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Casting and Solidification Processing

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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 31116

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Prof. Dr. Paolo Ferro

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Department of Engineering and Management, University of Padova, Stradella San Nicola 3, 36100 Vicenza, Italy
Interests: raw materials; structural integrity of welded joints and additively manufactured components; welding and heat treatment simulation; cast iron; stainless steels; material selection
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Dear Colleagues,

Casting is one of the most important shaping processes largely used and consolidated throughout the world to produce near-net-shaping parts. The advantages compared to other manufacturing processes are evident: relative low production cost and time, high ranges of thicknesses and masses allowed, possibility to shape alloys that are only castable (cast iron or certain light alloys), highly adaptability to the requirements of mass production and last, but not least, the excellent bearing quality of the casted parts. However, all these advantages could be lost if the process parameters are not correctly calibrated to obtain near defect-free casting components. In most foundries, such parameter calibration is entrusted to experience rather than real knowledge of the rules governing the solidification phenomena. A comprehensive understanding of those rules is still unknown to the academic world and represents a formidable challenge. This Special Issue will collect recent research works about casting and solidification processing in order to give the reader an overview of the actual knowledge about casting phenomena. Papers dealing with, experimental, theoretical, and numerical analyses of casting and solidification processing are welcome.

I was asked by the Journal Metals to be the Guest Editor for a Special Issue devoted to “Casting and Solidification Processing”. Given your expertise in the field, I would like to invite you to submit a manuscript to be considered for inclusion in the Special Issue. Manuscripts should be submitted through the journal’s web platform. There will be a slot activated for the Special Issue “Casting and Solidification Processing”. Please do not forget to “tick” the correct box accordingly. The manuscripts will undergo the standard review process of the journal and will be judged exclusively based on their scientific content.

I look forward to hearing from you at your earliest convenience.

Prof. Dr. Paolo Ferro
Guest Editor

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Keywords

Microstructure
Solidification
Defect
Modeling
Casting processes

Published Papers (13 papers)

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Editorial

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2 pages, 161 KiB

Open AccessEditorial

Casting and Solidification Processing

by Paolo Ferro

Metals 2022, 12(4), 559; https://doi.org/10.3390/met12040559 - 25 Mar 2022

Cited by 1 | Viewed by 1221

Abstract

Casting is one of the most important shaping processes, largely used and consolidated throughout the world to produce near-net-shaping parts [...] Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

Research

Jump to: Editorial

15 pages, 5015 KiB

Open AccessFeature PaperEditor’s ChoiceArticle

Development of an Experimental Setup to Investigate Influences on Component Distortion in Gravity Die Casting and a First Variation of Temperature Control Strategy

by Nino Wolff, Tobias Hohlweck, Uwe Vroomen, Andreas Bührig-Polaczek and Christian Hopmann

Metals 2021, 11(12), 2028; https://doi.org/10.3390/met11122028 - 14 Dec 2021

Cited by 6 | Viewed by 2051

Abstract

Distortion (1), residual stresses and hot cracks can facilitate significant decreases in quality characteristics of casting products. Their reduction by a suitable component design (2) and process control is therefore desirable. In the casting process, these characteristics are assumed as a result of the combination of solidification shrinkage paired with the local self-feeding and the geometric constraints imposed on the component by the mold. In gravity die casting (3) of aluminum (4) with thermally well conducting and rigid metal molds, the control of solidification through a localized adjustment of the heat balance (5) appears to be a suitable approach to minimize these effects. The development of an experimental setup for the assessment of the interdependencies of the alloy, casting geometry and cooling are described in this work. A first series of experiments with A356 aluminum alloy and the introduction to the different methods of evaluation are presented. Furthermore, an approach to improve the understanding of the underlying mechanisms is outlined. Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

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22 pages, 8270 KiB

Open AccessArticle

A Model-Based Predictive Controller of the Level of Steel in the Mold with Disturbances Using a Repetitive Structure

by Rogério P. do A. Pereira, Gustavo M. de Almeida, José L. Felix Salles, Marco A. de S. L. Cuadros, Carlos T. Valadão, Ricardo O. de Freitas and Teodiano Bastos-Filho

Metals 2021, 11(9), 1458; https://doi.org/10.3390/met11091458 - 15 Sep 2021

Cited by 6 | Viewed by 2069

Abstract

Keeping the level of steel in the mold of the continuous casting process constant is fundamental for the quality of the steel produced and, consequently, its commercial value. It is challenging, considering the several disturbances that cause undesired variations in the mold level. The aim of this paper is to apply a repetitive structure composed of two controllers, a generalized predictive controller (GPC) and a repetitive GPC (R-GPC) with constraints to mitigate the bulging and clogging/unclogging disturbances and the casting speed variation in the mold level of the process. The R-GPC controller has the same characteristics as the GPC, such as performance, robustness to disturbances, and insertion of constraints, and its advantage is the elimination of periodic disturbances. The repetitive structure will be implemented with a robustness filter and tuned by a genetic algorithm (GA). The controller tests are performed by simulations of a nonlinear mathematical model of the mold level, validated using real data from the steel industry. The proposed controller reduces the bulging disturbance amplitude by 98.5% and at 25% of the frequency of reversions in the valve. Consequently, the proposed controller allows an increase in the valve life span, a reduction in maintenance costs, and quality improvement in the steel slab. Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

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13 pages, 7218 KiB

Open AccessArticle

Effect of Cooling Rates on the Local—Overall Morphology Characteristics of Solidification Structure at Different Stages for High Carbon Steel

by Jianghai Cao, Zihang Zeng, Fuli Zhang, Dongwei Guo and Zibing Hou

Metals 2021, 11(8), 1291; https://doi.org/10.3390/met11081291 - 16 Aug 2021

Cited by 6 | Viewed by 2502

Abstract

The solidification characteristics of 70 steel at the stage of the superheat elimination and the liquid–solid phase transformation were analyzed at cooling rates from 10 to 150 °C/min based on a high-temperature confocal scanning laser microscope (HT-CSLM). Secondary dendrite arm spacing (SDAS) and fractal dimension (D) were used to quantitatively describe the local compactness and overall self-similar complexity of the solidification morphology. It was found that the cooling rate had a very important influence on the local and overall morphology characteristics of solidification structures. At the superheat elimination stage, the cooling rate affected the morphology of the microstructure through the dynamic structural fluctuation between the generation and disappearance of atomic clusters in the molten steel. At the liquid–solid phase transformation stage, the cooling rate affected the local morphology of the microstructure by affecting the solute diffusion rate between dendrite arms, while it affected the overall morphology by changing the concentration undercooling at the front of all solidified interfaces. The presented results show that adjusting the cooling system at the superheat elimination stage can also be an important way to control the solidified morphology of different alloys. Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

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14 pages, 10798 KiB

Open AccessArticle

Relationship between Microstructure Evolution and Tensile Properties of AlSi10Mg Alloys with Varying Mg Content and Solidification Cooling Rates

by Maressa Gandolfi, Marcella Gautê Cavalcante Xavier, Leonardo Fernandes Gomes, Rodrigo André Valenzuela Reyes, Amauri Garcia and José Eduardo Spinelli

Metals 2021, 11(7), 1019; https://doi.org/10.3390/met11071019 - 24 Jun 2021

Cited by 10 | Viewed by 1833

Abstract

This work explored and contrasted the effect of microstructure on the tensile properties of AlSi10Mg alloys generated by transient directional solidification depending on variations in cooling rate and magnesium (Mg) content (i.e., 0.45 and 1 wt.% Mg), with a focus on understanding the dendritic growth and phases constitution. Optical and scanning electron (SEM) microscopies, CALPHAD, and thermal analysis were used to describe the microstructure, forming phases, and resulting tensile properties. The findings showed that the experimental evolution of the primary dendritic spacing is very similar when both directionally solidified (DS) Al-10 wt.% Si-0.45 wt.% Mg and Al-10 wt.% Si-1 wt.% Mg alloys samples are compared. The secondary dendritic spacing was lower for the alloy with more Mg, especially considering the range of high growth velocities. Moreover, a greater fraction of (Al + Si + Mg₂Si) ternary eutectic islands surrounding the α-Al dendritic matrix was noted for the alloy with 1 wt.% Mg. As a result of primary dendritic spacings greater than 180 μm related to lower cooling rates, slightly higher tensile properties were attained for the Al-10 wt.% Si-0.45 wt.% Mg alloy. In contrast, combining dendritic refining (<150 μm) and a larger Mg₂Si fraction, fast-solidified DS Al-10 wt.% Si-1 wt.% Mg samples exhibited higher tensile strength and elongation. The control of cooling rate and fineness of the dendritic array provided a new insight related to the addition of Mg in slightly higher levels than conventional ones, capable of achieving a better balance of tensile properties in AlSi10Mg alloys. Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

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10 pages, 4821 KiB

Open AccessArticle

Microstructural Characterization and Mechanical Property of Al-Li Plate Produced by Centrifugal Casting Method

by Qingle Tian, Kai Deng, Zhishuai Xu, Ke Han and Hongxing Zheng

Metals 2021, 11(6), 966; https://doi.org/10.3390/met11060966 - 16 Jun 2021

Cited by 2 | Viewed by 1851

Abstract

Using a centrifugal casting method, along with deformation and aging, we produced a high-strength, low-anisotropy Al-Li plate. The electron probe microanalysis, transmission electron microscope, differential scanning calorimetry, and X-ray diffraction were used to clarify the evolution of strengthening phases. Experimental results showed that centrifugal-cast Al-Li plate consisted of intragrain δ′—(Al,Cu)₃Li precipitate and interdendritic θ′—Al₂Cu particles. After cold-rolling to a reduction ratio of 60% and annealing at 800 K for 90 min, both primary θ′ and δ′ were dissolved in solid solution. Aging at 438 K for 60 h led to the formation of two kinds of precipitates (needle-like T₁—Al₂CuLi and spherical δ′ in two sizes), which acted as the main strengthening phases. The average values of ultimate tensile strength and yield strength for the anneal-aged plate reached 496 MPa and 408 MPa, with a total elongation of 3.9%. The anneal-aged plate showed mechanical anisotropy of less than 5%. The tensile fracture morphology indicated a typical intergranular fracture mode. Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

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15 pages, 5622 KiB

Open AccessArticle

Effect of Titanium Modification on Microstructure and Impact Toughness of High-Boron Multi-Component Alloy

by Xiangyi Ren, Shuli Tang, Hanguang Fu and Jiandong Xing

Metals 2021, 11(2), 193; https://doi.org/10.3390/met11020193 - 21 Jan 2021

Cited by 6 | Viewed by 1631

Abstract

This work investigated the microstructure and mechanical property of high-boron multi-component alloy with Fe, B, C, Cr, Mo, Al, Si, V, Mn and different contents of Ti. The results indicate that the as-cast metallurgical microstructure of high-boron multi-component alloys consist of ferrite, pearlite and borocarbide. In an un-modified alloy, continuous reticular structure of borocarbide is observed. After titanium addition, the structure of borocarbide changes into a fine and isolated morphology. TiC is the existence form of titanium in the alloy, which acts as the heterogeneous nuclei for eutectic borocarbide. Moreover, impact toughness of the alloy is remarkably improved by titanium modification. Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

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21 pages, 5731 KiB

Open AccessArticle

Neuro-Fuzzy System for Compensating Slow Disturbances in Adaptive Mold Level Control

by Guillermo González-Yero, Reynier Ramírez Leyva, Mercedes Ramírez Mendoza, Pedro Albertos, Alfons Crespo-Lorente and Juan Manuel Reyes Alonso

Metals 2021, 11(1), 56; https://doi.org/10.3390/met11010056 - 29 Dec 2020

Cited by 6 | Viewed by 1544

Abstract

Good slow disturbances attenuation in a mold level control with stopper rod is very important for avoiding several product defects and keeping down casting interruptions. The aim of this work is to improve the accuracy of the diagnosis and compensation of an adaptive mold level control method for slow disturbances related to changes of stopper rod. The advantages offered by the architecture, called Adaptive-Network-based Fuzzy Inference System, were used for training a previous model. This allowed learning based on the process data from a steel cast case study, representing all intensity levels of valve erosion and clogging. The developed model has high accuracy in its functional relationship between two compact input variables and the compensation coefficient of the valve gain variations. The future implementation of this proposal will consider a combined training of the model, which would be very convenient for maintaining good accuracy in the Fuzzy Inference System using new data from the process. Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

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13 pages, 3366 KiB

Open AccessArticle

Effect of Modification with Different Contents of Sb and Sr on the Thermal Conductivity of Hypoeutectic Al-Si Alloy

by Jin Guo, Zhi-Ping Guan, Rui-Fang Yan, Pin-Kui Ma, Ming-Hui Wang, Po Zhao and Jin-Guo Wang

Metals 2020, 10(12), 1637; https://doi.org/10.3390/met10121637 - 05 Dec 2020

Cited by 14 | Viewed by 2153

Abstract

In this paper, the effects of size, morphology and distribution of eutectic silicon on the thermal conductivity of Al-8Si alloy modified by Sr (0.04, 0.08, 0.12 wt.%) and Sb (0.1, 0.3, 0.5 wt.%) elements with T6 heat treatment were investigated. The results show that the modified fibrous eutectic silicon has a significant capability of improvement of thermal conductivity, while the amount of the modifier has a relatively weak effect on thermal conductivity. After T6 treatment, the fracture or spheroidization of the flake eutectic silicon and the disappearance of clustering phenomenon could raise thermal conductivity, but the coarsening of fibrous eutectic silicon is inconducive to thermal conductivity. Finally, the effect of eutectic silicon on electron transport is analyzed in detail, which could provide a reference for enhancing the thermal (or electrical) conductivity of hypoeutectic Al-Si alloy through effective microstructure control. Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

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18 pages, 5574 KiB

Open AccessArticle

Application of a Novel Chamfered Mold to Suppress Corner Transverse Cracking of Micro-Alloyed Steel Slabs

by Guoliang Liu, Qing Liu, Chenxi Ji, Bin Chen, Haibo Li and Ke Liu

Metals 2020, 10(10), 1289; https://doi.org/10.3390/met10101289 - 26 Sep 2020

Cited by 8 | Viewed by 2419

Abstract

A novel chamfered mold is developed to solve the problem of corner transverse cracking in micro-alloyed steel slabs. The shape of the slab was changed from four corners and sides to eight corners and sides due to the use of a chamfered mold. Based on numerical simulation, the solidification and heat transfer of different steel grades in the mold are studied. The results reveal rapid solidification shrinkage of molten steel in the upper area of the mold and slow solidification shrinkage in the lower area; thus, a double-taper mold is designed according to these results. The first area of the variable taper falls in the range of 250–400 mm from the top of the mold, and the design method of double inclined water channels in the chamfered face is found to be the most helpful for the formation of a uniform initial shell and reducing hotspots of the mold. Actual production results show that the quality of the slab is better when the heat flux of the narrow face is larger than that of the broad face. Corner transverse cracking in micro-alloyed steels is greatly reduced from an incidence of 4.2% to less than 0.3%. In addition, the chamfered mold is applied in IF (interstitial free) steel production, and the edge quality of hot rolled sheets is found to also be dramatically improved. Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

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12 pages, 3573 KiB

Open AccessArticle

Melting and Flowing Behavior of Mold Flux in a Continuous Casting Billet Mold for Ultra-High Speed

by Jie Yang, Dengfu Chen, Fengting Qin, Mujun Long and Huamei Duan

Metals 2020, 10(9), 1165; https://doi.org/10.3390/met10091165 - 28 Aug 2020

Cited by 10 | Viewed by 3163

Abstract

High casting speed coincides with the development trend of billet continuous casting, which significantly changes the casting characteristics. A mathematical model of the billet mold, which includes multiphase fluid flow, transient heat transfer, and solidification during ultra-high speed of the casting process was developed. The model is first applied to investigate the flow field of molten steel in the mold, studying the influence of steel flow upon the melting and flowing behavior of mold flux. The temperature and velocity distributions of the flux pool that formed above the molten steel surface are described. A parametric study on the melting temperature and viscosity of mold flux on liquid flux thickness and flow velocity is then carried out. Finally, the model is used to derive the relationship between interfacial tension and level fluctuations. The predictions provide an improved understanding of the melting and flowing behavior of mold flux in the billet mold and give the guidance for the design and optimization of mold flux for ultra-high speed of billet casting. Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

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14 pages, 3354 KiB

Open AccessArticle

Experimental Continuous Casting of Nitinol

by Gorazd Lojen, Aleš Stambolić, Barbara Šetina Batič and Rebeka Rudolf

Metals 2020, 10(4), 505; https://doi.org/10.3390/met10040505 - 14 Apr 2020

Cited by 15 | Viewed by 3420

Abstract

Commercially available nitinol is currently manufactured using classic casting methods that produce blocks, the processing of which is difficult and time consuming. By continuous casting, wherein molten metal solidifies directly into a semi-finished product, the casting and processing of ingots can be avoided, which saves time and expense. However, no reports on continuous casting of nitinol could be found in the literature. In this work, Φ 12 mm nitinol strands were continuously cast. Using a graphite crucible, smelting of pure Ni and Ti in a medium frequency induction furnace is difficult, because it is hard to prevent a stormy reaction between Ni and Ti and to reach a homogeneous melt without a prolonged long holding time. Using a clay-graphite crucible, the stormy reaction is easily controlled, while effective stirring assures a homogeneous melt within minutes. Strands of nearly equiatomic chemical compositions were obtained with acceptable surface quality. The microstructure of strands containing over 50 at. % Ni, consisted of Ti₂Ni and cubic NiTi, whereas the microstructure of strands containing less than 50 at. % Ni consisted of TiNi₃ and cubic NiTi_. This is consonant with the results of some other authors, and indicates that the eutectoid decomposition NiTi → Ti₂Ni + TiNi₃ does not take place. Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

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12 pages, 4973 KiB

Open AccessArticle

Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach

by Arun Prabhakar, Michail Papanikolaou, Konstantinos Salonitis and Mark Jolly

Metals 2020, 10(2), 252; https://doi.org/10.3390/met10020252 - 13 Feb 2020

Cited by 6 | Viewed by 3251

Abstract

Sand casting of lead sheet is a traditional manufacturing process used up to the present due to the special features of sand cast sheet such as their attractive sheen. Similarly to any casting process, sand casting of lead sheet suffers from the presence of surface defects. In this study, a surface defect type, hereby referred to as ‘grooves’, has been investigated. The focus has been laid on the identification of the main factors affecting defect formation in this process. Based on a set of screening experiments performed using Scanning Electron Microscopy (SEM) as well as the existing literature, a number of factors affecting the formation of such defects was identified and their corresponding significance was estimated using the Analysis of Variance (ANOVA) technique. The obtained results suggest that the most significant factor affecting defect formation in sand casting of lead sheet is the composition of the moulding mixture. Defect formation was also proven to be dependent on the sand grain fineness, the quality of the melt and some of the interactions between the aforementioned process parameters. Finally, an optimal set of process parameters leading to the minimisation of surface defects was identified. Full article

(This article belongs to the Special Issue Casting and Solidification Processing)

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