scholarly journals The Influence of Ingate Size on the Lost Foam Casting Process

2012 ◽  
Vol 12 (2) ◽  
pp. 171-174 ◽  
Author(s):  
T. Pacyniak ◽  
R. Kaczorowski
Keyword(s):  
Casting Process ◽  
Lost Foam Casting ◽  
Cavity Pressure ◽  
Calculation Algorithm ◽  
Original Calculation ◽  
Mould Cavity ◽  
Cavity Filling ◽  
Gas Gap ◽  
Lost Foam ◽  
Mould Casting

The Influence of Ingate Size on the Lost Foam Casting Process The article presents analysis of the influence of ingate size on the Lost Foam casting process. In particular, analysis of simulation tests has been carried out to determine the ingate size influence on the rate of filling of the mould cavity, pressure in the gas gap and size of the gas gap. A specially prepared mathematical model of the process and an original calculation algorithm were used in simulation tests of full-mould casting. The tests have indicated that the increase of the ingate size results in the increase of filling rate and increase of pressure of gases in the gas gap. However, significant influence on mould cavity filling occurs only when the ingate size is less than ~1 cm2.

Synthesis and Characterization of New Refractory Coatings Based on Talc, Cordierite, Zircon and Mullite Fillers for Lost Foam Casting Process

2014 ◽  
Vol 59 (1) ◽  
pp. 89-95 ◽  
Author(s):  
A. Prstić ◽  
Z. Aćimović-Pavlović ◽  
A. Terzić ◽  
L. Pavlović
Keyword(s):  
Microstructural Analysis ◽  
Casting Process ◽  
Lost Foam Casting ◽  
X Ray Diffraction ◽  
X Ray ◽  
Software Application ◽  
Design And Optimization ◽  
Refractory Coatings ◽  
Particle Size And Shape ◽  
Lost Foam

Abstract Refractory coatings based on different refractory fillers (talc, cordierite, zircon and mullite) for application in Lost Foam casting process were investigated. Design and optimization of the coatings composition with controlled, rheological properties included, and consequently synthesis were achieved by application of different coating components, namely different suspension agents and fillers and by alteration of the coating production procedure. Morphologic and microstructural analysis of fillers was carried out by means of scanning electronic microscope. X-ray diffraction analysis by means of X-ray diffractometer was applied in determination and monitoring the phase composition changes of the refractory fillers. An analysis of the particle size and shape was carried out by means of the PC software application package OZARIA 2.5. To assess the effects of application of individual refractory coatings, a detailed investigation of structural and mechanical properties of the moldings obtained was performed. Highlight was placed on revealing and analyzing surface and volume defects present on moldings. Radiographic molding tests were carried out by means of the X-ray device SAIFORT type-S200. Attained results are essential for the synthesis of refractory coatings based on high-temperature fillers and their applications in Lost Foam casting process for manufacturing of moldings with in-advance-set properties.

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 The Effect of a Thin-Wall Casting Mould Cavity Filling Conditions on the Casting Surface Quality

2016 ◽  
Vol 16 (4) ◽  
pp. 222-226
Author(s):  
A. Trytek ◽  
A.W. Orłowicz ◽  
M. Tupaj ◽  
M. Mróz ◽  
O. Markowska ◽  
...  
Keyword(s):  
Casting Process ◽  
Casting Defects ◽  
Thin Wall ◽  
High Concentration ◽  
Casting Surface ◽  
Metallographic Examination ◽  
Furan Resin ◽  
Mould Cavity ◽  
Cavity Filling ◽  
Iron Manganese

Abstract The paper presents results of metallographic examination of faults occurring in the course of founding thin-walled cast-iron castings in furan resin sand molds. A non-conformance of the scab type was Observed on surface of the casting as well as sand buckles and cold shots. Studied the chemical composition by means of a scanning electron microscope in a region of casting defects: microanalysis point and microanalysis surface. Around the observed defects discloses high concentration of oxides of iron, manganese and silicon. A computer simulation of the casting process has been carried out with the objective to establish the cause of occurrence of cold shots on casting surface. The simulation was carried out with the use of NovaFlow & Solid program. We analyzed the flowing metal in the mold cavity. The main reason for the occurrence of casting defects on the surface of the casting was gating system, which caused turbulent flow of metal with a distinctive splash stream of liquid alloy.

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

Thermal Analysis during Solidification of Mg-4%.wtAl Alloy during Lost Foam Casting Process

2011 ◽  
Vol 686 ◽  
pp. 371-377 ◽  
Author(s):  
D.H. Hou ◽  
S.M. Liang ◽  
Rong Shi Chen ◽  
En Hou Han ◽  
C. Dong
Keyword(s):  
Thermal Analysis ◽  
Grain Size ◽  
Casting Process ◽  
Expanded Polystyrene ◽  
Solidification Structure ◽  
Lost Foam Casting ◽  
Dendrite Morphology ◽  
Dendrite Coherency ◽  
Foam Pattern ◽  
Lost Foam

The lost foam casting (LFC) process utilizes the expanded polystyrene (EPS) foam pattern for the production of metallic components. The thermal degradation of the foam pattern has a significant effect on microstructure of the component. Dendrite coherency is important for the determination of the formation of the solidification structure and cast ability of alloys. The effects of the dendrite coherency on grain size in Mg-4Al alloy have been studied using the two-thermocouple thermal analysis technique in the solidified sample. The results also indicate that the grain size increases with the temperature interval between liquids (TN) and dendrite coherency point (TDCP), The solid fraction at DCP (fsDCP) expressed in percent strongly dependents on the dendrite morphology during solidification.

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