Dimensional accuracy in quick plastic forming of aluminum alloy using demolding mechanism

This study focuses on quick plastic forming (QPF), product dimensional tolerances, and removal methods. The traditional curled metal shell mold in QFP, has limitations such as long process time and unstable quality. Therefore, this investigation designed a demolding mechanism, in order to improve the process efficiency and dimensional accuracy of QPF, in the manufacture of metal casings. The research results show that the proposed mechanism can significantly decrease the process time, because it replaces most of the operations of specimens movement after forming completely. The shorter process time reduce the die temperature loss during operation, thus also improving the efficiency by eliminating the need to wait for the die to return to its operation temperature. In terms of dimensional tolerance, the tolerance grade of QPF process was determined using the standard deviation, and found to be between IT10 and IT14. This range covers the scope of CNC cutting and stamping processing, indicating that the process has commercial value in the production of metal casings, because the current mainstream manufacturing process of metal casings comprises casting, stamping and CNC machining.

Choice of materials properties and of shell molds structure by investment models

The paper presents a mathematical model optimizing the choice of material and morphological structure of the shell mold (SM), which has the highest resistance to cracking when pouring liquid metal into it. To solve this problem, the theory of small elastoplastic deformations and the heat equation, as well as proven numerical methods, were used. The objective function min – max was constructed from control variables characterizing the properties of the molding material of the shell. The process of heating an axisymmetric shell mold was considered when pouring liquid metal into it. The resistance of the shell form was estimated by the stresses arising in it. An algorithm for solving this problem was compiled. Using numerical schemes and program complexes developed in previous studies, an algorithm for solving the optimization problem was constructed and the values of control variables were found in which the shell mold does not break even in the presence of a rigid process – pouring steel into a cold shell mold. Analysis of the influence of weight of each of the found parameters on the value of the constructed objective function is given. Using a mathematical experiment, the morphological structure of the shell mold was studied. The shell mold of five layers is considered. The corrected system of equations makes it possible to take into account the properties of the layers made of different materials. Calculations were performed when the layer of the shell mold from material found by optimization occupies different positions in its cross section. In this case, the remaining layers of the mold are made of traditional ceramics. The optimal location of this layer was found. It is shown that the presence of several layers with the found properties does not affect the increase in crack resistance of the shell mold.

Effects of Mold Materials on the Interfacial Reaction between Magnesium Alloy and Ceramic Shell Mold during Investment Casting

In order to suppress the interfacial reaction between the ceramic shell mold and the magnesium molten alloy during the investment casting process, a mold material with a high thermodynamic stability based on alkaline zirconium sol (CH4NO3Zr) binder and corundum (Al2O3) powder was prepared. The effects of the mold materials and casting thicknesses on the interfacial reaction were investigated by an optical microscope, X-ray diffraction, a scanning electron microscope, and an energy dispersive spectroscope analysis. The results suggested that the casting poured by the conventional ZrSiO4 mold has a serious reaction on the surface, and the reaction was more severe when the casting thickness was increased. The oxidation layer was approximately 300 μm in some severe areas of 45 mm thickness. The XRD and EDS results showed that the reaction interface mainly contains MgO and Mg2Si. While the casting poured by the Al2O3 mold provides a light and smooth surface, the reaction layer was only 1.5 μm on average. The reaction interface mainly contains MgO and Mg2F.

Evaluating Silicon Carbide-Based Slurries and Molds for the Manufacture of Aircraft Turbine Components by the Investment Casting

Silicon carbide (SiC) is a promising material for the fabrication of ceramic shell molds due to its high mechanical strength, hardness, thermal shock resistance, and thermal conductivity compared with commonly used slurries. This article describes the test results of casting materials, i.e., SiC-based powders and aqueous binders with aluminum oxide nanoparticles, as well as the parameters of slurries used for prime coats and structural layers. Tests were also performed to evaluate the physical and mechanical properties of SiC-based shell molds for the manufacture of aircraft turbine components. Two SiC-based slurries with solid concentrations of 65 and 70 wt.% were prepared, and their viscosity, density, pH, quantity, thickness, and copper plate adhesion (plate weight test) were investigated. Fourteen days were required to prepare and evaluate the slurry parameters. The results showed that SiC-based slurries had a Zahn cup #4 outflow time of 33.1 s to fabricate the first two coats and 14.8 s to fabricate the shell mold structural layers. Three series of SiC-based shell mold samples were prepared: after dewaxing (PW1), after burnout preheating at 700 °C (PW2), and after annealing at 1200 °C (PW3). The bending mechanical strength, Young’s modulus, and Weibull’s modulus of the samples were calculated, and the roughness (Ra and Rq) and microstructures of samples were also analyzed (SEM). Inner defects were evaluated by CMT (µCT). The Ra and Rq values of the prime coat of the SiC-based shell mold did not exceed 5 µm. The fabricated SiC shell molds had bending mechanical strengths from 1.21–2.28 MPa, Young’s modulus of 102.97–207.66 MPa, and a Weibull’s modulus from 5.36–9.94. The shell molds fabricated on the technical scale met the requirements specified for industrial shell molds.

PENGEMBANGAN PROSES PEMBUATAN IMPELLER DENGAN CETAKAN KULIT

Impeller merupakan komponen pompa air yang cukup vital dan umumnya terbuat dari kuningan yangharganya relatif mahal, maka dilakukan pengembangan dan dibuat dengan material paduan aluminium yanglebih murah. pembuatannya dicor dengan metode cetakan kulit (shell mold casting) Alat peleburanmenggunakan tungku crucible sederhana. Untuk mendapatkan performa dan karakteristik pada materialdengan uji mekanis dan fisik yaitu uji tarik, uji kekerasan, uji impak, uji komposisi material serta strukturmikro. Cetakan cor terbuat dari pasir cor jenis silika (SiO2) dengan ukuran butiran 0.06–0.1 mm, dengancampuran resin fenol dan katalis sebagai pengikat dan pengering resin. Komposisi aluminium paduan dibuattiga variabel, 1% Cu, 3% Cu dan 5% Cu.Kekuatan tarik maksimum 9950 N/mm², kekerasan maksimum 376N/mm², tenaga pukul impak 45 Joule.