten metal, the varying size of cellular structures, solidification shrinkage and so on. Recently these problems have been solved by a number of researches and some manufacturers produce foamed aluminum by their own methods. We have been employing a batch casting process and manufacturing foamed aluminum under the tradename ALPORAS® since 1986. This paper presents the manufacturing process, physical properties and some typical applications of ALPORAS.

Development of a Sand Mold Press Casting Process: “Post-Filled Formed Casting Process”

2008 ◽  
Vol 2 (4) ◽  
pp. 253-258 ◽  
Author(s):  
Kunihiro Hashimoto ◽  
◽  
Kazuhiro Ota ◽  
Junichi Iwasaki ◽  
Yutaka Hagata ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Molten Metal ◽  
Casting Process ◽  
Sand Mold ◽  
Mold Design ◽  
Large Reduction ◽  
Velocity Control ◽  
Key Factors ◽  
Casting Method ◽  
The Press

This paper presents the development of a sand mold press casting process called the “Post-Filled Formed Casting Process.” In this process, molten metal is directly poured into the lower mold; the upper mold then falls down on the lower mold, and both molds are then matched. This method does not use a sprue cup and runner. Therefore, both the quantity of scrap and energy consumption are enormously reduced. This means that the sand mold press casting process is an eco-friendly casting process resulting in a large reduction of CO2 gas. During the last few years, the author's group has been devoted to developing this method as a national project. Mold design for casting, pouring control, and velocity control of the press have been identified as key factors in manufacturing sound products. In this paper, we provide an overview of this novel casting method and present the fundamental results obtained.

Numerical simulation of heat transfer and fluid flow of molten metal in MMA–St copolymer lost foam casting process

2010 ◽  
Vol 210 (14) ◽  
pp. 2071-2080 ◽  
Author(s):  
Ali Charchi ◽  
Mostafa Rezaei ◽  
Siyamak Hossainpour ◽  
Jamal Shayegh ◽  
Sohrab Falak
Keyword(s):  
Heat Transfer ◽  
Numerical Simulation ◽  
Fluid Flow ◽  
Molten Metal ◽  
Casting Process ◽  
Lost Foam Casting ◽  
Lost Foam
Sign in / Sign up

Export Citation Format

Share Document