ABSTRACT An extrusion-based additive manufacturing process for investment casting shell mould is introduced in this paper. This process uses silica sol bauxite slurry to build shell mould. The shell mould is made up of thin walls around the casting cavity, and its additive manufacturing process is actually the building process of walls. The effect of process parameters on the dimensional accuracy of

ABSTRACT The effect of surface morphologies of Al insert, including smooth surface (SS), straight knurling (SK) and hatching knurling (HK) on interfacial microstructure, mechanical properties and fracture behaviour of Al/Mg bimetallic composites by a novel compound casting was studied in this work. The thicknesses of the interface layers of the SK-s and HK-s bimetallic composites, respectively, increased

ABSTRACT In foundries, it becomes necessary to minimise the machining allowance for economic reasons. It will save resources and costs by reducing the energy and expenses incurred on re-melting, machining and tooling. A deeper understanding of the complicated microstructures developed within about 3.5 mm of the mould-metal interface is necessary. The current research work uses a unique experimental

ABSTRACT The current study investigated the effect of heat treatment parameters, including solution treatment temperature (STT), time, and quench rate, on the microstructure, defects, and hardness of an Al-16Si-6Cu Shift fork die-cast alloy. The changes in primary silicon particle (PSP) features were examined quantitatively by optical microscopy, coupled with image analysis and SEM equipped with EDS

ABSTRACT The aim of this study is to investigate at the mechanical characteristics of Fe3O4 particle reinforced with 7075 aluminium alloy composite. The composites of different weight percentage 2%, 4%, 6%, and 8% of Fe3O4 reinforcement were prepared using stir casting technique. Prepared composite samples were examined for mechanical properties like tensile percentage elongation and hardness test

ABSTRACT The demand for long casting sequences together with a wide range of different steel grades inherently leads to the generation of incompatible steel intermixing during a grade change. This paper describes the development of an optimisation tool for casting sequences based on a mixing model. The mixing model accounts for mixing in the tundish and in the liquid core of the strand and was calibrated

ABSTRACT In this work, OM, SEM/EDS, XRD, DSC, and tensile test were used to study the effect on mechanical and thermodynamic properties of Al-10Si-0.8Fe alloys with Al-Ti-C (0.5 wt.%) and xCe (viz. 0.2, 0.4, 0.6 and 0.8 wt.%) compound addition. After adding compound additives to Al-10Si-0.8Fe, the average size of SDAS decreased and the mechanical properties increased. When Ce is 0.6 wt.%, The smallest

ABSTRACT For reducing the forming cost of the PAN-based carbon fibre preforms, a water glass binder was used as a substitute for conventional silica binder. The preforms were infiltrated with an aluminium alloy melt by squeeze casting to fabricate the fibre-reinforced composites. The microstructure and properties of the composites were compared to the composites using the silica binder. In the composites

ABSTRACT The aim of this study is to improve the tribological behaviour of aluminium alloys by using grain refiner and modifier. The effects of Al5Ti1B grain refiner and Al10Sr modifier additives on friction and wear properties on A380, A357 alloys produced by pouring sand andpermanent mould casting were investigated. Abrasion tests were carried out under dry conditions against St1040 steel disc using

ABSTRACT In the casting method, it is crucial to properly make the moulding design to produce sound parts. Volumetric change, especially during the solidification of spheroidal graphite cast irons, may show different behaviour compared to steel and aluminium castings. In this study, castings were carried out with single and double feeders with varying casting parameters of green sand and resin mould

ABSTRACT Phenolic resins are in-organic polymers with properties that make them high-strength binders with great potential for modification. The base-catalyzed phenol-formaldehyde resins provide the desired hardness to the core avoiding sand slipping on the surface. A modified resol type phenolic resin is developed for this study with minimum ingredients to compare it with existing recipes in the literature

ABSTRACT In the current article, the influence of titanium on the hot ductility of peritectic-microalloyed steels, in the temperature range 600°C to 950°C, was investigated by tensile testing. The morphology of the fracture and the behaviour of precipitates, inclusions and microstructures near the fracture surface were observed and discussed. It was found that within the test temperature range, the

ABSTRACT In the foundry for the production of moulds and cores, mixtures based on water glass are widely used. During their hardening, the coagulation of liquid glass occurs, as a result of which the mixture obtains high strength characteristic. A significant drawback of moulding mixtures based on water glass is low knockout due to increased sintering ability of water glass with moulding sand. To improve

ABSTRACT Friction stir processing (FSP) is a solid-state processing method that can be used as a microstructural modifier or a post-processing technique. It can be applied to refine the grain structure. It is an eco-friendly manufacturing approach with negligible harmful gases and can be applied to all types of engineering materials. With the continuous development in FSP, now it is used to develop

ABSTRACT Different weight ratios of cerium (0.5, 1 and 2 wt.%) were produced in a controlled atmosphere by High Pressure Die Cast method to Mg-6Al-0.3Mn-1Sn alloy. The influence of cerium on microstructure and high-temperature mechanical properties was investigated. The microstructure study revealed that the main alloy contains intermetallic phases such as α-Mg, β- Mg17Al12, Mg2Sn and Al11Ce3. The

ABSTRACT Al-Sn immiscible alloys possess enhanced tribological properties with increased fatigue strength, which makes them competent among self-lubricating bearing materials. In the present work, a direct chill (DC) casting simulator has been designed and manufactured to cast Al-Sn alloy by forced convection technology. The study embodies two different mechanisms for mechanical forced convection (MFC)

ABSTRACT When designing a new material for hot rolling rolls, it is necessary to be aware of the conditions in the later utilisation phase. The first step is to quantify stresses, and temperatures the material must tolerate operating in the rolling mills. These characteristics are evaluated by direct measurements and hot rolling simulations. Simulations targeted the identification of the temporal and

ABSTRACT For manufacturing of steel wires, tubes and profiles in hot rolling mills, the toughest conditions occur in the front rolling stands where the mechanical load comes along with a constant change of hot rolling stock and cooling liquid. Conventional roll materials as pearlitic or acicular cast irons are not able to overcome these intense conditions because of their lack of ductility. A fine

ABSTRACT A bimetallic composite roll with the cladding layer of high-speed steel (HSS) and the roll core of ductile cast iron (DCI) was manufactured by the electroslag remelting cladding (ESRC) technology, and the changes in the graphite morphology, matrix structure, and mechanical properties of the DCI core before and after the ESRC process were compared. The DCI core was first heated to a very high

ABSTRACT First-principles calculation was carried out to investigate the mechanism of Zr poisoning Al-5Ti-B grain refiners via Ti (or Zr)-adsorbed TiB2 models. The results show that the most energetically favourable sites for both adsorptions of Zr and Ti are bridge- and hollow-sites. The calculated results show that (i) adsorption energy of Ti is slightly more negative than that of Zr; (ii) The adsorption

ABSTRACT The solubility of hydrogen in solid binary aluminium alloys has been investigated with data from the literature. As in liquid binary alloys, analysis has shown the effect of Cu, Mg, Si and Zn additions on normalised hydrogen solubility can be estimated by using exponential fits. The method developed previously to estimate hydrogen solubility in liquid commercial alloys has been extended to

ABSTRACT In this study, HPDC is introduced into the production of oil circuit board, aiming to solve forming defects and provide a complete design concept for the exploitation of die-casting process in large castings. First, the die-casting die was designed and its rationality was verified, but the unreasonable selection of injection process parameters caused casting non-conformance. Next, the experimental

ABSTRACT Gas permeability of moulds and cores is an important factor to consider in the casting process. In foundries, gas permeability is measured by using instruments which give dimensionless numbers. This approach enables the comparison of values between samples and is often not quantified in units. In this study, a custom-made measurement system is introduced that applies Darcy’s law, where pressure

ABSTRACT In the cast iron industry, mould sand quality and the most efficient recovery of used sand into the system are critical. For this purpose, the optimum values of the factors (humidity, active bentonite and coal dust) affecting the green strength, gas permeability and shear strength of the mould sand were determined in this study. The optimum mixture ratio, which makes the green strength, gas

ABSTRACT In this research, the effects of laser surface hardening treatment on the phase transformation of austempered and quench-tempered grey cast irons were investigated. It was found that there were four zones in the matrix of austempered grey cast iron and three zones in the matrix of quench-tempered grey cast iron produced by the laser hardening process. Both cast irons had central laser-hardened

ABSTRACT Nowadays, Squeeze casting is considered as a convenient process for developing quality piston components. In this paper, casting methods such as squeeze casting and die casting techniques are used for compare the tensile behavior of Al-Si piston in the view of casted and heat-treated aspects. K-Nearest Neighbour (KNN) algorithm is used for predicting the tensile fracture of the squeeze casted

ABSTRACT Shapiro–Wilks test is popularly used for testing the normality of the data. Shapiro–Wilks test using the idea of neutrosophic statistics is discussed in this paper. The necessary equations are given under the indeterminacy environment. The testing procedure of the proposed test is given and explained with the help of chemical data. The performance of the proposed Shapiro–Wilks test is discussed

ABSTRACT The first-principle calculation was used to understand new insight of Ca element refining grain structure in commercial purity Mg. Negative adsorption energy, strong ionic bond and negative shift of partial density of states verify that Ca element is readily adsorbed on the surface of MgO. Combined with analysis of interfacial bonding between Mg2Ca and α-Mg, new insight of Mg2Ca layer formed

ABSTRACT Dendrite coherency or dendrite impingement is an important factor for determining solidification microstructure and casting defects of alloys. In this research, the effect of various cooling rates and Al-5Ti-1B grain refiner contents on the dendrite coherency point (DCP) characteristics of an Al-Si-Mg alloy designated as A357 has been studied. The results showed that both mentioned parameters

ABSTRACT The composite components with complex-shape and containing different nanoparticle contents and sizes were successfully produced by the short-process thixoforming. Based on the developed constitutive model, numerical simulation of thixoforming for the composites with a high solid fraction was carried out, and the relevant experiments were performed. The influences of temperature and forming

ABSTRACT The effect of pouring temperature on microstructure and bonding properties of the Mg/aluminised steel bimetallic castings prepared by the solid–liquid compound casting process was investigated in this paper in order to improve the interface bonding of the Mg/aluminised steel bimetallic castings. The results show that the Mg/aluminised steel bimetallic castings produced with different pouring

ABSTRACT In the present study, an attempt has been made to utilise spent alumina catalyst (SAC) and carbonised eggshell (CAES) in the fabrication of AA5052-based composite material. Cr was also added to further enhance the tensile strength, hardness and corrosion resistance of the material. Results showed that by adding 4.5% SAC, 4.5% CAES and 1.5% Cr in aluminium alloy, mechanical properties such

ABSTRACT The first-principle calculation was used to understand new insight of Ca element refining grain structure in commercial purity Mg. Negative adsorption energy, strong ionic bond and negative shift of partial density of states verify that Ca element is readily adsorbed on the surface of MgO. Combined with analysis of interfacial bonding between Mg2Ca and α-Mg, new insight of Mg2Ca layer formed

ABSTRACT In the present study, the effect of Ce alloying element with different quantities (1 and 2 wt.%) on the microstructure and mechanical properties of Mg-5Sn-2Al alloy was investigated. Phase analyses and microstructural studies were carried out using XRD and SEM. It was observed that base alloy was composed of the α-Mg and Mg2Sn intermetallic phase, and after Ce addition Ce5Sn4 intermetallic

ABSTRACT The formation of bonding between Al and Fe after the initial compound casting and during a heat treatment regime is investigated. No significant bonding was observed between the two metals after the initial casting. This observation was attributed to the presence of oxide films on the liquid Al and solid Fe alloys. The heat treatment of the cast part at 973 K (700°C) for at least 15 min is

ABSTRACT High-silicon cast steels and proper heat treatment cycles were designed in order to obtain carbide-free bainitic microstructures. The design process allowed to obtain the desired microstructures after heat treatment cycles compatible with industrial practices and using low amounts of inexpensive alloying elements. The different chemical compositions and austempering temperatures tested resulted

ABSTRACT Optical analysis, dilatometry as well as neutron diffraction are utilised to investigate the phase transition within ductile iron both in-situ and after the heat treatment process for perferritic isothermed ductile iron (IDI). A suitable annealing temperature is chosen by calculating a phase diagram for the investigated alloy. The phase transition which happens slightly above upper intercritical

ABSTRACT The effect of thermal exposure on the elevated-temperature mechanical properties of heat-treated Al-12Si-4Cu-1Ni-1 Mg-2Mn piston alloys was investigated using optical microscopy (OM), scanning electron microscope (SEM), transmission electron microscopy (TEM), and tensile tests at elevated temperatures. The results showed that coarsening of the strengthening precipitates following a prolonged

ABSTRACT In this study, thermophysical properties of a commonly used silica sand were investigated and their relation to its granulometric and chemical composition was studied. Thermal expansion and differential scanning calorimetry tests were performed on individual fractions of the silica sand together with X-ray fluorescence measurements to determine their constituents. It was found that the various

ABSTRACT The evolution of nitrogen gas formation in cast iron was studied based on the information of the N solubility in the carbon-saturated iron-containing Mn and Si over the wide temperature range. In order to verify the accuracy of the Fe-Mn-Si-C phase diagram, the transition temperatures of the Fe-Mn-2.7 wt%Si-Csat alloys were measured according to the Mn concentration using a differential scanning

ABSTRACT For improving the mechanical strength of cast irons, a fully pearlitic matrix is sought by alloying with tin, copper and manganese. This applies in particular to the compacted graphite irons considered here. While average macro- and micro-hardness values were similar for the four fully pearlitic alloys under study, it was found that high copper and low tin content showed some very high maximum

ABSTRACT The effects of cooling rate and carbon equivalent on the tensile strength of pearlitic lamellar graphite cast irons were investigated. The cooling rate was varied from 6°C/s to 35°C/s for values of the carbon equivalent equal to 4.17% and 3.83%. The increase in the cooling rate promoted the refining of the eutectic cell size, primary dendrite modulus, interdendritic hydraulic diameter and

ABSTRACT A new method for mould filling calculation of lost foam casting (LFC) was developed based on the main hypothesis, which assumes that every point on the melt-pattern interface moves in the radial direction. The value of the normal velocity is calculated by an empirical formula, which is the function of the degree of vacuum, pattern density, pouring temperature, metallic static head, etc. At

ABSTRACT The process of multistep nucleation during solidification in hypoeutectic Al-Mg-Si casting alloys was investigated. The morphology of the nucleating particles, Mg2Si primary crystals and Al-Mg2Si eutectic, was investigated with scanning electron microscopy (SEM) on polished and deep etched microsections. The mechanism of formation of the Mg2Si crystal was attributed to heterogeneous nucleation

ABSTRACT The effect of P/S-wave on the solidification feeding and the mechanism of vibration promoting the solidification feeding in the low-pressure casting are discussed in the paper. The casting defects were analysed by X-ray non-destructive testing and the buoyancy method. It can be found that the compactness of casting is greatly improved by vibration. In the solidification feeding, according

ABSTRACT The concept of converting dendritic structures into globular morphologies through solid-state deformation, termed as strain-induced melt activation (SIMA), is assessed. Although the original invention defined the specific two-stage deformation scenario, almost four decades of extensive research, involving a variety of ferrous and non-ferrous alloys, subjected to conventional and severe plastic

ABSTRACT An experimental study focused on the determination of mechanical properties of synthetic green sand system using Nagavali river sand by adding banana peel powder as an additive. Compression strength, shear strength, mould hardness bulk density and permeability are the various properties found in the laboratory following standard testing procedures. Sand aggregate is prepared by mixing the

ABSTRACT Heterogeneous nucleation based on the spherical cap model has been used in this study to evaluate nucleation pressure and the number of hydrogen atoms necessary for nucleation. Calculations have shown that the minimum heterogeneous nucleation pressure that can be achieved is in the order of 1 GPa, which is four orders of magnitude larger than the values assumed in the literature. Implications

ABSTRACT To study the influence of the microstructure of cast iron on the adhesion of an epoxy coating, ferritic, pearlitic and austempered samples were prepared in as-received, polished and oxidised states. A pull-off test (dry adhesion) was performed before immersing in water while the cross-cut test was made after 24 days of exposition in distilled water (wet adhesion). X-rays were combined with

Data for solubility of hydrogen in binary liquid aluminium alloys have been reanalysed by normalising alloy hydrogen solubility data with that for pure aluminium reported in the same study. This method has eliminated one source of variation, namely due to difference in experimental conditions between studies. Analysis has shown the effect of Cu, Mg, Si and Zn additions on normalised hydrogen solubility

ABSTRACT Data for solubility of hydrogen in binary liquid aluminium alloys have been reanalysed by normalising alloy hydrogen solubility data with that for pure aluminium reported in the same study. This method has eliminated one source of variation, namely due to difference in experimental conditions between studies. Analysis has shown the effect of Cu, Mg, Si and Zn additions on normalised hydrogen

ABSTRACT In this study, Polymer (Primecast® 101-EOS)patterns were produced with the EOS Formiga P110 system, and these patterns were compared with conventional wax patterns using their suitability for the investment casting (IC) method. Besides, Scanning Electron Microscope (SEM) and Thermal Analysis (DSC and TGA) were applied produced to investigate the properties of Primecast® patterns and their

ABSTRACT Functionally graded Cu-10Sn-5Ni/10B4C composite was fabricated using horizontal centrifugal casting. Microstructural and mechanical properties were superior at reinforcement-rich inner zone where wear tests were conducted based on response surface methodology five-level run order, using pin on disc tribometer. Results showed that wear rate increases linearly with increase in load and sliding

ABSTRACT The effect of Zr (0.1, 0.3, 0.5 wt. %) addition on microstructural morphology, hardness, mechanical properties and fracture behaviour of gravity cast Al-12.4Si alloy has been studied. The unmodified Al-12.4Si alloy consists of non-uniformly distributed coarse and irregular shape primary and eutectic silicon particles with sharp corners in Al phase. However, the Zr added Al-12.4Si alloys have

ABSTRACT A high shake-out temperature after casting is beneficial from a production point of view due to the need of a shorter cooling line in the foundry. However, a higher shake-out temperature might also lead to increased residual stresses due to faster cooling. In order to get a good agreement between simulated and measured temperature curves it is important to adjust material data and heat transfer

ABSTRACT In this study, a chromium carbide layer was fabricated by an in-situ casting technique on ductile iron cast components. The procedure consists of (i) applying a ferrochrome slurry at the surfaces of silica sand moulds to create a surface layer (e.g. coating) and (ii) use a ductile iron alloy to cast the coated moulds. The microstructure of the realised surface layer was characterised and analysed

ABSTRACT A two diagram procedure was used to assess the microstructure effects on tensile strain hardening in different silicon strengthened ductile irons produced through different cooling rates. In the Matrix Assessment Diagram, the data from different ductile irons were identified through lines. While with Si 2.5 wt-% the intercept of the best fitting line was positive in agreement with the physical

ABSTRACT Both the mechanical properties and microstructure of die-casting ADC12 + x(La+Yb) alloy (x = 0, 0.3 wt.%, 0.6 wt.%, 0.9 wt.%) were investigated. It was found that the main compounds of the ADC12 matrix die-casting alloy are block-shaped and strip-shaped α-AlFeMnSi phase and net-shaped copper phase which was located at the grain boundary. Mixed rare earth (La+Yb) refined the microstructure

ABSTRACT This study investigates the mechanical properties of Intercritically Austempered Ductile Iron (IADI) obtained after the heat treatment of ductile irons having different as-cast microstructures and Si concentrations. Tensile strength, impact strength and hardness are measured. The results show that it is possible to obtain acceptable IADI microstructures starting from different as cast microstructures

ABSTRACT Ultrasonic melt treatment (UST) is known for refining microstructures including intermetallic compound (IMC)s, and it is expected that the microstructural benefits induced by UST may reduce the time and temperature of solid solution treatment (SST). The effect of UST on SST for an Al-7Si-2Cu-1 Mg alloy was investigated in terms of changes of volume fraction of IMCs in connection with the tensile