scholarly journals Local microwave heating of sand molds as a means to overcome design limitations in sand mold casting

2014 ◽  
Vol 12 ◽  
pp. 21-28 ◽  
Author(s):  
O. Wiedenmann ◽  
R. Ramakrishnan ◽  
P. Saal ◽  
E. Kılıç ◽  
U. Siart ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Microwave Heating ◽  
Casting Process ◽  
Sand Mold ◽  
Metal Casting ◽  
Temperature Dependent ◽  
Selective Heating ◽  
Thermodynamic Simulations ◽  
Mold Casting ◽  
Absorbing Materials

Abstract. Microwave induced selective heating outmatches conventional mold heating by convective heat transfer in means of energy efficiency and cycle time. Moreover, it provides the opportunity of a local manipulation of solidification and cooling processes within the sand casting mold. In this paper, we investigate the suitability of different highly absorbing materials to indirectly heat up the mostly microwave transparent sand mold. The temperature-dependent permittivity of the involved materials is determined by resonator experiments and subsequently used to simulate the electromagnetic field and the thermodynamic response of the sand mold prior to a metal casting process. Experimental results are presented and compared with the outcome of the coupled electromagnetic-thermodynamic simulations and the influence of local microwave heating on the solidification and cooling of the cast is studied.

Effect of Different Gating Systems and Sand Mold Binder on the Cast-Quality of Bicycle Frame Produced through Sand Casting Method

2020 ◽  
Vol 402 ◽  
pp. 100-107
Author(s):  
Akhyar ◽  
Husaini ◽  
Masri Ali ◽  
Nurdin Ali ◽  
Farhan Ahmad
Keyword(s):  
Water Glass ◽  
Casting Process ◽  
Sand Mold ◽  
Casting Defects ◽  
Casting Method ◽  
Mold Casting ◽  
Furan Resin ◽  
Bicycle Frame ◽  
The Impact

The bicycle frame produced through the metal casting process by recycling aluminum alloys can be an environmentally friendly alternative solution. Mold types and gating systems used generally affects the quality of the casting product. In this experiment, the effect of gating number and riser type variations (for sand binder) observed on casting defects, hardness, and impact value. Subsequently, chemical composition and microstructure of recycled aluminum metal from bicycle frames produced through sand mold casting are also evaluated. Three types of risers are bentonite, water glass, and furan resin. The results indicate that mold with two gating system has a low porosity as casting defects. The cast-bike frame produced using furan resin reaches the highest hardness value of 46 HRB compared to water glass and bentonite as the binder of sand-molds. The impact test observes 3.9 J carried out by the ASTM E23 sample at room temperature.

scholarly journals CFD Optimization Method to Design Foam Residue Traps for Full Mold Casting

2021 ◽  
Author(s):  
Yuto Takagi ◽  
Masahiro Inagaki ◽  
Ken’ichi Yano
Keyword(s):  
Molten Metal ◽  
Casting Process ◽  
Optimization Method ◽  
Post Treatment ◽  
Metal Casting ◽  
Mold Casting ◽  
Casting Design ◽  
Cfd Optimization ◽  
Product Part

Full mold casting is a casting process in which a mold made of wood or metal is substituted for a styrofoam model. This metal casting process is advantageous for the production of large-sized castings because it uses a foamed model. However, this unique process of melting a foamed model causes a problem which is the foamed model remains dissolved in the casting. This is called foam residue defect and is specific to full mold casting. In this study, we propose a new casting design called a residue trap to reduce these residue defects. This residue trap collects the residue of foam models included in the molten metal, which tends to be generated when the temperature of the molten metal becomes low by being attached to the product part in the same way to overflows. We also optimized the shape of the residue trap in terms of easing of post-treatment and increasing efficiency of collecting foam residue. Eventually, the effectiveness of the residue trap was verified by actual full mold casting experiments.

Analysis of Interfacial Heat Transfer Coefficient of Green Sand Mold Casting for Aluminum and Tin-Lead Alloys by Using a Lump Capacitance Method

2006 ◽  
Vol 129 (4) ◽  
pp. 595-600 ◽  
Author(s):  
Hsien-Chi Sun ◽  
Long-Sun Chao
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Transfer Coefficient ◽  
Casting Process ◽  
Sand Mold ◽  
Interfacial Heat Transfer Coefficient ◽  
Interfacial Heat Transfer ◽  
Green Sand ◽  
Air Gaps ◽  
Capacitance Method

During the casting process of green sand mold, air gaps will form between the metal and sand mold. The air gaps will make it difficult to analyze the heat transfer at the mold/metal interface. Generally, an interfacial heat transfer coefficient is employed to evaluate the heat flux transferred across the air gaps. Though the interfacial heat transfer coefficient is highly important, its value is not easily obtained by using the direct experimental or theoretical method. With temperature-measured data, some inverse methods can be used to predict the coefficient. However, the latent heat released and undercooling during the solidification of the molten metal and the moisture of the green sand mold complicate the associated temperature calculations. To overcome this difficulty, a lump capacitance method is proposed in this study to calculate the interfacial heat transfer coefficient for the casting process in green sand mold. Thermalcouples are utilized to measure the temperatures of sand mold and metal. The geometry of casting is cylindrical and the castings are A356 alloy and Sn-20 wt. % Pb alloy. With the predicted interfacial coefficients, the temperature field of the metal was solved numerically. Based on the solidification time, the numerical results are in good agreement with the experimental ones. This verified the feasibility of the proposed method and it can be applied in the future study or design of a casting process.

scholarly journals Heat Transfer Studies on Solidification of Casting Process

2021 ◽  
Author(s):  
L. Anna Gowsalya ◽  
Mahboob E. Afshan
Keyword(s):  
Heat Transfer ◽  
Casting Process ◽  
Industrial Applications ◽  
Sand Mold ◽  
Heat Transfer Mechanism ◽  
Heat Transfer Characteristics ◽  
Transfer Characteristics ◽  
Complex Shapes ◽  
Transfer Behavior ◽  
Shrinkage Behavior

This chapter deals with the heat transfer characteristics between the cast and the mold. Generally the heat transfer behavior between the cast and the sand mold is used and all the three modes of heat transfer are studied. The heat transfer characteristics from the cast is at a faster rate for a die mold than for the sand mold. Since the sand mold is used for most of the industrial applications for the complex shapes of metal the heat transfer and the shrinkage behavior in solidification has to be understood perfectly. In this chapter, since the heat transfer mechanism and the shrinkage behavior of the metal in the sand mold is interrelated, hence were predominantly discussed.

scholarly journals Microstructure And Mechanical Properties Of An Al-Zn-Mg-Cu Alloy Produced By Gravity Casting Process

2015 ◽  
Vol 60 (2) ◽  
pp. 871-874 ◽  
Author(s):  
S. Saikawa ◽  
G. Aoshima ◽  
S. Ikeno ◽  
K. Morita ◽  
N. Sunayama ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Tensile Properties ◽  
High Strength ◽  
Casting Process ◽  
Total Elongation ◽  
Sand Mold ◽  
Structural Components ◽  
Gravity Casting ◽  
Cu Alloy ◽  
Mold Casting

Abstract High-strength aluminum alloy are widely used for structural components in aerospace, transportation and racing car applications. The objective of this study is to enhance the strength of the Al-Zn-Mg-Cu alloy used for gravity casting process. All alloys cast into stepped-form sand mold (Sand-mold Casting; SC) and Y-block shaped metal mold(Permanent mold Casting; PC) C and then two –step aged at 398-423 K after solution treated at 743 K for 36 ks. The tensile strength and total elongation of the two-step aged SC alloys were 353-387 MPa and about 0.4% respectively. This low tensile properties of the SC alloys might be caused by remaining of undissolved crystallized phase such as Al2CuM, MgZn2 and Al-Fe-Cu system compounds. However, good tensile properties were obtained from PC alloys, tensile strength and 0.2% proof stress and elongation were 503-537 MPa, 474-519 MPa and 1.3-3.3%. The reason of the good properties in PM alloys, is the lowed amount of undissolved crystallized phase than that of SC ones and primary crystallized alpha-Al phase was finer due to high cooling rate at solidification in casting.

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