Effect of pattern coating thickness on characteristics of lost foam Al–Si–Cu alloy casting

Karimian, Majid; Ourdjini, Ali; Idris, Mohd Hasbullah; Jafari, Hassan

doi:10.1016/s1003-6326(11)61433-7

Cited by 20 publications

(12 citation statements)

References 14 publications

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“…특히, 최근에는 독일을 중심으로 자동차용 알루미늄 주조부품을 제 조하는데 소실모형주조공정을 적용하게 되면서 국내에서도 이 에 대한 연구개발의 필요성이 높아지고 있는 상황이다. 주조 용 알루미늄합금을 소실모형주조공정으로 제조하는 경우 주조 제품의 기계적 성질은 주조 미세조직, 주입온도, 모래의 종류 등 여러 변수들의 영향을 받으며, 또한 다른 주조공정에 비 해 단점인 기공의 발생도 이러한 변수들과 밀접하게 연관되 어 있는 것으로 보고되어 있다 [2][3][4][5][6]. 소실모형주조의 특성상 기공이 두꺼운 제품부위에 쉽게 발생할 수 있어 실제 기계적 성질에 미치는 변수의 영향을 명확하게 파악하기 어려운데, 예를 들어 Sr을 사용한 Al-Si계 합금의 개량화처리를 한 경 우 공정 Si의 형상 개선으로 인해 기계적 성질이 향상될 수 있는 반면에 두꺼운 부위에서는 기공형성이 많아지면 심각한 특성저하가 유발된다 [7].…”

Section: 서 론unclassified

Mechanical Properties and Mold Filling Capability of Al-Si-Mg Casting Alloy Fabricated by Lost Foam Casting Process

Kim¹,

Ha²,

Choe³

2016

Journal of Korea Foundry Society

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The lost foam casting process was used to fabricate Al-Si-Mg cast specimens, and the effects of the chemical composition and process variables on the tensile properties and the mold filling ability were investigated. Some porosity formation was observed in thick sections of the casting and better tensile properties were obtained for thin sections, presumably because of their lower porosity and the higher cooling rate. Tensile properties were not clearly enhanced by grain refining treatment with Ti; however, the elongation was significantly improved by Sr modification of the Al-Si-Mg alloy. The mold filling distance was generally proportional to the pouring temperature of the melt, and the distance was also increased by the addition of Ti.

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Section: 서 론unclassified

Mechanical Properties and Mold Filling Capability of Al-Si-Mg Casting Alloy Fabricated by Lost Foam Casting Process

Kim¹,

Ha²,

Choe³

2016

Journal of Korea Foundry Society

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“…This process uses expandable polystyrene as the pattern and gating system and remains in the mould until pouring of liquid metal. When in contact with molten metal, the polystyrene pattern liquidises and evaporates and escapes through the pattern coating [4]. The rates of the liquidation and evaporation strongly depend on the casting parameters [5].…”

Section: Introductionmentioning

confidence: 99%

Effects of Casting Parameters on Shape Replication and Surface Roughness of LM6 Aluminium Alloy Cast Using Lost Foam Process

Karimian

Ourdjini

Idris

et al. 2014

Trans Indian Inst Met

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In this paper, an experimental investigation on shape replication and surface roughness of Al-12 wt% Si alloy casting produced by lost foam casting process was conducted. 5-step shape patterns incorporated with top and bottom gates were used. Four top gating systems with different pouring cup configurations namely single-middle, single-side, double and single-wide and a simple bottom gate design were investigated to appropriate filling to produces sound casting. Three sand vibration times of 1, 2 and 3 min were used for the moulding process. Molten metal was poured at five different temperatures of 660, 680, 700, 720 and 740°C. Shape replication and surface roughness of the cast samples were analysed visually and by roughness tester, respectively. The results showed that pouring cup design has a significant effect on the replication and surface integrity of the castings. It was also found that single topwide pouring cup as well as lower vibration time and higher pouring temperature provided castings with better shape replication and smoother surface finish with a surface roughness of 19-20 lm compared to 25-31 lm for castings produced with other cup configurations.

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“…Karimian et al investigated the influences of the coating thickness on product quality. When the coating film is thin, the amount of pyrolysis gas emitted from the foamed model is higher, and the amount of residue due to pyrolysis is reduced [5]. In addition, studies on the analysis of molten metal flow behavior in vanishing model casting have been actively conducted using CFD simulation [6,7].…”

Section: Introductionmentioning

confidence: 99%

CFD Optimization Method to Design Foam Residue Traps for Full Mold Casting

Takagi¹,

Inagaki²,

Yano³

2021

Casting Processes and Modelling of Metallic Materials

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Full mold casting is a casting process in which a mold made of wood or metal is substituted for a styrofoam model. This metal casting process is advantageous for the production of large-sized castings because it uses a foamed model. However, this unique process of melting a foamed model causes a problem which is the foamed model remains dissolved in the casting. This is called foam residue defect and is specific to full mold casting. In this study, we propose a new casting design called a residue trap to reduce these residue defects. This residue trap collects the residue of foam models included in the molten metal, which tends to be generated when the temperature of the molten metal becomes low by being attached to the product part in the same way to overflows. We also optimized the shape of the residue trap in terms of easing of post-treatment and increasing efficiency of collecting foam residue. Eventually, the effectiveness of the residue trap was verified by actual full mold casting experiments.

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Effect of pattern coating thickness on characteristics of lost foam Al–Si–Cu alloy casting

Cited by 20 publications

References 14 publications

Mechanical Properties and Mold Filling Capability of Al-Si-Mg Casting Alloy Fabricated by Lost Foam Casting Process

Mechanical Properties and Mold Filling Capability of Al-Si-Mg Casting Alloy Fabricated by Lost Foam Casting Process

Effects of Casting Parameters on Shape Replication and Surface Roughness of LM6 Aluminium Alloy Cast Using Lost Foam Process

CFD Optimization Method to Design Foam Residue Traps for Full Mold Casting

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