Elimination of solidification shrinkage defects in the casting of aluminum alloy

Ali, Rashid; Zafar, Muhammad Sohail; Manzoor, Tareq; Kim, Woo Young; Rashid, Muhammad Usman; Abbas, S. Zameer; Zai, Behzad Ahmed; Ali, Muddassir

doi:10.1007/s12206-022-0416-z

Cited by 5 publications

(4 citation statements)

References 16 publications

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“…They can be used, for example, in medicine and pharmacy as systems for the controlled release of drugs, in biotechnology for the immobilization of enzymes, and in the construction of sensors. [17][18][19] Poly(N,N′-dimethylaminoethyl methacrylate) (PDMAEMA) is an example of a water-soluble polymer that responds to temperature and pH changes exhibiting a reversible phase transition (T CP ) within the range 20 °C-80 °C. [20][21][22][23] Polyesters like poly(ε-caprolactone) (PCL), polylactide (PLA), and polyglycolide (PGA) are known to be biocompatible, biodegradable, and non-immunogenic, hence they are commonly used in the biomedical field.…”

Section: Introductionmentioning

confidence: 99%

The structure–self-assembly relationship in PDMAEMA/polyester miktoarm stars

et al. 2022

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Section: Introductionmentioning

confidence: 99%

The structure–self-assembly relationship in PDMAEMA/polyester miktoarm stars

et al. 2022

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“…Most conventional leisure boat propellers are manufactured using traditional gravity-casting processes [19]. While cost-effective, these gravity-casting processes have limitations in controlling casting defects such as internal shrinkage voids or gas porosity [20].…”

Section: Introductionmentioning

confidence: 99%

Development of Low-Pressure Die-Cast Al−Zn−Mg−Cu Alloy Propellers—Part Ⅰ: Hot Tearing Simulations for Alloy Optimization

Kim,

Kim

2024

Materials

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Recent advances in the leisure boat industry have spurred demand for improved materials for propeller manufacturing, particularly high-strength aluminum alloys. While traditional Al-Si alloys like A356 are commonly used due to their excellent castability, they have limited mechanical properties. In contrast, 7xxx series alloys (Al−Zn−Mg−Cu based) offer superior mechanical characteristics but present significant casting challenges, including hot-tearing susceptibility (HTS). This study investigates the optimization of 7xxx series aluminum alloys for low-pressure die-casting (LPDC) processes to enhance propeller performance and durability. Using a constrained rod-casting (CRC) method and finite element simulations, we evaluated the HTS of various alloy compositions. The results indicate that increasing Zn and Cu contents generally increase HTS, while a sufficient Mg content of 2 wt.% mitigates this effect. Two optimized quaternary Al−Zn−Mg−Cu alloys with relatively low HTS were selected for LPDC propeller production. Simulation and experimental results demonstrated the effectiveness of the proposed alloy compositions, highlighting the need for further process optimization to prevent hot tearing in high Mg and Cu content alloys.

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“…This cycle of casting and taking x-rays of the samples are both costly and time consuming. Therefore, a lot of research has been conducted to understand the physics behind these defects [14][15][16][17][18][19][20][21] and reproducing them using computer simulations. The initial simulations produced two-dimensional (2D) axisymmetric, branchless dendrite features that lacked the details needed to understand the issues that develop during the manufacturing processes.…”

Section: Introductionmentioning

confidence: 99%

A Review of Large-Scale Simulations of Microstructural Evolution during Alloy Solidification

Cusato,

Nabavizadeh,

Eshraghi

2023

Metals

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During the past two decades, researchers have shown interest in large-scale simulations to analyze alloy solidification. Advances in in situ X-ray observations of the microstructural evolution of dendrites have shown defects that can be very costly for manufacturers. These simulations provide the basis for understanding applied meso-/macro-scale phenomena with microscale details using various numerical schemes to simulate the morphology and solve for transport phenomena. Methods for simulating methodologies include cellular automaton, phase field, direct interface tracking, level set, dendritic needle networks, and Monte Carlo while finite element, finite difference, finite volume, and lattice Boltzmann methods are commonly used to solve for transport phenomena. In this paper, these methodologies are explored in detail with respect to simulating the dendritic microstructure evolution and other solidification-related features. The current research, from innovations in algorithms for scaling to parallel processing details, is presented with a focus on understanding complex real-world phenomena. Topics include large-scale simulations of features with and without convection, columnar to equiaxed transition, dendrite interactions, competitive growth, microsegregation, permeability, and applications such as additive manufacturing. This review provides the framework and methodologies for achieving scalability while highlighting the areas of focus that need more attention.

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Elimination of solidification shrinkage defects in the casting of aluminum alloy

Cited by 5 publications

References 16 publications

The structure–self-assembly relationship in PDMAEMA/polyester miktoarm stars

The structure–self-assembly relationship in PDMAEMA/polyester miktoarm stars

Development of Low-Pressure Die-Cast Al−Zn−Mg−Cu Alloy Propellers—Part Ⅰ: Hot Tearing Simulations for Alloy Optimization

A Review of Large-Scale Simulations of Microstructural Evolution during Alloy Solidification

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