Observations on the Thermal Response and Mold Filling Behavior of an AZ91E Magnesium Alloy Cast by the Lost Foam Casting Process

2007 ◽  
Vol 539-543 ◽  
pp. 1609-1614
Author(s):  
Lukas Bichler ◽  
Comondore Ravindran
Keyword(s):  
Magnesium Alloy ◽  
Thermal Response ◽  
Casting Process ◽  
Mold Filling ◽  
Lost Foam Casting ◽  
Lost Foam ◽  
Alloy Cast

Functions of Step Gating System in the Lost Foam Casting Process

2012 ◽  
Vol 591-593 ◽  
pp. 940-944 ◽  
Author(s):  
Hong Zhou ◽  
Li Heng Luo
Keyword(s):  
Mass Flux ◽  
Flux Ratio ◽  
Casting Process ◽  
Mold Filling ◽  
Lost Foam Casting ◽  
Gating System ◽  
Bottom Side ◽  
Total Mass Flux ◽  
Filling Characteristics ◽  
Lost Foam

In order to explore whether the step gating system played a role in lost foam casting (LFC) process, this paper simulated the mold filling process of a step gating system with an auxiliary sprue and three side ingates by using the gravity LFC model of the code FLOW-3D, and analyzed its mold filling characteristics in LFC. It is found the mass flux ratio through the bottom-side ingate exceed 82% the total mass flux, much more than through the others. And it is also found the metal temperature of the middle region in the height direction is lower than the upper region or bottom region. The results show that the step gating system is not able to achieve its main roles in LFC. Our results can be used to design gating system in LFC.

Numerical Modeling of EPS Foam Decomposition in the Lost Foam Casting Process

2005 ◽  
Author(s):  
X. J. Liu ◽  
S. H. Bhavnani ◽  
R. A. Overfelt
Keyword(s):  
Heat Transfer ◽  
Process Parameters ◽  
Experimental Studies ◽  
Casting Process ◽  
Mold Filling ◽  
Lost Foam Casting ◽  
Interfacial Heat Transfer Coefficient ◽  
Filling Process ◽  
Foam Pattern ◽  
Lost Foam

The importance of smooth mold filling in the lost foam casting process has been recognized for a long time. The more uniform the filling process, the better the quality of the casting products that are produced. Successful computer simulations can help reduce the number of trials and cut down the lead time in the design of new casting products by better understanding the complex mechanisms and interplay of different process parameters in the mold filling process. In this study, a computational fluid dynamics (CFD) model has been developed to simulate the fluid flow of molten aluminum and the heat transfer involved at the interfacial gap between the metal and the expanded polystyrene (EPS) foam pattern. The commercial code FLOW-3D was used because it can track the front of the molten metal by a Volume of Fluid (VOF) method and allow complicated parts to be modeled by the Fractional Area/Volume Ratios (FAVOR) method. The code was modified to include the effects of varying interfacial heat transfer coefficient based on gaseous gap pressure which is related to foam degradation and coating permeability. The modification was validated against experimental studies and the comparison showed better agreement than the basic model. Process parameters such as initial metal temperature, foam pattern property, and gating system were investigated. The defect prediction model was also used to study the dependence of defect formation on the process variables.

scholarly journals Mold Filling Analysis in Lost Foam Casting Process for Aluminum Alloys and Its Experimental Validation

2003 ◽  
Vol 44 (10) ◽  
pp. 2169-2174 ◽  
Author(s):  
Jer-Haur Kuo ◽  
Jui-Ching Chen ◽  
Yung-Ning Pan ◽  
Weng-Sing Hwang
Keyword(s):  
Aluminum Alloys ◽  
Experimental Validation ◽  
Casting Process ◽  
Mold Filling ◽  
Lost Foam Casting ◽  
Filling Analysis ◽  
Lost Foam

Measurements of Decomposed EPS Gases Pressure and Molten Metal-Polymeric Foam Interface Velocity During Lost Foam Casting Process: Part 1—Disconnect Casting

2000 ◽  
Author(s):  
Sayavur I. Bakhtiyarov ◽  
Ruel A. Overfelt
Keyword(s):  
Pressure Fluctuations ◽  
Interface Velocity ◽  
High Sensitivity ◽  
Casting Process ◽  
Mold Filling ◽  
Vacuum Pressure ◽  
Small Scale ◽  
Lost Foam Casting ◽  
Vacuum Casting ◽  
Lost Foam

Abstract Process parameters of lost foam casting were studied experimentally on a commercial scale for two casting techniques: conventional and vacuum assisted gravity castings. The paper presents the results of the foundry experiments focused on the time and spatial dependent aspects of mold filling of a commercial pattern (Disconnect). A small-scale commercial model was designed and fabricated to conduct the experiments to study the thermo- and hydrodynamics of the mold filling characteristics. A high sensitivity linear output capacitive sensor was used to record the rate of sand flow and compaction in flask while horizontal and/or vertical vibrations were applied. A computer aided thermometric technique was used to study the heat-related processes in the counter-gravity lost foam vacuum casting. A complete pattern of vacuum/pressure fluctuations is obtained during counter-gravity vacuum casting using bi-directional vacuum/pressure transducer. Tolerance analyses were performed for styrofoam patterns and their cast products produced by the conventional and vacuum assisted casting procedures.

Properties of Pressurized Lost Foam Casting of Al-11Si Alloy

2011 ◽  
Vol 383-390 ◽  
pp. 1730-1734 ◽  
Author(s):  
Ali Asghar Niakan ◽  
M.H. Idris ◽  
Ali Ourdjini ◽  
Majid Karimian
Keyword(s):  
Vickers Hardness ◽  
Testing Machine ◽  
Applied Pressure ◽  
Indentation Test ◽  
Casting Process ◽  
Fine Sand ◽  
Lost Foam Casting ◽  
Lost Foam ◽  
Alloy Cast ◽  
Sand Size

Lost Foam Casting, pressurized casting, solidification, mechanical properties. Abstract. The paper presents the result of investigation on aluminum-silicon (LM6) alloy cast using pressurized lost foam casting process. The study investigated the effect of pressure and sand size on hardness and roughness of the casting produced. Air pressure of 1, 2, 3 and 4 bars was applied on the solidifying alloy poured in mould of sand sized 40-60(AFS). The roughness and hardness of the casting was measured using Hobson (Surtronic 3+) and Vickers hardness testing machine respectively and reported in the average of ten readings. For roughness measurement of the solidified castings, measurement was conducted in 25mm run whilst 11kgf was applied for Vickers hardness indentation test. The results show that using of finer sand size besides applying pressure during solidification of LM6 alloy has significant influence on roughness and hardness of the alloy. Increasing the applied pressure and used of fine sand size expedited heat transfer from the melt to the mould and surrounding thus decreasing solidification time. Consequently, reduced casting surface roughness as well as increased in hardness.

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