International Journal of Metalcasting最新文献_第9页

Bonding Bare Steel Insert to A354 Sand Casting Using Ultrasound-Assisted Cast-on Methods 使用超声辅助浇注方法将裸钢插入件粘接到 A354 砂铸件上

IF 2.6 3区材料科学

International Journal of Metalcasting Pub Date : 2024-05-02 DOI: 10.1007/s40962-024-01340-6

Dashan Sui, Qingyou Han

{"title":"Bonding Bare Steel Insert to A354 Sand Casting Using Ultrasound-Assisted Cast-on Methods","authors":"Dashan Sui, Qingyou Han","doi":"10.1007/s40962-024-01340-6","DOIUrl":"https://doi.org/10.1007/s40962-024-01340-6","url":null,"abstract":"A conventional cast-on (CCO) method requires costly procedures for steel insert and molten metal processing in order to produce bimetal sand castings of acceptable bonding quality. We explored the feasibility of using ultrasound-assisted cast-on methods for producing bimetal sand castings using as-received bare steel inserts and an un-degassed molten A354 alloy. The ultrasound-assisted methods included a direct ultrasound-assisted cast-on (DUACO) method and an indirect ultrasound-assisted cast-on (IUACO) method. Mathematical calculations were carried out to understand the conditions under which metallurgical bonding could occur using CCO in a sand casting process. Results of this study showed that the CCO method was unable to metallurgically bond as-received bare steel inserts to A354 alloy under the conditions of this study. The IUACO method was capable of producing metallurgical bonding between as-received inserts and un-degassed A354 alloy with bonding quality identical to that obtainable using coated inserts following stringent procedures for insert and molten metal processing. The DUACO method was much more effective than the IUACO method in producing high-quality metallurgical bonding between bare steel insert and un-degassed A354 alloy. Microstructural analysis indicated that a continuous layer of intermetallic phases was formed at the steel/aluminum interface in castings produced by DUACO method. Push-out test revealed that the shear strength of the bond produced by the DUACO method approached around 80 MPa. Mechanisms under which defect-free metallurgical bonding was formed were discussed.","PeriodicalId":14231,"journal":{"name":"International Journal of Metalcasting","volume":"5 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-05-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140884320","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Evaluation of Two New Cast Aluminum Alloys for High Performance Cylinder Heads 评估用于高性能气缸盖的两种新型铸铝合金

IF 2.6 3区材料科学

International Journal of Metalcasting Pub Date : 2024-05-02 DOI: 10.1007/s40962-024-01341-5

Qigui Wang, Andrew Bobel, Mike Walker, Devin Hess, Herb Doty, Dale Gerard

引用次数: 0

Applying the Spacing Transform on Secondary Dendrite Arm Spacing Measurements of a Cast High-Strength Low-Alloy Steel 在铸造高强度低合金钢的二次枝晶臂间距测量中应用间距变换

IF 2.6 3区材料科学

International Journal of Metalcasting Pub Date : 2024-04-28 DOI: 10.1007/s40962-024-01328-2

Z. Yang, D. Ezemenaka, C. Monroe

引用次数: 0

Cooling Curves of Concentrated Alloys, Steelmaking Slag, and Lithium Iron Phosphate 浓缩合金、炼钢炉渣和磷酸铁锂的冷却曲线

IF 2.6 3区材料科学

International Journal of Metalcasting Pub Date : 2024-04-28 DOI: 10.1007/s40962-024-01323-7

Delin Li

引用次数: 0

Improving Scattered Defect Grading in Castings Digital Radiographs via Smoothing the One-Hot Encoding 通过平滑单热编码改进铸件数字射线照片中的散射缺陷分级

IF 2.6 3区材料科学

International Journal of Metalcasting Pub Date : 2024-04-22 DOI: 10.1007/s40962-024-01335-3

Han Yu, Xingjie Li, Xue Hao, Zhaowei Song, Shangyu Liu, Xinyue Li, Chunyu Hou, Huasheng Xie

{"title":"Improving Scattered Defect Grading in Castings Digital Radiographs via Smoothing the One-Hot Encoding","authors":"Han Yu, Xingjie Li, Xue Hao, Zhaowei Song, Shangyu Liu, Xinyue Li, Chunyu Hou, Huasheng Xie","doi":"10.1007/s40962-024-01335-3","DOIUrl":"https://doi.org/10.1007/s40962-024-01335-3","url":null,"abstract":"Ensuring the precise grading of discontinuities is imperative to guarantee the quality of castings and enhance profitability in casting production. Recent grading methods leveraging computer vision are advanced by performing a single-label image classification or regression, which loses the intrinsically ordinal relationship. Motivated by this observation, we propose a label smoothing technology for ordinal variables to convert the level of each defect instance into a discrete probability distribution, aiming to model the noise label and ordinal relationship. Furthermore, we design a convolutional neural network framework based on multi-task learning. This framework, by simultaneously learning the level label distribution and regressing the level directly, outperforms a single-task network in terms of overall performance. Finally, we construct a casting gas porosity defect grading dataset. Experimental results on this dataset highlight the significant advantages of our proposed method compared to traditional single-label image classification or regression algorithms.","PeriodicalId":14231,"journal":{"name":"International Journal of Metalcasting","volume":"28 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140636428","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Gravity and Semisolid Casting of Self-Healing Aluminum Matrix Composites 自愈合铝基复合材料的重力铸造和半固态铸造

IF 2.6 3区材料科学

International Journal of Metalcasting Pub Date : 2024-04-22 DOI: 10.1007/s40962-024-01333-5

Sumit Sharma, Masum Bellah, Vaibhav Srivastava, Pradeep Rohatgi

引用次数: 0

A Coupled Numerical Scheme for Simulating Liquid Metal Cooling Process in the Production of Superalloys 模拟超合金生产中液态金属冷却过程的耦合数值方案

IF 2.6 3区材料科学

International Journal of Metalcasting Pub Date : 2024-04-22 DOI: 10.1007/s40962-024-01312-w

Shengxu Xia, Yuzhang Lu, Zhaofeng Liu, Jianzheng Guo, Jian Zhang

{"title":"A Coupled Numerical Scheme for Simulating Liquid Metal Cooling Process in the Production of Superalloys","authors":"Shengxu Xia, Yuzhang Lu, Zhaofeng Liu, Jianzheng Guo, Jian Zhang","doi":"10.1007/s40962-024-01312-w","DOIUrl":"https://doi.org/10.1007/s40962-024-01312-w","url":null,"abstract":"The constant evolution of computer-aided engineering techniques continues to enhance our understanding of the liquid metal cooling process. Conventional methodologies often rely on fixed heat exchange coefficients for computing the thermal interaction between casting modules and the liquid coolant. This paper introduces a novel coupled numerical scheme integrating computational fluid dynamics (CFD) and solidification analysis. Within this framework, the commercial software ANSYS Fluent® addresses the CFD aspect of the coolant, while the ProCAST® handles the solidification simulation. The solidification process is simulated through solving heat conduction equation in which the heat flux boundary condition on the external surface of the cast module is determined according to the convective coolant flow. The CFD simulation based on the Navier–Stokes equations furnishes the heat flux at the module-coolant interface, taking the temperature field of the cast module as input. The coupled method is validated first with a test case in which a module is immersed inside coolant, followed by a multiphase flow simulation, wherein a casting module is pulled into the liquid tin bath from a gas-phase position. Both simulations reveal temperature variations in the coolant. Comparison with conventional heat exchange coefficient approaches confirms the influence of these variations on cooling curves. The coupled model is further used to investigate the effect of withdrawal rates on the solidification process, exhibiting qualitative agreement with experiments.","PeriodicalId":14231,"journal":{"name":"International Journal of Metalcasting","volume":"40 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140636427","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Wear Resistance and Mechanical Properties of 7085 Alloy via Adding CNTs Based on Ultrasonic Casting 基于超声波铸造的添加 CNT 的 7085 合金的耐磨性和机械性能

IF 2.6 3区材料科学

International Journal of Metalcasting Pub Date : 2024-04-22 DOI: 10.1007/s40962-024-01329-1

Li Anqing, Jiang Ripeng, Li Ruiqing

{"title":"Wear Resistance and Mechanical Properties of 7085 Alloy via Adding CNTs Based on Ultrasonic Casting","authors":"Li Anqing, Jiang Ripeng, Li Ruiqing","doi":"10.1007/s40962-024-01329-1","DOIUrl":"https://doi.org/10.1007/s40962-024-01329-1","url":null,"abstract":"High-energy ultrasound has been proposed to ameliorate the uniform dispersion the reinforcement and used widely fabricating in high strength metal matrix composites. In this work, 7085 aluminum (Al) metal matrix composites with varying contents of reinforcement carbon nanotubes (CNTs) (0–1.2 wt.%) were fabricated by surface modification treatment and ultrasound-assisted casting technique. The wear resistance and mechanical properties of the composites were investigated. The addition of reinforcement CNTs particles led to an improvement in the mechanical properties of the composite from 126.4 to 187.2 MPa and the hardness from 128 to 169.4 HV. The wear resistance results showed that with the addition of the 1.0 wt.% CNTs, the wear rate of the reinforcement composite was 1.42×10−3mm3/Nm, and the depth and width of the abrasion marks reached the optimal value. At the same time, the formation of Al4C3 will be beneficial to further enhance the mechanical properties of the alloy. However, excess CNTs tends to agglomerate, which will deteriorate the properties of the composites. This also indicates that the synergistic fabrication of multiple processes could offer CNTs/7085 composite a great promising candidate for engineering applications.","PeriodicalId":14231,"journal":{"name":"International Journal of Metalcasting","volume":"40 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140636553","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Industry 4.0 Adoption Using AI/ML-Driven Metamodels for High-Performance Ductile Iron Sand Casting Design and Manufacturing 利用人工智能/ML 驱动的元模型进行高性能球墨铸铁砂型的设计和制造，实现工业 4.0

IF 2.6 3区材料科学

International Journal of Metalcasting Pub Date : 2024-04-22 DOI: 10.1007/s40962-024-01338-0

Jiten Shah, Brian Began

{"title":"Industry 4.0 Adoption Using AI/ML-Driven Metamodels for High-Performance Ductile Iron Sand Casting Design and Manufacturing","authors":"Jiten Shah, Brian Began","doi":"10.1007/s40962-024-01338-0","DOIUrl":"https://doi.org/10.1007/s40962-024-01338-0","url":null,"abstract":"Data-centric near-real-time intelligent process control for smart manufacturing in an Industry 4.0 era is of tremendous value. Design and manufacturing of high-performance ductile iron sand castings is a multi-variant complex process with much uncertainty involved. As a result, in spite of a well-controlled operation and an experienced workforce, iron foundries in a production environment do face sporadic shrinkage and lots with nonconforming property requirements, resulting in scrap or rework. A framework and methodology consisting of AI (artificial intelligence) and ML (machine learning) tools, coupled with ICME (integrated computational materials engineering) and process simulation tools, will be presented to quantify uncertainty (UQ). Metamodels, both predictive and prescriptive in near real time were developed using such AI/ML techniques using historical production and selective design of experiments (DOE)-generated additional data. The data will be presented including details on successful corrective action production trials. The proposed framework and approach is applicable to solve such complex problems encountered in the foundry and machining operations where there is uncertainty.","PeriodicalId":14231,"journal":{"name":"International Journal of Metalcasting","volume":"139 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140636688","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Impact of Temperature of Cast Iron Chills on Tensile Properties in the Aluminum Precisions Sand Casting Process 铸铁冷却温度对铝精密砂型铸造工艺拉伸性能的影响

IF 2.6 3区材料科学

International Journal of Metalcasting Pub Date : 2024-04-22 DOI: 10.1007/s40962-024-01325-5

Robert Mackay, Glenn Byczynski

{"title":"Impact of Temperature of Cast Iron Chills on Tensile Properties in the Aluminum Precisions Sand Casting Process","authors":"Robert Mackay, Glenn Byczynski","doi":"10.1007/s40962-024-01325-5","DOIUrl":"https://doi.org/10.1007/s40962-024-01325-5","url":null,"abstract":"The latest generation of high-performance cylinder blocks are produced with the Precision Sand Castings Process which sometimes uses a monolithic cast iron chill that promotes enhanced solidification conditions that improve both tensile and fatigue performance. However, monolithic chills tend to be re-used quite quickly and thus can be significantly above room temperature during the next subsequent casting. To deter the potential deleterious effects, this may cause most casting practitioners to enforce a strict room temperature condition of the chill prior to use. However, this may necessitate a higher number of chills in the system or the implementation of chill cooling stations, both of which involve higher capital investment. The authors will address the most optimal method to address thermal management of chills by documenting the mechanical and microstructural property impact and its compliance in the bulkhead (next to chill) and head bolt columns (60 mm away from the chill) to the chill temperature prior to casting. The Quality Index will reflect the chill temperature impacts based on the mechanical properties results for this manuscript.","PeriodicalId":14231,"journal":{"name":"International Journal of Metalcasting","volume":"31 1","pages":""},"PeriodicalIF":2.6,"publicationDate":"2024-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140636686","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0