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Juergen Jakumeit (Access e.V.)18/06/2019, 16:10HighlightIn modern automotive structural components, metal sheets are combined with casting parts to enable a light and mechanical stable structure. In this study, the bonding between steel metal sheets and aluminum casting parts are achieved as part of the high pressure die casting (HPDC) process. In this way additional bonding steps like welding can be omitted. Gas enclosure at the interface...Go to contribution page
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Marie Bedel (MSMP Laboratory)18/06/2019, 16:30Oral PresentationIn Low Pressure casting (LPC), the filling stage is led by gradually increasing the gas pressure above the liquid metal, which is pushed through the pipe and into the mould cavity. In opposite to gravity casting, the LPC filling stage however does not only depend on the filling system and part geometries. By smartly choosing the pressure casting ramp, one could control the filling flow and...Go to contribution page
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Tungky Subroto (Brunel University London)18/06/2019, 16:50Oral PresentationUltrasonic processing (USP) during direct-chill (DC) casting of light metal alloys is typically applied in the sump of a billet. This approach, though successful for structure refinement and modification, has two main drawbacks: (a) mixture of mechanisms that rely heavily on dendrite fragmentation and (b) a limited volume that can be processed by a single ultrasonic source. We suggest moving...Go to contribution page
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Suwaree Chankitmunkong (King Mongkut's University of Technology Thonburi)18/06/2019, 17:10Oral PresentationPiston Al-Si eutectic alloys are used to produce direct-chill cast billets for subsequent forging. Because of a very complex composition and multi-phase heterogeneous structure, it is necessary to control the formation of primary and eutectic compounds either through alloying or casting conditions (or both). In this study we used ultrasonic melt processing above or across the liquidus line...Go to contribution page
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Johann Peter Mogeritsch (Montanuniversitaet Leoben)18/06/2019, 17:30Oral PresentationFor directional solidification experiments with low withdrawal rates near and even below the constitutional undercooling limit of the corresponding alloy, a sample is needed which reveals a homogeneous concentration along the sample axis. As stirring in samples of a certain length is difficult, homogenization by rapid solidification is very common. Hereby, the liquid sample is rapidly moved...Go to contribution page
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Wanqi Jie (State Key Laboratory of Solidification Processing, Northwestern Polytechnical University))20/06/2019, 16:10HighlightA mathematical model has been established to coupling predict the formation of inverse segregation and porosity for up-vertical unidirectional solidification of Al-Cu alloys. Based on the analysis on the redistribution behaviours of both gas element and the alloying elements in the mushy zone. The model first investigates the volume change during solidification intensively, including the...Go to contribution page
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Shishira Bhagavath (Indian Institute of Technology Bombay, Mumbai)20/06/2019, 16:30Oral PresentationThe alloy casting process is one of the major manufacturing processes to produce near net shape components. The casing process is prone to a wide variety of defects, with hot tear being one of the most detrimental. The two main factors generally recognized as the primary cause for formation of hot tears are the mechanical response of the mush (which effects its permeability), and the...Go to contribution page
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In-Sung Cho (Korea Instititue of Industrial Technology)20/06/2019, 16:50Oral PresentationIn the present study, effect of cooling rate on the formation of the porosity in the thick aluminum sand casting was investigated. Nowadays large scale thick aluminum casting replaces steel frame for vacuum chamber for semiconductor production, with the consideration of weight and cost reduction. Several thick aluminum castings were manufactured using chill with temperature measurements. The...Go to contribution page
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Savya Sachi (Université de Lorraine, CNRS, IJL, F-54000 Nancy, France)20/06/2019, 17:10Oral PresentationCorrect prediction of composition heterogeneities and grain structure across a steel ingot is critical in optimizing the industrial processing parameters for enhanced performance. The columnar to equiaxed transtion (CET) is a microstructural transition which is strictly controlled as it affects the mechanical properties of the final product along with the macrosegregation patterns. Larger...Go to contribution page
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Kjerstin Ellingsen (SINTEF)20/06/2019, 17:30Oral PresentationAl-Mn alloys (3003) alloys are the preferred alloy series for brazed heat-exchangers for applications in the automotive industry. Cu, Si and other alloying elements are added in different amounts to improve alloy properties and achieve excellent thermal efficiency, high strength and corrosion resistance. Addition of Cu and Si results in longer solidification intervals which makes the alloys...Go to contribution page
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Alan A. Luo (Ohio State University)21/06/2019, 10:30HighlightSolidification microstructure of metal castings determines their as-cast mechanical properties. Accurate prediction of as-cast grain structure and key defects (such as porosity) is critical in the design and manufacturing of metal castings using an integrated computational materials engineering (ICME) approach. In this talk, a three-dimensional (3-D) model based on cellular automaton (CA) and...Go to contribution page
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Ville-Valtteri Visuri (Process Metallurgy Research Unit, University of Oulu)21/06/2019, 10:50Oral PresentationAdvanced numerical simulation models for continuous casting of steel were developed in Finland by Casim Consulting and Aalto University in cooperation with the University of Oulu and the steel industry. The aim was to develop models that are scientifically rigorous, but also computationally fast enough to be used in online applications. The models developed are a transient three-dimensional...Go to contribution page
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Jianxin Zhou (InteCAST Software Center/ Huazhong University of Science and Technology)21/06/2019, 11:10Oral PresentationNumerical simulation technology has been widely used in the field of casting because of its visibility and forward-looking. However, for numerical simulation prediction of complex shape castings, the designer usually considers pouring under ideal conditions. The thermal property parameters used are uniform standardized parameters, and less consideration is given to the physical property...Go to contribution page
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Amir Horr (senior Scientist)21/06/2019, 11:30Oral PresentationOne of the crucial ingredients of today’s numerical simulation technologies is their cross-scale and cross-platform capabilities for material processes applications. Handling of simultaneous evolution paths at various scales\times (i.e., multi-scaling) during complex material processes where materials microstructure & microchemistry interact with meso and macro events, is one of awkward...Go to contribution page
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Yongjia Zhang (Huazhong University of Science and Technology)21/06/2019, 11:50Oral PresentationNumerical simulation of casting filling process with complex shape is time-consuming. Compared with the traditional SOLA-VOF method, the lattice Boltzmann method (LBM) calculates the pressure field by particle distribution functions instead of the correction of the velocity and pressure fields, which greatly simplifies the calculation process. In addition, the LBM provides a flexible approach...Go to contribution page
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Yun Chen (Institute of Metal Research, Chinese Academy of Sciences)21/06/2019, 12:10Oral PresentationThe manufacturing of special steel forgings normally follows the basic technical process from casting, homogenization annealing, pre-heating, forging and post-heat treatment after forging. Such treatment obviouly is high-cost, energy dissipation and long manufacturing cycle. In terms of the formation mechanism of internal casting defects such as macrosegregation, shrinkage cavity and coarse...Go to contribution page
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