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Metallic Foundry/Casting and Gating System Optimization
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Metallic Foundry/Casting and Gating System Optimization

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (10 October 2023) | Viewed by 13725

Special Issue Editors

Prof. Dr. Jan Jezierski

E-Mail Website
Guest Editor
Department of Foundry Engineering, Faculty of Mechanical Engineering, Silesian University of Technology, 7 Towarowa Street, 44-100 Gliwice, Poland
Interests: cast iron; cast steel; crystallization process; quality of castings; high pressure die casting; gating systems; automation and robotization in foundry; pneumatic conveying; wastes management
Special Issues, Collections and Topics in MDPI journals
Dr. Rafał Dojka

E-Mail Website
Guest Editor
Odlewnia RAFAMET Sp. z o. o., Staszica 1, 47-420 Kuźnia Raciborska, Poland
Interests: gating system design; crystallisation of alloys; modification of alloys; manufacturing optimisation; welding technologies

Special Issue Information

Dear Colleagues,

Foundry engineering remains one of the leading manufacturing techniques. In the production of many elements, it cannot be replaced by any other technique that offers the same economic efficiency and the highest possible quality. However, to keep up with new and current trends, including ecological and resource optimization, it is necessary to continuously develop foundry science and practice. This Special Issue will serve as a forum for specialists in foundry engineering to share and explore the latest research results, mainly (but not only) in the field of optimization of foundry technologies, including:

  • Design and manufacture of casting molds in any technology;
  • Using computer simulations to optimize the shapes of the mold cavity and gating systems with technological and machining allowances;
  • Results of model, semi-industrial, and industrial tests to improve the efficiency of using liquid metal (yield);
  • The processes of crystallization and solidification of castings in terms of limitations resulting from manufacturing conditions; valuable case studies are welcome;
  • Ecological aspects of implementing new and optimized technologies, materials and processes, including waste management;
  • Metallurgy of casting alloys, to obtain the highest quality liquid metal, which is a key requirement for the production of high-quality castings;
  • Other issues that, after consultation with the Guest Editor, will be included in this thematic issue.

On behalf of myself and the Editorial Board of the Materials journal, I invite everyone to submit a publication that I am sure will enjoy great recognition and, thanks to the professional MDPI team, will achieve high readership and citation rates.

With best regards

Prof. Dr. Jan Jezierski
Dr. Rafał Dojka
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • casting processes
  • casting defects
  • gating system design
  • high performance alloys
  • metallurgical advancements
  • quality management

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Published Papers (6 papers)

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Research

19 pages, 5674 KiB  
Article
The Effect of CoAl2O4 as a Nucleating Agent and Pouring Temperature on the Microstructure and Properties of Inconel 713C® Nickel-Based Superalloy Castings
by Rafał Cygan and Łukasz Rakoczy
Materials 2023, 16(16), 5588; https://doi.org/10.3390/ma16165588 - 11 Aug 2023
Cited by 1 | Viewed by 1642
Abstract
In this work, three melt-pouring temperatures (1450 °C, 1480 °C, 1520 °C) and CoAl2O4 inoculant contents in the shell mold’s primary coating (0 wt%, 5 wt%, and 10 wt%) were selected to study microstructural and mechanical property changes of the [...] Read more.
In this work, three melt-pouring temperatures (1450 °C, 1480 °C, 1520 °C) and CoAl2O4 inoculant contents in the shell mold’s primary coating (0 wt%, 5 wt%, and 10 wt%) were selected to study microstructural and mechanical property changes of the Inconel 713C® nickel-based superalloy. The castings’ phase transformation temperatures, phase constitution, microstructure, and mechanical properties at room and elevated temperatures were investigated via thermodynamical simulations, differential thermal analysis, light and scanning electron microscopy, energy-dispersive X-ray spectroscopy, and tensile and stress-rupture tests. The pouring temperature and inoculant content strongly influenced the mean equiaxed grain size, which ranged between 2.36 and 6.55 mm. The primary microstructure of Inconel 713C® castings, owing to its complex chemical composition, comprised multiple phases, including γ, γ’, MC, M3B2, and Ni7Zr2. The mean size of γ’ was in the 0.446–0.613 μm range, depending on the casting variant. Grain refinement with CoAl2O4 at ambient temperature for each melt-pouring temperature led to increased yield strength (YS) and ultimate tensile strength (UTS). YS was in the range of 775–835 MPa, while UTS was in the range of 868–1010 MPa. A reverse trend was observed in samples that crept in 982 °C/152 MPa, while for each variant, the time to rupture exceeded 30 h. The maximum time to rupture was 46.1 h obtained in the unmodified casting poured at 1480 °C. Full article
(This article belongs to the Special Issue Metallic Foundry/Casting and Gating System Optimization)
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21 pages, 7936 KiB  
Article
A Novel Approach to Visualize Liquid Aluminum Flow to Advance Casting Science
by Casey Bate, Philip King, Jay Sim and Guha Manogharan
Materials 2023, 16(2), 756; https://doi.org/10.3390/ma16020756 - 12 Jan 2023
Cited by 8 | Viewed by 2739
Abstract
Turbulent filling of molten metal in sand-casting leads to bi-films, porosity and oxide inclusions which results in poor mechanical properties and high scrap rate of sand castings. Hence, it is critical to understand the metal flow in sand-molds, i.e., casting hydrodynamics to eliminate [...] Read more.
Turbulent filling of molten metal in sand-casting leads to bi-films, porosity and oxide inclusions which results in poor mechanical properties and high scrap rate of sand castings. Hence, it is critical to understand the metal flow in sand-molds, i.e., casting hydrodynamics to eliminate casting defects. While multiple numerical methods have been applied to simulate this phenomenon for decades, harsh foundry environments and expensive x-ray equipment have limited experimental approaches to accurately visualize metal flow in sand molds. In this paper, a novel approach to solve this challenge is proposed using Succinonitrile (SCN) as a more accurate metal analog in place of water. SCN has a long history in solidification research due to its BCC (Body-Centered-Cubic) crystal structure and dendrite-like solidification (melting temperature ~60 °C) like molten aluminum. However, this is the first reported study on applying SCN through novel casting hydrodynamics to accurately visualize melt flow for casting studies. This paper used numerical simulations and experiments using both water and SCN to identify the critical dimensionless numbers to perform accurate metal flow analog testing. Froude’s number and wall roughness were identified as critical variables. Experimental results show that SCN flow testing was more accurate in recreating the flow profile of molten aluminum, thus validating its utility as a metal analog for metal flow research. Findings from this study can be used in future metal flow analysis such as: runner, in-gate and integrated filling-feeding-solidification studies. Full article
(This article belongs to the Special Issue Metallic Foundry/Casting and Gating System Optimization)
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18 pages, 15032 KiB  
Article
Influence of Weather Conditions and Mechanical Reclamation on Molding Sand with Alkali-Phenolic Binder for Manganese Cast Steel
by Mariusz Łucarz, Dariusz Drożyński, Aldona Garbacz-Klempka, Jan Jezierski, Dariusz Bartocha, Tomasz Wróbel, Krzysztof Kostrzewa and Edward Feliks
Materials 2023, 16(1), 71; https://doi.org/10.3390/ma16010071 - 21 Dec 2022
Cited by 3 | Viewed by 1759
Abstract
The article presents the results of research on the properties of molding sands in Alphaset technology (alkaline-phenolic). These sands are often used in steel foundries, producing large castings. However, knowledge about them, and especially about the changeability of their properties with the change [...] Read more.
The article presents the results of research on the properties of molding sands in Alphaset technology (alkaline-phenolic). These sands are often used in steel foundries, producing large castings. However, knowledge about them, and especially about the changeability of their properties with the change of environmental conditions (seasons), is still insufficient. Various compositions of molding sand were analyzed based on fresh chromite sand and reclaimed sand. A binder and hardener in various mass ratios were used to prepare the mass. The research methodology included, among others, tests of tensile and bending strength, permeability, abrasion, gas emissivity, and ignition losses. These tests were carried out for summer and winter conditions. The results showed the optimal proportions of resin and hardener, showed the influence of ambient temperature on the properties of the molding sand, and the possible ratio of reclaimed sand in relation to fresh sand. However, you should always remember to verify them under the conditions of a specific foundry. Full article
(This article belongs to the Special Issue Metallic Foundry/Casting and Gating System Optimization)
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16 pages, 10775 KiB  
Article
Technological Optimization of the Stirrup Casting Process with the Use of Computer Simulations
by Marcin Małysza, Robert Żuczek, Dorota Wilk-Kołodziejczyk, Krzysztof Jaśkowiec, Mirosław Głowacki, Piotr Długosz and Piotr Dudek
Materials 2022, 15(19), 6781; https://doi.org/10.3390/ma15196781 - 30 Sep 2022
Cited by 6 | Viewed by 1998
Abstract
The article presents the optimization of high-pressure die casting process technology for equestrian stirrups with the application of computer simulation. In the initial stage, the output technology was analyzed, and on the basis of a series of virtual experiments the cause of defects [...] Read more.
The article presents the optimization of high-pressure die casting process technology for equestrian stirrups with the application of computer simulation. In the initial stage, the output technology was analyzed, and on the basis of a series of virtual experiments the cause of defects in the casting was highlighted. The optimization process includes different designs of a gating system. Additionally, the casting application properties were evaluated in an exploitation simulation, taking into account predicted defects resulting from the casting and solidification process. Based on the conducted analyses, technological changes were made to the casting technology design allowing the defects occurring in the original technological concept to be removed. Full article
(This article belongs to the Special Issue Metallic Foundry/Casting and Gating System Optimization)
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31 pages, 42392 KiB  
Article
The Importance of the Geometry of the Down Sprue in the Gravity Casting Process
by Rafał Dojka, Jan Jezierski and Michał Szucki
Materials 2022, 15(14), 4937; https://doi.org/10.3390/ma15144937 - 15 Jul 2022
Cited by 6 | Viewed by 2782
Abstract
This article presents the results of experiments on the optimization of down sprue geometry in the process of pouring sand molds. Theoretical assumptions and computer simulation tests are presented. The starting point was the theory and experience of gas entrapment caused mainly by [...] Read more.
This article presents the results of experiments on the optimization of down sprue geometry in the process of pouring sand molds. Theoretical assumptions and computer simulation tests are presented. The starting point was the theory and experience of gas entrapment caused mainly by a poorly designed gating system and the down sprue. Simulations were performed using Magmasoft software. First, initial studies were carried out to determine how the geometry (mainly the channel cross-section) of the sprue affects the problem, and then a detailed experiment was carried out on the so-called ‘short sprue’ version. The air entrapment process was analyzed, as were the parameters of the liquid alloy flow that passes through the analyzed channels. Nine geometric versions of the sprue were proposed and analyzed, and the results allowed us to conclude which sprue geometry is the best from the point of view of minimization of the gas entrapment problem. Full article
(This article belongs to the Special Issue Metallic Foundry/Casting and Gating System Optimization)
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14 pages, 14185 KiB  
Article
Gating System Optimization for EV31A Magnesium Alloy Engine Body Sand Casting
by Andrzej Kiełbus and Robert Jarosz
Materials 2022, 15(13), 4620; https://doi.org/10.3390/ma15134620 - 30 Jun 2022
Cited by 5 | Viewed by 1879
Abstract
The research presented in this paper aimed to change the existing gating system that would enable the engine body casting, from a new EV31A magnesium alloy, of the required quality. For this reason, the casting process simulations used the MAGMASoft software, followed by [...] Read more.
The research presented in this paper aimed to change the existing gating system that would enable the engine body casting, from a new EV31A magnesium alloy, of the required quality. For this reason, the casting process simulations used the MAGMASoft software, followed by the experimental validation of the achieved results. The results achieved in the first stage of the cast computer simulation enabled the identification of potential problems and factors that reduce the casting quality. However, the proposed design modifications eliminated the inadequate delivery of liquid metal to the casting’s critical areas by adequately controlling the mold cavity filling and solidification process. The experiment validated the simulations of the computer casting defects at the various stages. The results enabled the new EV31A magnesium alloy to be implemented in industrial production. Full article
(This article belongs to the Special Issue Metallic Foundry/Casting and Gating System Optimization)
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