Papers by Keyword: Casting

Abstract: This study focuses on the development of magnesium-zinc (Mg-Zn) matrix alloys enriched with rare earth elements (RE), aiming to evaluate both their structural characteristics and in vitro biological responses. The designed alloys incorporated varying amounts of Zn, Nd, Ce, Gd, Zr, and Ca. Two specific EZ43 alloy compositions were synthesized using an induction-heated furnace under a protective gas atmosphere, differing in their Nd-to-Ce weight ratios (1:2 and 2:1). Following casting, the alloys were homogenized at 400 °C for 24 hours to eliminate dendritic structures and minimize elemental segregation. X-ray fluorescence (XRF) was employed to assess the chemical compositions, while scanning electron microscopy (SEM) provided detailed insight into microstructural features and potential intermetallic phases. Biocompatibility was evaluated through cytotoxicity and genotoxicity tests, conducted in accordance with internationally recognized standards to ensure reliability. Results indicated no genotoxic effects and demonstrated high cell viability up to 142% particularly in Nd-enriched samples. Statistical analysis revealed significant differences in biological behavior between the Nd-rich and Ce-rich alloys, with Nd contributing positively to cellular responses. These findings emphasize the importance of RE composition in influencing biocompatibility and suggest that Nd-enriched Mg-Zn alloys hold strong promise for biomedical applications requiring both structural integrity and favorable biological interaction.

Abstract: By replacing the interface with sharp change properties with a functionally graded material with a gradually changing composition, a stable interface can be formed for mechanical and functional properties. In this study, the final goal is to functionally grade the interface between aluminum and alumina (Al₂O₃)/aluminum (Al) composites. First, the segmentation velocity of Al₂O₃ particles under gravity was measured to clarify the possibility of functional grading. The starting materials used were A356.0 Al alloy and α-type Al₂O₃ particles. The segmentation velocity obtained by the experiment was much faster than the theoretical velocity obtained by Stokes' law. It seems Stokes' law assumes that the particles are spherical and there is no interaction between particles, but the actual particle velocity was affected by the actual particle shape and interaction between particles. These factors affect the change in the segmentation velocity. The height of the mold was set to 40 mm, and an Al₂O₃ particle/Al composite with a particle size of 6.7 μm was placed on the top and an Al alloy was placed on the bottom in the mold, melted, and rapidly solidified after 12 sec., and an Al₂O₃ particle-dispersed Al alloy functionally graded composite was obtained under gravity.

Abstract: In this work, nanocomposites Alloy 625-xTiB₂ (x=1.25; 2.5; 3.75; 5.0 wt%) were processed through suction casting. The microstructure and selected properties were analyzed using light microscopy, scanning electron microscopy and energy dispersive X-ray spectroscopy. It has been observed that introducing TiB₂ particles into Alloy 625 strongly influences the as-cast microstructure. A dendritic microstructure with irregular distribution of the strengthening precipitates has been revealed. In reference Alloy 625, the Nb-rich carbides and Laves phase precipitates exist in the interdendritic spaces. The TiB₂ interacted with the liquid Alloy 625 during suction casting, leading to microstructural changes like more precipitates in interdendritic spaces including newly formed B-rich phases.

Abstract: Deep learning has achieved great progress in image recognition, segmentation, semantic recognition, and game theory. It also shows potential to solve scientific computing such as simulation problems in engineering. On the other hand, the numerical simulation method requires constitutive modelling, involves a huge computation volume and takes a long time. In this paper, two mirror U-Net models were proposed for the simulation of the heat transfer during the casting process. These models include an upper U-Net branch for the treatment of the geometries of casting, mold, and chill, and a lower U-Net branch for the treatment of the initial temperature field. Their difference is whether the bottoms of upper and lower U-Nets are shared. These two branches tackle the problems involving the input of a geometrical model which consists of three types of materials and the input of an initial or current temperature field image. These models were trained and validated with a big database with hundreds of casting shapes. The prediction results show that the average accuracy reaches 98.8%.

Abstract: Currently, the manufacturing industries play an important part in the global economy. I t is critical for the industries to maintain the high standards of goods and products. Various machines / systems have been developed for determining dimensional stability or the lack of filling in a casting product, thereby rejecting the defective products. The existence of the casting product is detected using an infrared or ultrasonic sensor. When a product arrives along the conveyer, the sensor can detect its measurements. If the product has the necessary proportions and dimensions, it is moved to the accepted bin; otherwise, it is denied by a pneumatic actuator and placed in the rejecter bin. Eventually, a profound learning model that categorizes into two different categories has been studied to automate the manual inspection procedure in the casting failure system. This automated casting fault separation machine is accurate, reliable and low cost which makes it suitable for small scale industries with easy segregation of high quality products. The objective of this paper is to review the various automatic systems developed for separating casting fault.

Abstract: Innovation in the automotive field is now growing rapidly. New materials are considered to be incorporated in automotive design if they have economic and vehicle performance benefits. This research investigates the change of the Magnesium (Mg) addition and heat treatment to the mechanical properties and microstructure of the car chassis prototype with Al10Si Aluminum alloy base material. The process of casting using the High-Pressure Die Casting method. Variation of Mg (3, 4, 5 wt%) to increase the strength of mechanical properties of Al10Si aluminum alloy material. In the casting process, the first Al10Si heated up to 690°C. Mg is incorporated into the heating furnace, then stirred by a mechanical stirrer. Stirring speed of 90 rpm and stirring time of 120 seconds. After it has poured into the mold, the casting temperature is 740°C. Then cools the room to room temperature 39°C. Then performed, heat treatment, using the method of age hardening and artificial aging. The test results prove that the hardening heat treatment makes the grain size smaller. Small grain size, then increase the strength of the material with the addition of Mg elements.

Abstract: A powder metallurgical process has been applied to synthesize the FeNiCr+Y₂O₃ oxide dispersion strengthened (ODS) alloys. The composition of the reinforcing Y₂O₃ added into matrix was varied from zero to 2.0 percent weight. Raw powders were carefully weighed with a four-digit balance. Y₂O₃ powder was pre-linked into Fe powder as the dominant element in the matrix by manually ground for half an hour. Ni and Cr powders were then mixed evenly for the next a half hour to obtain FeNiCr+Y₂O₃ precursor. Avoiding agglomeration and grain coarsening, the precursor was uniformly homogenized by milling for 20 hours. The precursors were then compressed at an isostatic pressure of 100 kN to 12 grams of pellets each. To prevent sample erosion during smelting with an electric arc furnace (EAF), crystal growing mechanism by conventional sintering was performed at 900 °C for 2 hours. This strengthens the bonds between precursors in forming ODS alloys. The samples were then melt-casted in the arc by 4 times flips. As a result, the neutron diffraction analysis and SEM-EDS strongly reveal the austenitic crystal structure and Y2O3 oxide successfully dispersed in the cast-alloy respectively. The microstructures with Y2O3 oxide spread uniformly overall the cast-alloy surfaces.

Abstract: An acetabular implant is a cup-shaped implant that wraps around the head of the femur at the hip joint. Severe damage to the acetabular implant results in bone turnover. To meet the needs of implants, appropriate implant manufacturing techniques are needed. Investment casting is the most widely used casting method because it has the best dimensional accuracy. To help reduce production costs in the industry, this research was carried out using the ProCast 2018 Software. In this study using the 2018 ProCast Software with investment casting techniques with CoCrMo material and variations in the orientation of the mold pattern, namely 0^o, 45^o, 90^o and variations in the shape of the sprue including straight sprue , tapper sprue, and reverse tapper sprue. From these variations, the most optimal result is the tapper sppue variation with 0^o print pattern orientation. With the results of the analysis related to the temperature distribution that occurs, fluidity, solidification process and the most optimal shrinkage porosity.

Abstract: Sand casting is a metal casting process to make a component by pouring molten metal into the sand mold. The casting process, the sand is the fundamental material used for mold making. The sand used is generally silica sand, river sand, mountain sand, and beach sand. The sand for molding must have requirements such as having formability, suitable permeability, good distribution of sand grain size, resistance to high temperatures, suitable binder composition, and sand must be cheap. This study investigated to determine the potential of Krueng Mane river sand in Aceh Indonesia for its possible use for metal casting. The important properties studied are moisture content, total clay content, grain fineness number, and grain shape. Tests are carried out following the standards and procedures defined by the American Foundrymen’s Society (AFS). Results obtained revealed that the river sand has average moisture content of 7.78 %, clay content of 3.20%, and grain fineness number (GFN) of 46. Krueng Mane river sand will be suitable for casting of casting of light steel, heavy grey steel, medium grey iron, and non-ferrous metals, with the addition of binding agent in suitable proportion.

Abstract: In this work, an attempt is made to reduce Molding defects using Taguchi Method. The input parameters used are Runner Lower Diameter, Runner Upper Diameter, Runner height, In gate height, and Pouring time. The response parameters selected as per the study of molding process requirements of the industry are Product yield(%). The L8 orthogonal array is used as per Taguchi method. The experimentation is conducted and the responses are measured. Significant progress has been made in determining the appropriate values of molding process variables to expand molding quality using diverse techniques during the last few decades. The design of sand-molding process variables has been recognized as one of the most critical aspects of molding quality. This research work focuses on improving the molding quality and yield percentage. The data analysis is made by S/N ratio and ANOVA. The result revealed the optimal setting to minimize the defect.