About Residual Stress State of Castings: The Case of HPDC Parts and Possible Advantages through Semi-Solid Processes

Fracchia, Elisa; Gobber, Federico Simone; Mus, C.; Kobayashi, Yuji; Rosso, Mario

doi:10.4028/www.scientific.net/ssp.327.272

Cited by 2 publications

(2 citation statements)

References 32 publications

(37 reference statements)

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“…The composite casting process uses chromite ore sand with stronger heat storage capacity for the thicker side, and uses the quartz sand with stronger heat storage capacity for the thickest side, so the solidification time of all sides of the casting is about 300 s, almost achieving simultaneous solidification [18,4].…”

Section: Numerical Simulation Of Temperature Field During Solidificat...mentioning

confidence: 99%

Numerical Simulation and Optimal Control of Composite Nonlinear Mechanical Parts Casting Process

Li,

Wang

2024

SCPE

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In order to understand the numerical simulation and optimal control of the casting process of Machine element, the author proposed a study based on the numerical simulation and optimal control of the casting process of composite Machine element. Firstly, the author analyzed the structural characteristics of composite Machine element, introduced them in detail, and studied their casting technology in combination with the actual situation. Secondly, the casting process of composite Machine element was simulated by using numerical simulation method, and the temperature field and flow field in the casting filling and solidification process were analyzed. Finally, selecting square cylinders with different wall thicknesses as typical components, the scheme design of traditional single casting process and multi material composite casting process based on dieless casting composite forming technology were carried out. Finite element numerical simulation and experimental research were conducted on the two processes, respectively. The results indicate that: The casting obtained by the multi material composite casting process almost solidifies simultaneously around 200 seconds later, and the graphite morphology around the casting is Type A, with a length of about 100 um, with small differences and uniform distribution; The minimum difference in tensile strength around the casting is about 3.8%, and the maximum increase in tensile strength value is 21%. This research achievement can provide technical reference for high-performance and high-quality casting of complex iron castings. In order to improve the casting quality, the author optimized the casting process of composite Machine element by numerical simulation.

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Section: Numerical Simulation Of Temperature Field During Solidificat...mentioning

confidence: 99%

Numerical Simulation and Optimal Control of Composite Nonlinear Mechanical Parts Casting Process

Li,

Wang

2024

SCPE

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“…Micro-hardness was adopted instead of macro-hardness because smaller indentations may permit observing the different hardness values in both the eutectic region and α-Al. X-ray analyses were conducted on castings comparing the residual stresses of the component in the as-cast condition and heat-treated condition by a diffractometer (portable X-ray Residual Stress Analyzer μ-X360s, equipped with Cr X-ray target) [8,9].…”

Section: Semi-solid Casting Of Structural Materialsmentioning

confidence: 99%

Characterisation of Residual Stresses of Rheocast Al Alloy

Fracchia,

Gattelli,

Grande

2023

SSP

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Rheocasting is a semisolid casting process allowing to obtain near-net shape parts. Through the Rheocasting process, it is possible to achieve aluminium castings having a low grade of porosity if compared to traditional die-casting methods, encouraging the production of automotive frame parts. However, casting processes, as commonly known, may cause tensile residual stresses inside the parts. On the other hand, compressive stresses inside castings can significantly increase the life of components: residual compressive stresses increase the material's resistance by counteracting crack initiation and propagation. The cracks propagate when the material is under tensile stress, while the Rheocasting technique seems to promote compressive stresses inside the castings. This work aims to analyse an aluminium rheocasted frame component for race cars in both the as-cast and heat-treated conditions. First, the mechanical properties of the components were evaluated in terms of tensile tests and microhardness. Then, residual stresses were measured at specific points of the casting. Finally, the evolution of the residual stresses inside the component before and after heat treatment led to assessing the effect of the Rheocasting process condition and the heat treatment, proving the marked advantage of using such a technology.

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About Residual Stress State of Castings: The Case of HPDC Parts and Possible Advantages through Semi-Solid Processes

Cited by 2 publications

References 32 publications

Numerical Simulation and Optimal Control of Composite Nonlinear Mechanical Parts Casting Process

Numerical Simulation and Optimal Control of Composite Nonlinear Mechanical Parts Casting Process

Characterisation of Residual Stresses of Rheocast Al Alloy

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