Application of cores and binders in metalcasting

Czerwiński, F.; Mir, Mozhgan; Kasprzak, W.

doi:10.1179/1743133614y.0000000140

Cited by 39 publications

(27 citation statements)

References 6 publications

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“…For salt cores meant for use in high pressure die casting, Jelinek and Adamkova report values roughly between 0.7 and 2.3 MPa (shot cores) and 2.8 to 5.2 MPa (squeezed cores) . These values fall short by up to an order of magnitude of figures suggested by Czerwinski et al, who report bending strengths ranging from 6 to 30 MPa, depending on the actual composition of the salt core …”

Section: Resultsmentioning

confidence: 89%

“…For sand cores as used, e.g., in gravity or low pressure sand or die casting, typical binders can either be organic or inorganic. As organic binders, phenolic resins are commonly used . In contrast, inorganic binders − which should in principle be preferable from an economic perspective because of their low cost, environmental acceptability and high strength − are less common due to their high residual strength after casting, which counteracts demolding.…”

Section: Introductionmentioning

confidence: 99%

“…A possible alternative are salt cores. These are, e.g., used in gravity and low pressure die casting of aluminum components, e.g., for introducing channel structures in internal combustion engine pistons, and to some degree also in high pressure die casting . The main disadvantages of salt cores are their limited strength and the need to leach them out.…”

Section: Introductionmentioning

confidence: 99%

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New Core Technology for Light Metal Casting

et al. 2018

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A new concept for lost cores for gravity castings is presented. In contrast to the conventional principle of thermally breaking down binder strength, demolding of the new cores is based on a mechanical collapse of parts of the filler material. For this purpose, the usual sand filler is substituted for hollow microspheres with defined isostatic compression strength. After casting, the core is subjected to high hydrostatic pressure, leading to destruction of the hollow filler and a resulting loss of core structural strength and volume, allowing it to be washed out easily. In the present study, phosphate-, gypsum-, and cement-bonded cores with additions of hollow glass microspheres and cenospheres are produced and their bending strength and surface quality are determined. The core behavior during the casting process is evaluated using permanent mold gravity and low pressure aluminum casting experiments. Phosphate bonded materials containing 62 vol% of glass microspheres exhibit the best combination of surface quality and collapse behavior while reaching strength levels comparable to conventional sand cores. The study contributes to a deeper understanding of the collapse mechanisms, suggesting a major role of 1) open porosity of the matrix phase, 2) sufficient strength of the filler-matrix interface, and 3) filler particle shell integrity. Due to a lack of the latter, cenospheres are proved unsuitable for the new demolding approach.

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Section: Resultsmentioning

confidence: 89%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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New Core Technology for Light Metal Casting

et al. 2018

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“…T he cold box process using silica sand coated with resin binder is common in the casting industry for fabricating a broad range of sand cores [1][2][3] . The core, a mould part, is used to form internal holes and cavities in cast article [4] , which is molded when the coated sand in the magazine is injected into the cavities of the core box through the nozzles by high-pressure flow of dry air (Fig. 1).…”

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confidence: 99%

Erosion problem in tool steel using cold box core-making process

et al. 2019

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This paper presents the erosion results of the AISI H13 steel impinged by resin-bonded silica sand, using a testing rig that closely simulates the real blowing conditions during industrial core-making. Steel specimens were heat treated to obtain hardness of 294, 445 and 595 HV 200 (29, 45 and 55 HRC). Erosion tests were carried out at impingement angles from 20° to 90° and air drag pressures of 1.38, 2.07 and 2.76 bar (20, 30 and 40 psi). The main results are summarized as follows: (i) The harder material, the lower erosion; (ii) the maximum erosion rate is at 30°; (iii) Little difference in erosion rate at impact angle of 60° and 90° for a constant pressure tested regardless of the hardness level; (iv) As the pressure increases, so does the erosion rate, being more sensitive for low impact angles. Finally, a differential form of the general erosion equation is applied on a practical core-making case to evaluate the erosion rate of the H13 steel at 30° and 90° impingement angles.

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“…The GPU parallelization method can successfully solve the problem of low computational efficiency of the 3D sand shooting simulation program, and thus the developed GPU program is appropriate for engineering applications. [4] , but most efforts have gone to the development of a new binder system, and studies on the flow dynamics of the core shooting process are limited.…”

mentioning

confidence: 99%

GPU based numerical simulation of core shooting process

Zhang

et al. 2017

China Foundry

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Application of cores and binders in metalcasting

Cited by 39 publications

References 6 publications

New Core Technology for Light Metal Casting

New Core Technology for Light Metal Casting

Erosion problem in tool steel using cold box core-making process

GPU based numerical simulation of core shooting process

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