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A multiphase model was applied to simulate a core shooting process numerically. At the beginning of the research programme, simulations of the core shooting process with simple core box geometry (e.g. cylindrical core box) were carried out to examine the general applicability of the model used. In the next stage, simulations of core box geometry with complex flow behaviour of the sand-air motion were carried out to test the possibility of application of the model to industrial core box geometries. All the simulations were done in two and three dimensions. Experiments were carried out to validate the simulation results. Good agreement between simulation and experimental results indicates that the implemented multiphase model is suitable for modelling the core shooting process. Finally, the results of the simulation of core shooting of industrial core (wheel hub) are presented.IJCMR/538

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Local heat transfer in gravity die casting is of great importance for precision in terms of distortion, mechanical properties, and the quality of the castings due to its effect on solidification. Depending on contact conditions such as liquid melt to solid mold, a gap between mold and component, or contact pressure between casting and mold as a result of shrinkage, there are very large differences in heat transfer. The influences of mold material, mold coating and its influence of aging, mold temperature control, and layout on the heat transfer coefficient (HTC) were investigated experimentally for different contact cases. The experiments were carried out on a rotationally symmetrical experimental setup with modular exchangeable die inserts and cores using an AlSi7Mg0.3 alloy. From the results of the individual test series, the quantitative shares of the above-mentioned influencing variables in the respective effective heat transfer coefficients were determined by means of analysis of variance. From this, the parameters having the most significant influence on the local heat balance were derived.

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As researchers continue to seek the expansion of the material base for additive manufacturing, there is a need to focus attention on the Ni–Cu group of alloys which conventionally has wide industrial applications. In this work, the G-NiCu30Nb casting alloy, a variant of the Monel family of alloys with Nb and high Si content is, for the first time, processed via the laser powder bed fusion process (LPBF). Being novel to the LPBF processes, optimum LPBF parameters were determined, and hardness and tensile tests were performed in as-built conditions and after heat treatment at 1000 °C. Microstructures of the as-cast and the as-built condition were compared. Highly dense samples (99.8% density) were achieved after varying hatch distance (80 µm and 140 µm) with scanning speed (550 mm/s–1500 mm/s). There was no significant difference in microhardness between varied hatch distance print sets. Microhardness of the as-built condition (247 HV0.2) exceeded the as-cast microhardness (179 HV0.2.). Tensile specimens built in vertical (V) and horizontal (H) orientations revealed degrees of anisotropy and were superior to conventionally reported figures. Post heat treatment increased ductility from 20% to 31% (V), as well as from 16% to 25% (H), while ultimate tensile strength (UTS) and yield strength (YS) were considerably reduced.

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