Effects of Process Related Variations on Defect Formation in Investment Cast Components

• Autorzy: Raza M. , Silva P. , Irwin M. , Fagerström B. , Jarfors A. E. W.

Identyfikatory

DOI

10.24425/118820

• Języki publikacji: EN

Abstrakty

EN

Castability of thin-walled castings is sensitive to variation in casting parameters. The variation in casting parameters can lead to undesired casting conditions which result in defect formation. Variation in rejection rate due to casting defect from one batch to other is common problem in foundries and the cause of this variation usually remain unknown due to complexity of the process. In this work, variation in casting parameters resulting from human involvement in the process is investigated. Casting practices of different groups of casting operators were evaluated and resulting variations in casting parameters were discussed. The effect of these variations was evaluated by comparing the rejection statistics for each group. In order to minimize process variation, optimized casting practices were implemented by developing specific process instructions for the operators. The significance of variation in casting parameters in terms of their impact on foundry rejections was evaluated by comparing the number of rejected components before and after implementation of optimized casting practices. It was concluded that variation in casting parameters due to variation in casting practices of different groups has significant impact on casting quality. Variation in mould temperature, melt temperature and pouring rate due to variation in handling time and practice resulted in varying quality of component from one batch to other. By implementing the optimized casting instruction, both quality and process reliability were improved significantly.

Słowa kluczowe

EN

thin-walled castings; casting defects; process variations; foundry practice; investment casting

PL

odlewy cienkościenne; wady odlewu; zmiany procesu

• Wydawca: Komisja Odlewnictwa Polskiej Akademii Nauk Oddział w Katowicach
• Czasopismo: Archives of Foundry Engineering
• Rocznik: 2018
• Tom: Vol. 18, iss. 1
• Strony: 103--108
• Opis fizyczny: Bibliogr. 13 poz., rys.

Twórcy

autor

Raza M.

• School of Innovation, Design and Engineering, Mälardalen University. Eskilstuna, Sweden

autor

Silva P.

• TPC Components AB, Hallstahammar, Sweden

autor

Irwin M.

• TPC Components AB, Hallstahammar, Sweden

autor

Fagerström B.

• School of Innovation, Design and Engineering, Mälardalen University. Eskilstuna, Sweden

autor

Jarfors A. E. W.

• Materials and Manufacturing, School of Engineering, Jönköping University, Jönköping, Sweden

Bibliografia

• [1] Raza, M., Svenningsson, R., Irwin, M., Fägerström, B. & Jarfors, A.E.W. (2017). Effects of Process Related Variations on Fillablity Simulation of Thin-Walled IN718 Structures. International Journal of Metalcasting. 2017/11/20.
• [2] Shivappa, D.N., Rohit, & Bhattacharya, A. (2012). Analysis of Casting Defects and Identification of Remedial Measures – A Diagnostic Study. International journal of engineering inventions. 1(6), 1-5.
• [3] Capadona, J.A. & Albright, D.L. (1978). Review of fluidity testing as applied to lost-polystyrene investment castings. AFS Transactions. 1978.
• [4] Flemings, M.C. (1964). Fluidity of metals - techniques for producing ultra-thin sections castings. The British Foundryman. 57, 312-325.
• [5] Anglada, E., Meléndez, A., Maestro, L. & Domiguez, I. (2013). Adjustment of Numerical Simulation Model to the Investment Casting Process. Procedia Engineering. 63, 75-83.
• [6] Jakumeit, J., Subasic, E., Bünck, M. (2014). Prediction of Misruns in Thin Wall Castings Using Computational Simulation, in Shape Casting : 5th International Symposium, Hoboken, NJ, USA, John Wiley & Sons, Inc.
• [7] Jolly, M. (2002). (2002). Casting simulation: How well do reality and virtual casting match? State of the art review. International Journal of Cast Metal Research. 14, 303-313.
• [8] Campbell, J. & Oliff, I.D. (1971). Static and dynamic criteria for filling of thin section molds. AFS Cast Metals Research Journal. 7, 55-61.
• [9] Raza, M., Svenningsson, R., Irwin, M.,Fagerström, B. & Jarfors, A.E.W. (2017). Simulation based process design approach for manufacturing of light-weight cast components, presented at the Lighter International Conference 2017, Gothenburg, Sweden.
• [10] Chandraseckariah, H.S. & Seshan, S. (1994). Effect of foundry variables on fluidity of investment cast nickel-base superalloys. AFS Transactions. 2, 94-124.
• [11] Oliff, I. D., Lumby, R.J. & Kondic. V. (1965). Some new ideas on fluidity test mold design. Foundry. 93, 80-85.
• [12] Raza, M., Svenningsson, R. & Irwin, M. (2015). Experimental study of the filling of thin-walled investment Castings in 17-4PH stainless steel. Metallurgy and Foundry Engineering. 41,(02), 85-98.
• [13] Campbell, J. (2004). Castings practice - The 10 rules of castings. Elsevier Butterworth-Heinemann.

Uwagi

PL

Opracowanie rekordu w ramach umowy 509/P-DUN/2018 ze środków MNiSW przeznaczonych na działalność upowszechniającą naukę (2018)