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2 Journal of Achievements in Materials and Manufacturing Engineering

2 2016

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The effect of filter type on filling during Low Pressure Die Casting: a numerical study

Yavuz H., Kara A., Çubuklusu H. E., Çe Ö. B., Aybarç U.

Journal of Achievements in Materials and Manufacturing Engineering

2016

Vol. 75, nr 2

71--77

Purpose: Effect of filter types on filling during low pressure die casting researched to find optimal filtration design for wheel casting process. Design/methodology/approach: Three types of filters, which are commonly used during low pressure die casting for light alloy aluminium wheel production, investigated with numerical simulation. In addition, numerical simulation for without filter is made for control variable. According to numerical simulation results, filling time, molten metal velocity results are used to define suitability of the molten metal for wheel casting. Thirteen Control points and two filtration areas generated to calculate the molten metal velocities before and after the filtration areas. Findings: Three different filtration designs for aluminium wheel casting compared according to molten aluminium velocity results of numerical simulation in terms of flow of melt. Filtration design with flat filter is the optimal filtration design for aluminium wheels casting, according to numerical simulations. In addition, combination of other filters with flat filter is suggested to find optimal filtration design according to performance of filters during low pressure die casting. Research limitations/implications: 0.5 m/s velocity for molten metal is accepted as a critical maximum limit for reliable casting according to literature search on aluminium casting. No field test was done in this study. Originality/value: Effect of flow properties on casting quality is promising research field and the effect of filters is part of this research field.

Investigation and prevention of the residues formed in melting furnaces and transfer ladles used in low-pressure Al-casting technologies

Yay B., Akinci E., Güneren A., Karaali U., Çubuklusu H. E., Çe B.

Journal of Achievements in Materials and Manufacturing Engineering

2016

Vol. 78, nr 1

5--10

Purpose: Refractory life, in Al-casting processes such as alloy wheel production, is obviously affected by the inclusions formed in the transfer ladles and holding/melting furnaces in which melting, fluxing and degassing operations are carried out. The short refractory life affects, adversely, the economical aspect of the process. Therefore, a study on the physical and chemical properties of the above mentioned inclusions has been started. The main purpose of the study is to understand the relationships among the metallurgical processes taking place during casting, properties of the refractories used and the formation of inclusions. Design/methodology/approach: During this industry-university joint study, experimental studies using scanning electron microscopy (SEM), X-ray diffractometry (XRD) and optical microscopy were used to investigate the nature and properties of the inclusions. Also, corrosion behaviour of six different refractories was investigated by exposing them to molten aluminium.