Verification of the Thermal Expansion Effect of Silicone Molds Intended for Production of the Prototype Components using Vacuum Casting Technology

The article deals with vacuum casting technology and especially with the assessment of the influence of the tempering temperature of silicone molds on the dimensions of future castings. The aim was to evaluate the actual size of the castings, using different tempering temperatures of the molds and different casting materials. After examining the resulting dimensions of the individual castings, a procedure was established by which these effects could be minimized. In the end, a test of the proposed procedure is performed, which confirmed its correctness.

STUDY OF THE THERMAL EXPANSION COEFFICIENT OF SEVERAL SAND MIXTURES USED IN THE CASTING TECHNOLOGY: دراسة معامل التمدد الحراري لعدة خلائط من الرمال المستخدمة في تقنية الصب

The casting technology is one of the most important production processes, because of its special characteristics and features such as the ability to produce complex shapes and a wide range of compositions. This work aims to study several mixtures of sand with different structures in terms of permeability, strength, thermal expansion coefficient, comparing them, study the effect of the elements involved in the composition of these mixtures on those parameters, and create a database that can be used both in modeling processes or mold design, as when designing the sand mold The value of the sand expansion of the mold must be taken into account, otherwise the designer will face the problem of the possibility of exit some dimensions of the final product from the permissible range and thus rejecting the product, Or the product is undergone to deformations resulting from the expansion of mold sands, which must be avoided when designing the mold Knowing the characteristics of those sand mixtures helps the investor in choosing the most appropriate mixture for the required casting process in terms of engineering specifications or quantity, with the aim of less costly production by saving in choosing the most appropriate and least expensive sand mixture that serves the desired purpose.

Digital optimization of car’s hinged components

The purpose of this work is to reduce the weight of the car’s hinged structures (front and rear doors, tailgate and lock reinforcements) by using various types of optimization which involve removing material, changing thicknesses, and topography from parts (topology, topography, parameter and multivariate) as well as the interpretation of optimization results for specific types of production while maintaining the rigidity and strength characteristics. This technique is necessary to reduce the time for product development and reduce the cost of manufacturing parts. This study addressed the issue of the maximum possible weight reduction while meeting all the requirements (strength calculations, stiffness calculations, modal analysis, analysis of resistance to external loads, local rigidity of the door attachment points - strength loadcases, stiffness loadcases, modal, denting, IPI) and technological limitations (Envelope requirements, casting technology). The final design solution was required to contain visible changes from the original structure, meet performance requirements, and obtain a feasibility study from the production department.

Effect of P + Sr + RE Ternary Compound Modification on Microstructure of Eutectic Al-13wt%Si Alloy

Used Al-13wt%Si alloy was as raw material, the influence mechanism of Al-Sr, Al-P and Al-RE ternary compound modifier was studied by casting technology. The effects of P, Sr and RE modification on Al-13wt% Si were studied by metallographic microscope, scanning electron microscope and X-ray. The effects of the addition order and amount of modifier on the microstructure of Al-13wt% Si were investigated The results show that compared with a single modifier, P + RE + Sr ternary composite modifier has more obvious modification effect on eutectic silicon in Al-13%Si alloy: the microstructure of different morphology can be obtained by using different amount and order of adding modifier. When the amount and order of modifier are 0.5wt%Sr, 0.7wt%P, 1.5wt%RE,the eutectic silicon with small size and uniform distribution can be obtained. Eutectic silicon consists of 70 μm, the slender lamella is refined to 5 μm.

A Method for Characterising the Influence of Casting Parameters on the Metallurgical Bonding of Copper and Steel Bimetals

Traditional casting technology offers two mayor drawbacks towards research activities. On the one hand, time and resources needed for every casting are rather high. The mould has to be able to withstand the high temperatures introduced by the melt and provide cooling for the cast part. Preparation and installation of measuring equipment therefore takes time. Additionally, due to the high mass of the mould when compared to the cast part, parameter variations are rather limited in their resulting effect on the temperature-time profile being one of the most prominent factors regarding cast quality. Especially when pouring by hand, variations in casting times and rates superimpose effects created intentionally. Therefore, a different process was advanced and evaluated, allowing to minimise some of the drawbacks mentioned before. The key idea is to drastically reduce casting size to the dimensions of one specimen and to apply a highly automated production route. As such, a mirror furnace was modified as to allow the processing of melt. Due to the specimens size, an adaption of mechanical testing equipment was performed and evaluated. As an example, copper-iron bimetal specimens were examined by light microscopy, micro hardness testing, nanoindentation as well as tensile and torsion testing. As the results were consistent, the newly introduced method can be applied successfully in casting research. This allows for highly reproducible results, reducing the uncertainty of temperature measurements of a specimen due to the distance between them. The possibility of separating influencing variables like maximum temperature and cooling rate allows an analysis of the casting process, which would require different moulds to do so in traditional casting methods. The next steps will be directed at a broader variety of metals processed and at a direct comparison between the new process route and traditional casting technology.

RATIONALIZATION OF PRODUCTION OF SHAPED INSERTS FOR ROTOR CASTING

The article deals with the rationalization of the production of shaped inserts for casting rotors. The theoretical part describes the characteristics of shaped inserts for rotor casting, die casting technology, analysis of the existing technology of production of shaped inserts. The main part of the article is focused on the proposed technological process of production, comparison of existing and proposed process. The article concludes with a technical and economic benefit of the proposed solution and evaluation of the work. Rationalization of production has its justification in the development of the company and thus improve competitiveness in the market. These interventions in production offer the possibility of using new technologies that are beneficial both from an economic point of view and to improve working conditions. The article focuses on the description of the existing technology, its evaluation and subsequent processing of a new technological process.

Microstructural evolution of an Al–Mg–Si–Mn– Fe alloy due to Ti and P addition

This paper presents the results of research on material and microstructural effects in a hypoutectic Al–Mg– Si–Mn–Fe alloy, modified by the addition of Ti and Ti + P, in two series of castings, gravity and pressure. It has been found that the use of high pressure die casting technology allows for significant improvement of mechanical properties, especially tensile strength and plasticity of the examined alloy. On the other hand, the addition of Ti and Ti + P caused different material effects. In gravity castings, the addition of Ti and Ti + P caused a decrease in strength and plasticity, while in high-pressure castings, an increase in the values of these parameters was observed. The microstructural effects related to the foundry technology and those caused by Ti and P additions were revealed, such as differences in the phase composition of the interdendritic eutectics and in the morphology and dispersion of their phase constituents: Mg2Si and α-Al(Fe,Mn)Si.