Substation connectors, like many other high-voltage products, are tested once manufactured. However, the corona behavior of aged specimens can differ from that exhibited by newer ones, thus generating detrimental technical and environmental effects....
Resin-based binders are one of the main materials used in foundry molding and core sands. Self-curing sand with furfuryl resin is one of the most popular technologies in the production of molds and cores for complex, critical castings made of iron an...
The author-proposed skeletal sand mold, which mainly includes a shell, air cavities and a truss support structure, has been experimentally proven to be very useful in controlling the cooling of casting at local areas and at different periods of the c...
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...
Melt turbulence during mold filling is detrimental to the quality of sand castings. In this research study, the authors present a novel method of embedding Internet of Things (IoT) sensors to monitor real-time melt flow velocity in sand molds during...
With the development of the powder bed 3D printing process, sand casting can be performed with methods that are more advanced than the traditional ones, thus enabling new research on applied materials. When sand is 3D-printed with cement as a binder,...
The hollow sand mold can affect the cooling of the casting during the solidification process. A chimney structure of a hollow sand mold that mainly consists of a two-layer shell with through channels was proposed. The design method was proposed for t...
This paper investigates the casting defects of a stainless steel pump impeller manufactured through the sand casting process. The material characterization of austenitic steel AISI 316L was initially carried out, which examined the chemical compositi...
Cast irons are known to be easy to shape by sand casting due to their high eutectic fraction. Despite this fact, together with cost benefits, obtaining good quality castings is not an easy task, although it depends on the level of defects allowed in...
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 pres...
Implementing the concept of mixed construction in modern automotive engineering requires the joining of sheet metal or extruded profiles with cast components made from different materials. As weight reduction is desired, these cast components are usu...
Gravity sand casting simulations require accurate modelling of heat transfer phenomena to reliably evaluate the expected quality of the produced parts. Average model parameters can be easily retrieved from a validated database. However, these paramet...
Compound casting is a process in which a single component is made from two metallic materials, such as aluminum and steel. Solid-liquid bimetallic compounds can be produced by suitable process control. This technology can reduce the number of joining...
Traditional sand casting is limited by mold fabrication, cost control, and data collection, which restrict its further advancement. However, 3D sand printing technology represents a sophisticated rapid prototyping approach that directly utilizes thre...
In the conventional sand casting process, the size of the riser is made larger than that of the cavity (product part) in order for the molten metal in the riser to solidify at a later stage than the molten metal in the cavity. In this study, a contin...
As manufacturing industries pursue net-zero emission (NZE) goals, hybrid manufacturing processes that integrate additive manufacturing (AM) with traditional casting techniques are gaining traction for their sustainability potential across the globe....
The automotive industry is undergoing a rapid evolution to meet today’s challenges; therefore, continuous innovation and product development are needed. Validation tests on prototypes play a crucial role in moving new components into industrial...
New alloy processes have been developed and casting techniques are continuously evolving. Such constant development implies a consequent development and optimization of melt processing and treatment. The present work proposes a method for studying th...
Niyama and solid fraction criteria are used to predict the solidification porosity and microporosity in computing simulation of casting processes. The solid fraction permits us to determine the areas that solidify last and that are a candidate for pr...
In recent years, high-Si ductile cast irons (3–6% Si) have begun to be used more and more in the automotive and maritime industries, but also in wind energy technology and mechanical engineering. Si-alloyed ferrite has high strength, hardness a...
This work describes a novel approach for Al-7.5Si/Al-18Si liquid–liquid bimetal casting in sand and metallic moulds. The aim of the work is to facilitate and develop a simple procedure to produce an Al-7.5Si/Al-18Si bimetallic material with a s...
In this research, a comparative analysis has been carried out between a traditional sand casting process and a modern mould obtained by additive manufacturing (AM), in the context of aluminium parts production. In this case of AM, an inkjet 3D printi...
In this work, the results of the examinations of the effect of the mold material and mold technology on the microstructure and properties of the casts parts of ductile cast iron have been presented. Four different self-hardening molding sands based o...
Sand-casting is a well established primary process for manufacturing various parts of A356 alloy. However, the quality of the casting is adversely affected by the change in the magnitude of the control variables. For instance, a larger magnitude of p...
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 t...
The requirements placed on the foundry industry are mainly related to the need to maintain an appropriate quality–price ratio of the product and to maintain an appropriate production regime that takes into account modern legal solutions related...
The widespread application of WE43 (Mg-4Y-2Nd-1Gd-0.5Zr) alloy castings in aerospace components is hindered by the frequent formation of defects such as cracks, pores, and especially yttria inclusions. These defects necessitate subsequent welding. Ho...
This study presents a simulation modeling of the gravity filling of a sand casting mold with gray cast iron EN-GJL-250. An analysis of the fluid flow, the nature of the filling of the casting mold, and the possibility of forming defects, such as void...
Organic binder in sand cores, such as phenol-formaldehyde binder, rapidly decomposes above 550 K, releasing gases including volatile organic compounds (VOCs) and hydrocarbon gases. A rapid temperature rise in the core increases gas evolution during t...
This investigation is focused on the corrosion evaluation of an as-cast Al-Si alloy, obtained by two different casting methods: traditional sand casting and three-printing casting, using a binder jetted mold. The experimental results are discussed in...
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...
AISI M2 steel was smelted in a 150 kg medium-frequency induction furnace and cast to form round billets with a cross-section diameter of 100 mm via a vertical continuous caster and sand mold. The secondary dendrite arm spacing (λ2), cooling ra...
In sand casting, gas porosity is a common defect that can result in decreased strength, leakage, rough surfaces, or other problems. Although the forming mechanism is very complicated, gas release from sand cores is often a significant contributor to...
Lost-wax casting, also called precision casting, is the process of casting a duplicate metal sculpture cast an original sculpture. The ceramic shell mould used in lost-wax casting usually consists of several layers formed with fine zircon and granula...
This study investigates hazardous emissions from foundry binder systems, comparing organic resins (phenolic urethane, furan, and alkaline-phenolic) and clay-bonded green sand with inorganic alternatives (sodium silicate and geopolymer). The research...
Casting, as a fundamental process in metal forming, finds widespread applications in the manufacturing industry. The advent of 3D printing hollow sand mold technology presents a novel method for casting technology to revolutionize traditional dense s...
The aim of this study was to attempt to use barley malt as a natural, organic binder in the technology of molding sand. TGA analysis of the binder was performed, during which temperatures of thermal decomposition of its components were determined. Th...
The interaction between alloy melt and mold facecoats is the main factor affecting the surface quality of investment casting nickel-based superalloys. An investigation was undertaken to develop suitable refractories as facecoat materials for the dire...
Binder jetting is the most widely implemented additive technology for the fabrication of sand molds. However, the use of furan binder-jetting technology in the production of molds for vacuum casting is hindered by the thermal destruction of the furan...
In traditional casting, sand is used as a mould material to carry heat away from the melt. However, sand has certain disadvantages, such as poor thermal conductivity, burning of binders, undesirable transition resulting in mould failure, and defects...
Complex casting parts rely on sand cores that are both high-strength and can be easily decored after casting. Previous works have shown the need to understand the influences on the decoring behavior of inorganically bound sand cores. This work uses b...
To avoid cumbersome casting procedures in the production of pervious concrete, a new type of casting method through coating cementitious paste onto the preplaced aggregate skeleton is developed. To optimize the key performances and reveal their gover...
Having established that sulphur presence in the mould materials appears to have an important contribution in graphite degeneration at least in the casting surface layer, a research program is undertaken to explore the possible beneficial effect of su...
The shrinkage defects of Al-Cu-Mn-Ti alloy seriously hinder its application in high-performance engineering. In this study, mechanical vibration was introduced to low-pressure sand casting (LPSC) by a waveguide rod to eliminate shrinkage defects and...
The emergence of additive manufacturing is renovating the landscape of available production technologies. In this paper, we describe the fabrication of a closed vane pump impeller (ϕ 206 mm, height 68 mm, weight 4 kg) by binder jetting 3D printi...
Inorganic sand cores involving sodium silicate binder and microsilica have environmental advantages during the casting process of aluminum alloy. Nevertheless, the bending strength of sodium silicate-bonded sand (SSBS) needs to be further improved. I...
A large-sized backward-curved fan with high shape difficulty was designed, and fan performance was roughly predicted from computational fluid dynamics. Three gating systems of aluminum sand casting were designed to fabricate the fan. The flow pattern...
This paper presents the outcomes of extensive research targeting the development of high-performance alkyd and polyester resins used as binders in mould- and core-making permeable composite materials designated for large-size/complex-shape, heavy all...
An important issue in obtaining a good casting surface without defects in contact with the liquid metal is the use of protective coatings on the surface of the moulding sand forming the mould cavity. Protective coatings are based on highly refractory...
Increasingly strict regulations, as well as an increased public awareness, are forcing industry, including the foundry industry, to develop new binders for molding sands, which, while being more environmentally friendly, would simultaneously ensure a...
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