scholarly journals The Control of Solidification Kinetics of the Vacuum-cast Thin-wall Nickel-based Superalloys by Changing the Geometrical Characteristics of the Ceramic Mold

2013 ◽  
Vol 13 (4) ◽  
pp. 21-28 ◽  
Author(s):  
R. Cygan ◽  
D. Szeliga ◽  
P. Rokicki ◽  
J. Sieniawski ◽  
J.S. Suchy
Keyword(s):  
Casting Process ◽  
Ceramic Mold ◽  
Thin Wall ◽  
Aircraft Engines ◽  
Foundry Industry ◽  
Precision Casting ◽  
Geometrical Characteristics ◽  
Casting Technology ◽  
Solidification Kinetics ◽  
Kinetics Of

Abstract This paper provides an analysis of experimental research and results of investment casting process. Temperature field in a ceramic mold is one of the problems during numerical simulation. Reducing the costs of production in precision casting involves the reduction of scraps, which is one of the fundamental problems of the foundry industry. Reducing these costs is associated with optimization of precision casting technology of aircraft engines critical parts, including control of the solidification front in thin-walled castings of nickel super alloys cast in a vacuum. It is achieved by changing the geometrical characteristics of the ceramic mold. The results of the tests were used to optimize the industrial production of aircraft components in Precision Foundry of WSK Rzeszów. Temperature distribution gained in the conducted tests allowed verification and optimization of computer simulations.

scholarly journals The Influence of Benzoyl Peroxide on Gelation Rate of Silica Binder for Precision Casting

2013 ◽  
Vol 13 (2) ◽  
pp. 99-102
Author(s):  
M. Nadolski ◽  
Z. Konopka ◽  
M. Łągiewka ◽  
A. Zyska
Keyword(s):  
Benzoyl Peroxide ◽  
Colloidal Silica ◽  
Single Layer ◽  
Production Cycle ◽  
Drying Process ◽  
Precision Casting ◽  
Casting Technology ◽  
Shell Mould ◽  
Kinetics Of ◽  
Moulding Material

Abstract Substituting of ethyl silicate with ecologic sols of colloidal silica in the investment casting technology, resulting from the increased demands concerning environmental protection, caused the prolongation of production cycle for precision castings produced in multi-layer thin-walled ceramic shell moulds. Modification of Sizol 030 binder with benzoyl peroxide, proposed in the paper, was aimed at restriction of time needed for realization of a single layer of the shell mould, and by the same, of such a mould as a whole. Examination of kinetics of the drying process were held for the layers made of prepared moulding material and the influence of binder modification on the mould curing time was determined.

scholarly journals Application of Non-Destructive Methods to Quality Assessment of Pattern Assembly and Ceramic Mould in the Investment Casting Elements of Aircraft Engines/ Zastosowanie Nieniszczących Metod Do Oceny Jakości Woskowych Zestawów Modelowych Oraz Ceramicznych Form W Procesie Odlewania Precyzyjnego Elementów Silników Lotniczych

2014 ◽  
Vol 59 (4) ◽  
pp. 1517-1525 ◽  
Author(s):  
K. Zaba ◽  
S. Nowak ◽  
M. Kwiatkowski ◽  
M. Nowosielski ◽  
P. Kita ◽  
...  
Keyword(s):  
Computed Tomography ◽  
Quality Control ◽  
Infrared Camera ◽  
Casting Process ◽  
Operating Point ◽  
Actual State ◽  
Ceramic Mold ◽  
Precision Casting ◽  
Methods And Techniques ◽  
Thermal Imagers

Abstract The aim of this paper is manufacturing of turbocharger engine jet blades made of nickel superalloys. Processes for producing molds and casting realized in a production line are special processes. It means that the results are known only after inspection of the finished product. There is lack of the methods and techniques of effective and efficient quality control of the work in stock, above all molds. Therefore, the unknown is the state ceramic mold for the precision casting, which resulting in risk of referral to a defective mold of the casting process and thus give the product does not comply, is eliminated in the final inspection. One method of reducing this risk is particularly thorough monitoring of all parameters of each process and keeping them in the desired operating point. Operating point is a set of parameters of processes. Such monitoring is possible with the commitment to the methods and techniques to automatically, without human intervention, data collection and processing methods appropriate for use in operational control. The paper presents results of research on the attitude to the problem of a special process. This change is the introduction to the process efficient and effective form of quality control tools in the course of its preparation. In this case, the method of photogrammetry, thermal imaging and computed tomography were used. With the infrared camera will be possible to determine the temperature field, the disorder in relation to the pattern indicates the type of defect. Computed tomography and will be used to develop patterns of correlated defects associated with thermal imagers. Photogrammetry is the use of a model set of quality control (comparison of the actual state of the model *.CAD). It also allows the designation of a wall thickness of the mold.

Precision Casting of GTD222 Component with Complex Thin-Wall Structure

2017 ◽  
Vol 904 ◽  
pp. 46-49
Author(s):  
Guo Liang Zhu ◽  
Wei Wang ◽  
Rui Wang ◽  
Guo Xiang Wang ◽  
An Ping Dong ◽  
...  
Keyword(s):  
Large Scale ◽  
Wall Structure ◽  
Potential Candidate ◽  
Thin Wall ◽  
Aircraft Engines ◽  
Gating System ◽  
Good Oxidation Resistance ◽  
Precision Casting ◽  
Thin Walled

GTD222 superalloy is a potential candidate for large-scale complex thin-walled castings with high temperature resistance in the next-generation aircraft engines, due to its excellent creep performance, good oxidation resistance and favorable weldability. The precision casting of GTD222 with a complex thin-wall structure was investigated in this work. The good quality of the final cast indicated that the optimized gating system obtained by numerical simulation was satisfying.

scholarly journals Microstructure and Thermoelectric Properties of (Bi0.48Sb1.52)Te3 Thick Films Prepared with Tape Casting Method

Electronics ◽  
2021 ◽  
Vol 10 (2) ◽  
pp. 140
Author(s):  
Lichen Liu ◽  
Ziping Cao ◽  
Min Chen ◽  
Jun Jiang
Keyword(s):  
Thermoelectric Properties ◽  
Low Cost ◽  
Thick Films ◽  
Tape Casting ◽  
Casting Process ◽  
Casting Method ◽  
Glass Substrates ◽  
Conductive Films ◽  
Casting Technology

This paper reports the fabrication and characterization of (Bi0.48Sb1.52)Te3 thick films using a tape casting process on glass substrates. A slurry of thermoelectric (Bi0.48Sb1.52)Te3 was developed and cured thick films were annealed in a vacuum chamber at 500–600 °C. The microstructure of these films was analyzed, and the Seebeck coefficient and electric conductivity were tested. It was found that the subsequent annealing process must be carefully designed to achieve good thermoelectric properties of these samples. Conductive films were obtained after annealing and led to acceptable thermoelectric performance. While the properties of these initial materials are not at the level of bulk materials, this work demonstrates that the low-cost tape casting technology is promising for fabricating thermoelectric modules for energy conversion.

Development of Semi-Solid Die Casting Product Design and Die Design Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 256 ◽  
pp. 334-339 ◽  
Author(s):  
Song Chen ◽  
Fan Zhang ◽  
You Feng He ◽  
Da Quan Li ◽  
Qiang Zhu
Keyword(s):  
Product Design ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Thick Wall ◽  
Thin Wall ◽  
Gating System ◽  
Cross Sectional ◽  
Die Casting Process ◽  
Semi Solid

Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity makes product design and die design, such as gating system, overflow and venting system, be different between these two die casting processes. In the present paper, taking a clamp product as an example, analyses the product optimization and die design by comparing the experimental and computational numerical simulation results. For the clamp, product structure is designed to be suitable for characters of SSM die casting process. The gating system is designed to be uniform variation of thickness, making the cross-sectional area uniformly reduce from the biscuit to the gate. This design ensures semi-solid metal slurry to fill die cavity from thick wall to thin wall. Gate position is designed at the thickest location, the gate shape of semi-solid die casting is set to be much bigger than traditional liquid casting. A good filling behaviour can be achieved by aforementioned all these design principles and it will be helpful to the intensification of pressure feeding after filling.

Thin-Wall Steel Casting Process for Exhaust Components

2002 ◽  
Author(s):  
Nobuyoshi Sasaki ◽  
William L. Tordoff ◽  
Kazuyuki Kurisu ◽  
Yuji Yoshida
Keyword(s):  
Steel Casting ◽  
Casting Process ◽  
Thin Wall

The “Lost Wax” Process of Precision Casting

1950 ◽  
Vol 162 (1) ◽  
pp. 66-74 ◽  
Author(s):  
J. S. Turnbull
Keyword(s):  
Gas Turbine ◽  
Turbine Blades ◽  
Casting Process ◽  
Alternative Methods ◽  
Casting Technique ◽  
Gas Turbine Blades ◽  
Precision Casting ◽  
Good Surface ◽  
Wax Pattern ◽  
Good Surface Finish

The paper describes a casting process which differs from standard foundry practice in that it uses a wax pattern in a high refractory one-piece mould to produce metal castings with a good surface finish to an accuracy of ±0·002 inch. The process involves making a master pattern in either hard wood or metal, relating it to a soft metal die by precision casting technique, and then the production of wax patterns from the die on an injection machine. Finally, the wax patterns are invested in refractory moulds, the wax is melted out, the mould baked, and the metal component is cast. The “lost wax” process is advantageous in cases where ( a) the metal is unmachinable, or ( b) where the component is of an unmachinable shape, or ( c) where production by other methods takes too long. One of the most common applications is in the manufacture of gas-turbine blades. The tool costs are relatively low compared to the costs involved in alternative methods of manufacture, the die cost being a function of the number of castings required. The production of cheap castings is necessarily dependent on the scrap percentage being kept to a minimum; at present the scrap from the manufacture of gas-turbine blades is less than 30 per cent, and the author surmises that it would not be unreasonable to expect it to be less than 10 per cent in two years' time.

Numerical Simulation of Casting Deformation and Stress of A356 Aluminum Alloy Thin-Walled Frame Casting

2021 ◽  
Vol 1033 ◽  
pp. 24-30
Author(s):  
Yi Dan Zeng ◽  
Li Tong He ◽  
Jin Zhang
Keyword(s):  
Aluminum Alloy ◽  
Casting Process ◽  
Mold Temperature ◽  
Hot Cracking ◽  
Thin Wall ◽  
A356 Aluminum Alloy ◽  
Pouring Temperature ◽  
Thin Walled ◽  
Alloy Castings ◽  
A356 Aluminum

One of the main reasons for the scrap of cast thin-wall frame aluminum alloy castings is deformation and cracking. It is an effective method for solving the problem by predicting the distribution of casting stress, clarifying the size of the deformation and the location of the crack, and taking necessary measures in the process. This paper uses the ProCAST software to simulate the thermal stress coupling of A356 thin-walled frame castings, analyzes the influence of pouring temperature, pouring speed and mold temperature on the stress field distribution of castings, predicts the hot cracking trend and deformation, and optimizes Casting process..

Sign in / Sign up

Export Citation Format

Share Document