Effect of Casting Parameters on Porosity in LFC

2011 ◽  
Vol 148-149 ◽  
pp. 1198-1201
Author(s):  
S. Izman ◽  
Amirreza Shayganpour ◽  
M.H. Idris
Keyword(s):  
Energy Savings ◽  
Cast Alloy ◽  
Casting Process ◽  
Experimental Investigations ◽  
Lost Foam Casting ◽  
Thin Wall ◽  
Thin Sections ◽  
Casting Porosity ◽  
Lost Foam ◽  
Significant Factors

Cast aluminium alloys often contain microstructural defects resulting from the casting process such as porosity. Developments of Lost foam casting (LFC) process is considered as one of the most rapid in casting technology owing to its unique advantages on energy savings and capabilities to produce castings with thin sections. In the present research, experimental investigations in lost foam casting of aluminium-silicon cast alloy, LM6, were conducted. The main objective of the study was to evaluate the effect of different pouring temperatures, slurry viscosities, vibration times and sand sizes on the porosity of castings. A stepped pattern was used in the study and the focus of the investigations was at the thinnest 3 mm section. A full 2-level factorial design experimental technique was employed to plan the experiment and subsequently identify the significant factors which affect the casting porosity. The result shows that increasing in the pouring temperature decreases the porosity in the thin-wall section and finer sand size is more favourable than coarse size for LFC mould making process.

DOE Analysis of the Influence of Sand Size and Pouring Temperature on Porosity in LFC

2011 ◽  
Vol 121-126 ◽  
pp. 2661-2665
Author(s):  
S. Izman ◽  
Amirreza Shayganpour ◽  
M.H. Idris ◽  
Hassan Jafari
Keyword(s):  
Cast Alloy ◽  
Experimental Investigations ◽  
Lost Foam Casting ◽  
Thin Wall ◽  
Pouring Temperature ◽  
New Process ◽  
Casting Porosity ◽  
Lost Foam ◽  
Significant Factors ◽  
Sand Size

Lost foam casting is a relatively new process in commercial terms and is widely used to produce defect free castings owing to its advantages like producing complex shape and acceptable surface finish. In the present research, experimental investigations in lost foam casting of aluminium-silicon cast alloy, LM6, were conducted. The main objective of the study was to evaluate the effect of different sand sizes and pouring temperatures on the porosity of thin-wall castings. A stepped pattern was used in the study and the focus of the investigations was at the thinnest 3 mm section. A full 2-level factorial design experimental technique was employed to plan the experiment and subsequently identify the significant factors which affect the casting porosity. The result shows that increasing in the pouring temperature decreases the porosity in the thin-wall section of casting. Finer sand size is more favourable than coarse size for LFC mould making process.

Analysis of the Effect of Sand Size and Vibration Time on Surface Roughness in Lost Foam Casting of LM6 Alloy by Design of Experiments

2011 ◽  
Vol 337 ◽  
pp. 422-425 ◽  
Author(s):  
S. Izman ◽  
A Shayganpour ◽  
Mohd Hasbullah Idris
Keyword(s):  
Surface Roughness ◽  
Cast Alloy ◽  
Lost Foam Casting ◽  
Thin Wall ◽  
Vibration Time ◽  
Lost Foam ◽  
Sand Grain Size ◽  
Significant Factors ◽  
Sand Size

Abstract. In the present research, an experimental investigation in lost foam casting of an aluminum-silicon cast alloy, LM6, was conducted. The main objective of the study was to investigate the effect of different sand size and vibration time on the surface roughness of thin-wall castings. A stepped pattern with a 3 mm section in the thinnest step was used for the investigation. A full 2-level factorial design experimental technique was used to identify the significant factors which affect the surface roughness of casting. The results were evaluated by means of variance analysis. It is founded that surface roughness deteriorates with higher sand grain size and vice versa. In contrast, vibration time was found has no significant effect to the quality of casting surface.

Effect of Pressure on Structure and Properties of Lost Foam Casting of Al-11Si Cast Alloy

2011 ◽  
Vol 110-116 ◽  
pp. 639-643 ◽  
Author(s):  
Ali Asghar Niakan ◽  
M.H. Idris ◽  
Majid Karimian ◽  
A. Ourdjini
Keyword(s):  
Cast Alloy ◽  
Eutectic Silicon ◽  
Testing Machine ◽  
Applied Pressure ◽  
Casting Process ◽  
Optical Microscope ◽  
Lost Foam Casting ◽  
Image Analyzer ◽  
Effect Of Pressure ◽  
Lost Foam

The paper presents the results of an investigation on aluminum-silicon (LM6) alloy using pressurized lost foam casting process. The study investigated the effect of pressure on casting integrity-geometry, eutectic silicon spacing, particle roundness and hardness. Following air pressures: 1bar, 2bar, 3bar and 4bar were applied on the solidifying alloy. The eutectic silicon spacing and particle roundness were measured using optical microscope which was equipped with image analyzer by averaging of at least ten results as well as Vickers hardness testing machine. For casting integrity-geometry all surfaces of solidified castings were captured by digital camera for better observation. The results show that applying pressure during solidification of the LM6 alloy has significant influence on casting integrity-geometry, eutectic silicon spacing, particle roundness and hardness of the alloy. By increasing the applied pressure, solidification time decline. Consequently, silicon spacing reduces as well as increasing of hardness. Besides, rising air pressure lead to fulfilling of molten which improves the casting integrity and particle roundness.

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.

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