Papers by Keyword: Casting

Abstract: Nickel-copper alloys are commonly used in highly corrosive conditions where strength is required. Typical applications are in the marine sector, petrochemical industry, or energy facilities such as chemical tubes, pumps, heat exchangers and superheated steam systems. This paper compares the microstructure and mechanical properties of a cast alloy with a 3D printed alloy processed via a laser powder bed fusion (LPBF) technique. Small cylindrical specimens were used for tensile tests at room temperature (RT) and elevated temperatures up to 750 °C in air. The tensile stress-strain response was determined for both types of materials. At RT, LPBF material has a higher yield strength and ultimate tensile strength than a cast alloy. At elevated temperatures, the strength of both variants is comparable. However, the fracture elongation of the LPBF material is significantly lower over the entire range of investigated temperatures. Fracture surfaces and polished sections parallel to the specimen axis were investigated to compare the microstructure and damage mechanisms of the nickel-coper alloy 400 prepared by conventional casting and via LPBF.

Abstract: The Smart Foundry concept promises benefits of improved foundry supply chain quality, more sustainable metal processing, and improved customer support. A significant need includes automated data gathering and visualization of the data. In metal foundries regardless of manufacturing small parts in mass production or big parts in small production, metal castings are difficult to trace individually. Furthermore, to identify causes of defects through statistical correlation of recorded process inputs to inspected part defects becomes challenging. In this paper we present a sand-casting Smart Foundry operation including automated scan-based tracking of cast parts through the foundry and supply chain. This allowed process data collected to be automatically associated with the part being processed. This study proved that additively manufactured tags can be utilized in foundry serial production operations for direct-part-marking of castings and both digital tracking and process data collection of individual cast parts. Further we made use of the captured part-by-part data to develop a root cause analysis for quality defect causal correlation. The results indicated that the casting feature dimensional quality was highly correlated with variations in sand bending strength, tin content in aluminum, and pouring time, among others. Such insights are available when tracking process and part data as part of a Smart Foundry.

Abstract: A growing demand for advanced composite materials as well as diverse design requirements offering significant weight savings in comparison to conventional materials have all contributed to a growing interest in composite materials. This review paper is focused on Powder Metallurgy (P/M) process to fabricate magnesium based metal matrix composites. The excellent oxidation and corrosion resistance and low density of Silicon carbide have made it a popular material even at very high temperatures. Despite their very high specific strength, magnesium matrix composites possess excellent cast ability, good damping capabilities, and greater machinability. Therefore, this review paper discusses the importance, fabrication, and properties of magnesium matrix composite materials for industry applications. An examination of the properties of recently produced magnesium matrix composites by various researchers is presented in this review paper.

Abstract: A carbon fibre (CF) in the form of a rod (continuous fibre) was used as reinforcement due to its superior strength and modulus properties. Carbon fibre rod reinforced aluminium 6061 alloy metal matrix composite material was synthesized using the stir casting liquid metallurgy route. Aluminium based metal matrix composite materials are light in weight. Very few researchers were worked on carbon fibre rod reinforced metal matrix composites (MMC). Electroless nickel deposition on carbon fibre rods (2mm and 3mm diameter) were carried out for improvement in wettability. On carbon fibre rods, the effectiveness of electroless nickel coating was validated using SEM (scanning electron microscopy) and EDAX (Energy Dispersive X-Ray Spectroscopy) analysis. A further coating thickness of nickel was improved using nickel electroplating. In a cast iron mould, nickel-coated carbon fibre rods were arranged in a circular pattern. Completely degassed molten aluminium 6061 alloy was poured in cast iron mould at 600-700 °C. The enhancement in Tribological and mechanical properties is always a prerequisite for technological advancement in automobile sector. From synthesized composites (11.11% Vol. CF and 25% Vol. CF reinforcement) specimen were prepared for density tests, bulk and microhardness tests, friction and wear tests. Synthesized composite has low density, increased bulk and microhardness, low coefficient of friction and reduced wear rate in comparison with aluminium 6061 alloy. Keywords: Carbon Fibre (CF) rod, MMC, Nickel coating, Casting, Mechanical, Tribological

Abstract: A composite material is a combination of two or more materials that have advantages such as light weight, higher strength, corrosion resistance and low installation cost [1]. Composite materials are commonly found in aircraft, automotive, manufacturing and other industries [2,4]. Composite materials based on the type of reinforcement consist of types of fibers, particles and structures [5-14]. In this study, the particle composite material is made from a reinforcing powder made from liquid waste and used for the manufacture of motor vehicle body products (wing or bottom components). Composite reinforcing materials from liquid waste are obtained through the process of drying palm liquid waste or rubber in powder form. The manufacturing process of two-wheeled motor vehicle body products uses a casting process by making molds and products using the hand-laying coating method. The alloying material used in this research is Yukalac 156 BQTN-EC resin and reinforcement from liquid palm oil or rubber waste powder. The variation of the alloy becomes a parameter to evaluate the quality of the casting product analyzed in the form of the geometric characteristics of the product i.e. the dimensions and surface roughness. Variations of composite material alloys use a ratio of 1:1 to 5:1. From the results of the study, it is found that the dimensions are close to the design value with the smallest deviation at a composition ratio of 3:1 which surface roughness values is 2,18 to 3,13 μm for mold dies and 6,45 to 8,02 μm for product.

Abstract: It was carried out the research of variation of foam polystyrene hardness, and was observed the limiting temperature which take enable to cut the foam polystyrene with the use of thermo-tools.

Abstract: The article describes the features of the casting process in the chill mold of magnesium alloys. The main factors affecting the quality of the castings obtained are indicated. The main defects of magnesium castings obtained by chill mold casting, as well as possible ways to eliminate them, are revealed. Options for improving the efficiency of the casting process by optimizing the process parameters are proposed, as well as options for heat treatment that increase the physical and mechanical properties of ready-made castings are presented.

Abstract: The article describes the features of the process of casting copper alloys in the chill mold. The main properties of alloys depending on the content of various components in it are revealed. The main negative factors leading to a decrease in the casting properties of the process, as well as the quality of the castings obtained, are indicated. Based on the information and analytical review, possible options for improving the efficiency of the process are identified. These include: alloying, refining, modification, the use of various one-time coatings, the use of heat treatment of castings. The use of hard coatings applied by the method of physical vapor deposition in order to increase the efficiency of the entire casting process is proposed.

Abstract: Magnesium, a light weight alloy used in multiple engineering industrial applications because of its good Physical, Chemical and Thermal characteristics. Magnesium composites play an important role in partial or entire replacement of numerous alloys.This current work deals with Nano silicon carbide of about 100nm was incorporated with AZ91magnesium alloy through liquid state composite processing. Two samples are made using 0% Nano SiC and 3% Nano SiC and are characterized through tensile test in Universal Testing Machine, Micro hardness test in Vickers hardness tester and Microstructure in Optical Microscopy. From the study it was clear that there is a peak increase in hardness of about 36% when compared to as casted AZ91.

Abstract: The development of modern high-tech industries of industrial production is impossible without the development of new methods for processing materials with high mechanical characteristics. There is a growing need for an increase in the proportion of parts made of aluminum alloys, a more complex configuration of cast parts, an increase in their reliability and durability in operation, etc. All this poses for metallurgists and foundry workers the task of creating new technologies for producing alloys, improving the technical and economic characteristics of structural materials, improving the quality and reducing the cost of castings.Hypoeutectic silumins have good casting properties, good weldability, machinability and corrosion resistance. However, they are prone to the formation of a coarse needle-like state, which reduces their useful characteristics. To eliminate this phenomenon, it is necessary to apply special technologies and the most common is their modification, which provides grain refinement. This makes it possible to use silumins for the manufacture of castings of complex shapes with increased density and low shrinkage porosity. Such parts can withstand average loads in critical units. Aluminum-silicon alloy AK7 or (ASi7Mg0.3) is a typical silumin, which is in demand in the automotive industry, construction, aircraft construction, machine, automobile and tractor production. It is appreciated for its good casting properties, weldability, machinability and corrosion resistance.