Analyzing the Cooling Rate and Its Effect on Distribution of Pattern and Size of the Titanium Diboride Particles Formed

In this work, we synthesize Al/TiB2 metal matrix composites (MMC) based on the effect of cooling rate in the melt while pouring into the permanent mold condition. The objective of this paper is to achieve the desired distribution pattern and increased TiB2 particles’ size in the Al/TiB2 MMC ingot. Two halide salts, viz., potassium hexafluorotitanate (K2TiF6) and potassium tetrafluoroborate (KBF4), are procured and measured. The two salts were mixed with the aluminium melt in the crucible, and it is stirred manually with help of a graphite rod. Because of the exothermic reaction, the melt reacts very quickly and that is what dropped the salts slowly. The salt particles were synthesized because of the exothermic reaction, and it will allow the particles to grow. The size and distribution of particles differ at different place in the MMC. An FEA tool ProCAST was used to analyze the cooling rate of the melt, and SEM is used to study the microstructure of the ingot at different places. The microstructures helped to identify the size of reinforcement in the MMC. The TiB2 particles are distributed more at this location at 810°C, and the TiB2 particles formed various clusters in this zone as 70%–80%. Also, the tribological characteristics are analyzed with the help of the results.

RAFFMETAL EN AB-Al Si7Mg0.6 (EN AB-42200)

Raffmetal EN AB-Al Si7Mg0.6 (EN AB-42200) is a heat-treatable, Al-Si-Mg casting alloy in ingot form for remelting. It is used extensively for producing sand, permanent mold, and investment castings for applications requiring a combination of excellent casting characteristics, high strength with good elongation, and good corrosion resistance. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties. It also includes information on corrosion resistance as well as casting, heat treating, machining, and joining. Filing Code: Al-483. Producer or source: Raffmetal S.p.A.

EFFECT OF COOLING RATE ON MICROSTRUCTURE AND HARDNESS IN GRAY CAST IRON CASTING PROCESS

This study aims to investigate the thermal conditions of the molds, changes in microstructure and hardness of casting products using sand mold and permanent mold. The use of sand mold and permanent mold results in different cooling rates. Thermal analysis was performed using a thermocouple to obtain a temperature versus time curve. Metallographic observations were carried out using a Scanning Electron Microscope equipped with Energy-Dispersive X-ray Spectroscopy. The Vickers hardness test was carried out in three areas with different thicknesses. The results showed a constant temperature at 691 oC where the eutectoid phase reaction occurred. Testing with sand mold showed that cast iron with flake graphite was finer and spreader than graphite in cast iron produced by permanent mold. Meanwhile, gray cast iron from a casting process with a permanent mold has a higher hardness than gray cast iron from a casting process using a sand mold.

RAFFMETAL EN AB-Al Si7Mg0.3 (EN AB-42100)

Raffmetal EN AB-Al Si7Mg0.3 (EN AB-42100) is a heat-treatable, Al-Si-Mg casting alloy in ingot form for remelting. It is used extensively for producing sand, permanent mold and investment castings for applications requiring a combination of excellent casting characteristics, high strength with good elongation, and good corrosion resistance. This alloy can be produced to a wide range of mechanical properties by making small adjustments to the magnesium content and/or heat treatment. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties. It also includes information on corrosion resistance as well as casting, heat treating, machining, and joining. Filing Code: Al-480. Producer or source: Raffmetal S.p.A.

Evaluating the Application of Heating Conductor Surfaces Inside Plasma Sprayed Coatings in Permanent Mold Metal Casting Processes for Local, Near-Surface Heat Release

With casting being a complex process which involves several physical effects and interactions, a wide array of means for influencing such processes exist. Here, the liquid–solid phase change is of utmost importance, as it is a deciding factor for a part’s final properties. Especially with today’s high critical material property requirements, control of the solidification process is indispensable. For the most part, the cooling of a casting defines its solidification. What determines the cooling process is the heat balance of the system. The foundry industry has been using different approaches for influencing the heat balance for a long time. The application of different kinds of coatings with either insulating or heat transfer promoting properties as well as temperature control via cooling channels inside the mold is widely used. Progress in the field of plasma spraying of coatings and the application of heating conductor surfaces have rendered a new concept possible: The integration of heating conductors inside a coating allows for the release of heat in closest vicinity of the melt–mold interface. This paper depicts the use of numerical simulations to investigate the local application of heating conductor layers inside the mold surface coating for a permanent mold casting process and discusses concepts for influencing the heat balance that would not be possible with state-of-the-art cooling channel approaches.

RIO TINTO 354.2

Rio Tinto 354.2 is a heat-treatable, aluminum-silicon-copper-magnesium casting alloy (3xx.x series). It is available in the form of ingots for remelting to be used for the production of sand and permanent mold castings. Alloy 354.0 was developed especially for premium engineered casting applications requiring high strength and elongation, and sound castings. This datasheet provides information on composition, physical properties, elasticity, and tensile properties. It also includes information on corrosion resistance as well as casting and heat treating. Filing Code: Al-479. Producer or source: Rio Tinto Limited.