The effects of alloying elements on the as-cast microstructures and mechanical properties of heavy section ductile cast iron were investigated to develop press die material having high strength and high ductility. Mea...The effects of alloying elements on the as-cast microstructures and mechanical properties of heavy section ductile cast iron were investigated to develop press die material having high strength and high ductility. Measurements of ultimate tensile strength, 0.2% proof strength, elongation and unnotched Charpy impact energy are presented as a function of alloy amounts within 0.25 to 0.75 wt pct range. Hardness is measured on the broken tensile specimens. The small additions of Mo, Cu, Ni and Cr changed the as-cast mechanical properties owing to the different as-cast matrix microstructures. The ferrite matrix of Mo and Ni alloyed cast iron exhibits low strength and hardness as well as high elongation and impact energy. The increase in Mo and Ni contents developed some fractions of pearlite structures near the austenite eutectic cell boundaries, which caused the elongation and impact energy to drop in a small range. Adding Cu and Cr elements rapidly changed the ferrite matrix into pearlite matrix, so strength and hardness were significantly increased. As more Mo and Cr were added, the size and fraction of primary carbides in the eutectic cell boundaries increased through the segregation of these elements into the intercellular boundaries.展开更多
Porosity is a main defect in aluminum alloy castings, which is also thought to be severe in aluminum alloy castings produced by lost foam process due to the pyrolysis of the polystyrene foam pattern during pouring. Fu...Porosity is a main defect in aluminum alloy castings, which is also thought to be severe in aluminum alloy castings produced by lost foam process due to the pyrolysis of the polystyrene foam pattern during pouring. Fundamental experiments were carried out to evaluate the effect of process parameters such as the melt treatment, the cooling rate and the density of expanded polystyrene （EPS） foam on porosity in A356.2 bar casting. The effect of melt treatment including degassing and refining was investigated. The effect of cooling rate was also evaluated by changing the mold packing material such as the silica sand, the zircon sand and the steel shots. Gas entrapment due to the turbulent metal flow during mold filling in conventional molding process results in porosity. Mold filling sequence in lost foam process is different from that in conventional molding process. The effect of molten metal flow was estimated by comparing the density of the casting by conventional sodium silicate molding with that by lost foam process. Density measurement was conducted to analyze the extent of porosity in the casting. Source of the porosity in lost foam process can be divided into two factors, i.e. turbulence in molten metal flow and entraining residue or gas from the pattern during pouring.展开更多
Porosity is thought to be severe in aluminum alloy castings produced by lost foam process due to the pyrolysis of the polystyrene foam pattern during pouring, which results in detrimental effect in mechanical property...Porosity is thought to be severe in aluminum alloy castings produced by lost foam process due to the pyrolysis of the polystyrene foam pattern during pouring, which results in detrimental effect in mechanical property. The slow solidification rate promotes the formation of gassing pin holes, and relative weakness of the thermal gradients can cause micro-shrinkage if the outline of the part complicates feeding in the lost foam casting. One of the methods to eliminate the porosity is to apply high pressure to the molten metal like an isostatic forging during solidification. Fundamental experiments were carried out to evaluate the effect of the external pressure on the porosity and mechanical properties of A356.2 alloy bar in the lost foam casting. Solidification time and porosity decreased with increasing the applied pressure during solidification. Applying external pressure was effective in decreasing the porosity and increasing the elongation of the lost foam casting.展开更多
The effective surface treatment method for steel insert composited with Al base metal by expendable pattern casting （EPC） process and the bonding interface between steel insert and Al base metal were investigated.It...The effective surface treatment method for steel insert composited with Al base metal by expendable pattern casting （EPC） process and the bonding interface between steel insert and Al base metal were investigated.It was found that Zn plating on steel insert was effective on improving the bonding property between steel insert and Al base metal in EPC process.Zn is thought to promote the formation of diffusion layer.But almost none content of Zn was observed in the boundary which had been plated on the steel insert.A diffusion layer consisting of Al,Si and Fe was formed at the insert/alloy interface and its hardness was higher than the steel insert as matter of course Al base metal.This layer turned out to be intermetallic compounds of Al-Si-Fe system.Higher pouring temperature promoted the diffusion of Fe into Al alloy,so Fe content in intermetallic layers increased at higher pouring temperature.The layer nearest to steel disappeared due to applied pressure.展开更多
During the EPC (expendable pattern casting) process, one of the essential requirements is to prevent pattern distortion duringsand filling and compaction. A new method which vibrates the system in a two-dimensional ci...During the EPC (expendable pattern casting) process, one of the essential requirements is to prevent pattern distortion duringsand filling and compaction. A new method which vibrates the system in a two-dimensional circular mode has been appliedto the EPC process. The molding properties of unbonded sand obtained by this new vibration mode are investigated andcompared with those in the one-dimensional vertical mode. For adequate compaction of sand. the circular vibration mode ismore effective than the vertical mode. Sand became more fluidized by the circular vibration and the particle pressure coefficientwas close to unity The particle pressure coefficient, which is defined as the ratio of horizontal to vertical sand pressure, isresponsible for the effectiveness of sand filling.展开更多
We focused on the surface reinforcement of ligth weight casting alloys with Ni-AI intermetallic compounds by in-situ combustion reaction to improve the surface properties of non-ferrous casting components.In our previ...We focused on the surface reinforcement of ligth weight casting alloys with Ni-AI intermetallic compounds by in-situ combustion reaction to improve the surface properties of non-ferrous casting components.In our previous works,green compact of elemental Ni and Al powders were reacted to form Ni-3Al intermetallic compound by SHS （Self-propagating high temperature synthesis） reaction with the heat of molten Al alloy and simultaneously bonded with Al casting alloy.But some defects such as tiny cracks and porosities were remained in the reacted compact.So we applied pressure to prevent thermal cracks and fill up the pores with liquid Al alloy by squeeze casting process.The compressed Al alloy bonded with the Ni-3Al intermetallic compound was sectioned and observed by optical microscopy and scanning electron microscopy （SEM）.The stoichiometric compositions of the intermetallics formed around the bonded interface and in the reacted compact were identified by energy dispersive spectroscopy （EDS） and electron probe micro analysis （EPMA）. Si rich layer was formed on the Al alloy side near the bonded interface by the sequential solidification of Al alloy.The porosities observed in the reacted Ni-3Al compact were filled up with the liquid AI alloy.The Si particles from the molten Al alloy were detected in the pores of reacted Ni-3Al intermetallic compact.The Al casting alloy and Ni-3Al intermetallic compound were joined very soundly by applying pressure to the liquid Al alloy.展开更多
文摘The effects of alloying elements on the as-cast microstructures and mechanical properties of heavy section ductile cast iron were investigated to develop press die material having high strength and high ductility. Measurements of ultimate tensile strength, 0.2% proof strength, elongation and unnotched Charpy impact energy are presented as a function of alloy amounts within 0.25 to 0.75 wt pct range. Hardness is measured on the broken tensile specimens. The small additions of Mo, Cu, Ni and Cr changed the as-cast mechanical properties owing to the different as-cast matrix microstructures. The ferrite matrix of Mo and Ni alloyed cast iron exhibits low strength and hardness as well as high elongation and impact energy. The increase in Mo and Ni contents developed some fractions of pearlite structures near the austenite eutectic cell boundaries, which caused the elongation and impact energy to drop in a small range. Adding Cu and Cr elements rapidly changed the ferrite matrix into pearlite matrix, so strength and hardness were significantly increased. As more Mo and Cr were added, the size and fraction of primary carbides in the eutectic cell boundaries increased through the segregation of these elements into the intercellular boundaries.
文摘Porosity is a main defect in aluminum alloy castings, which is also thought to be severe in aluminum alloy castings produced by lost foam process due to the pyrolysis of the polystyrene foam pattern during pouring. Fundamental experiments were carried out to evaluate the effect of process parameters such as the melt treatment, the cooling rate and the density of expanded polystyrene （EPS） foam on porosity in A356.2 bar casting. The effect of melt treatment including degassing and refining was investigated. The effect of cooling rate was also evaluated by changing the mold packing material such as the silica sand, the zircon sand and the steel shots. Gas entrapment due to the turbulent metal flow during mold filling in conventional molding process results in porosity. Mold filling sequence in lost foam process is different from that in conventional molding process. The effect of molten metal flow was estimated by comparing the density of the casting by conventional sodium silicate molding with that by lost foam process. Density measurement was conducted to analyze the extent of porosity in the casting. Source of the porosity in lost foam process can be divided into two factors, i.e. turbulence in molten metal flow and entraining residue or gas from the pattern during pouring.
文摘Porosity is thought to be severe in aluminum alloy castings produced by lost foam process due to the pyrolysis of the polystyrene foam pattern during pouring, which results in detrimental effect in mechanical property. The slow solidification rate promotes the formation of gassing pin holes, and relative weakness of the thermal gradients can cause micro-shrinkage if the outline of the part complicates feeding in the lost foam casting. One of the methods to eliminate the porosity is to apply high pressure to the molten metal like an isostatic forging during solidification. Fundamental experiments were carried out to evaluate the effect of the external pressure on the porosity and mechanical properties of A356.2 alloy bar in the lost foam casting. Solidification time and porosity decreased with increasing the applied pressure during solidification. Applying external pressure was effective in decreasing the porosity and increasing the elongation of the lost foam casting.
文摘The effective surface treatment method for steel insert composited with Al base metal by expendable pattern casting （EPC） process and the bonding interface between steel insert and Al base metal were investigated.It was found that Zn plating on steel insert was effective on improving the bonding property between steel insert and Al base metal in EPC process.Zn is thought to promote the formation of diffusion layer.But almost none content of Zn was observed in the boundary which had been plated on the steel insert.A diffusion layer consisting of Al,Si and Fe was formed at the insert/alloy interface and its hardness was higher than the steel insert as matter of course Al base metal.This layer turned out to be intermetallic compounds of Al-Si-Fe system.Higher pouring temperature promoted the diffusion of Fe into Al alloy,so Fe content in intermetallic layers increased at higher pouring temperature.The layer nearest to steel disappeared due to applied pressure.
文摘During the EPC (expendable pattern casting) process, one of the essential requirements is to prevent pattern distortion duringsand filling and compaction. A new method which vibrates the system in a two-dimensional circular mode has been appliedto the EPC process. The molding properties of unbonded sand obtained by this new vibration mode are investigated andcompared with those in the one-dimensional vertical mode. For adequate compaction of sand. the circular vibration mode ismore effective than the vertical mode. Sand became more fluidized by the circular vibration and the particle pressure coefficientwas close to unity The particle pressure coefficient, which is defined as the ratio of horizontal to vertical sand pressure, isresponsible for the effectiveness of sand filling.
文摘We focused on the surface reinforcement of ligth weight casting alloys with Ni-AI intermetallic compounds by in-situ combustion reaction to improve the surface properties of non-ferrous casting components.In our previous works,green compact of elemental Ni and Al powders were reacted to form Ni-3Al intermetallic compound by SHS （Self-propagating high temperature synthesis） reaction with the heat of molten Al alloy and simultaneously bonded with Al casting alloy.But some defects such as tiny cracks and porosities were remained in the reacted compact.So we applied pressure to prevent thermal cracks and fill up the pores with liquid Al alloy by squeeze casting process.The compressed Al alloy bonded with the Ni-3Al intermetallic compound was sectioned and observed by optical microscopy and scanning electron microscopy （SEM）.The stoichiometric compositions of the intermetallics formed around the bonded interface and in the reacted compact were identified by energy dispersive spectroscopy （EDS） and electron probe micro analysis （EPMA）. Si rich layer was formed on the Al alloy side near the bonded interface by the sequential solidification of Al alloy.The porosities observed in the reacted Ni-3Al compact were filled up with the liquid AI alloy.The Si particles from the molten Al alloy were detected in the pores of reacted Ni-3Al intermetallic compact.The Al casting alloy and Ni-3Al intermetallic compound were joined very soundly by applying pressure to the liquid Al alloy.
