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Advances in the Science and Engineering of Casting Solidification: An MPMD Symposium Honoring Doru Michael Stefanescu

Advances in the Science and Engineering of Casting Solidification: An MPMD Symposium Honoring Doru Michael Stefanescu

Laurentiu Nastac (Editor), Baicheng Liu (Editor), Hasse Fredriksson (Editor), Jacques Lacaze (Editor), Chun-Pyo Hong (Editor), Adrian Catalina (Editor), Andreas Buhrig-Polaczek (Editor), Daan M. Maijer (Editor), Charles Andrew Monroe (Editor), Adrian S. Sabau (Editor), Roxana Ruxanda (Editor), Alan A. Luo (Editor), Subhayu Sen (Editor), Attila Diószegi (Editor)

ISBN: 978-1-119-09336-7

Feb 2015

448 pages


The book contains the proceedings of the honorary symposium “Advances in the Science and Engineering of Casting Solidification” (TMS2015, Orlando, Florida, March 15-19, 2015) held in honor of Professor Doru Michael Stefanescu, Emeritus Professor, Ohio State University and the University of Alabama, USA. The book encompasses the following four areas: 

(1) Solidification processing: theoretical and experimental investigations of solidification processes including castings solidification, directional solidification of alloys, electromagnetic stirring, ultrasonic cavitation, mechanical vibration, active cooling and heating, powder bed-electron beam melting additive manufacturing, etc. for processing of metals, polymers and composite materials;

(2) Microstructure Evolution: theoretical and experimental studies related to microstructure evolution of materials including prediction of solidification-related defects and particle pushing/engulfment aspects;

(3) Novel Casting and Molding Processes: modeling and experimental aspects including high pressure die casting, permanent casting, centrifugal casting, low pressure casting, 3D silica sand mold printing, etc.; and

(4) Cast Iron: all aspects related to cast iron characterization, computational and analytical modeling, and processing.

Preface xi

About the Honoree xiii

About the Editors xv

Solidification Processing I

Science of Casting and Solidification: ASM Handbook

Contributions - Honoring Professor Dora Michael Stefanescu 3
A. Lupulescu, S. Henry, K. Marken, and S. Lampman

On the Solidification of Metal Alloys during Microgravity Conditions 9
H. Fredriksson

Formation of the Tin Rich Layer and Inverse-Segregation in Phosphor Bronzes during Continuous Casting 15
S. Saleem, M. Vynnycky, and H. Fredriksson

A Model of Cavitation for the Treatment of a Moving Liquid Metal Volume 23
G. Lebon, K. Pericleous, I. Tzanakis, and D. Eskin

Ultrasonic Processing of 6061-Based Nanocomposites for High Performance Applications 31
S. Jia, P. Allison, T. Rushing, and L. Nastac

Numerical Modeling of the Dispersion of Ceramic Nanoparticles during Ultrasonic Processing of A356-based Nanocomposites 37
D. Zhang and L. Nastac

Optical Floating-Zone Crystal Growth of Heusler Ni-Mn-Sn Alloy 49
J. Yu, J. Ren, H. Li, and H. Zheng

Solidification Processing II

Modeling of Macrosegregation during Solidification of Steel Ingot Casting 57
W. Tu, H. Shen, and B. Liu

Scaling Analysis of Alloy Solidification and Fluid Flow in a Rectangular Cavity 65
A. Plotkowski, K. Fezi, and M. Krane

Structure and Casting Defects of Aluminum Billets Produced by Direct-Chill Casting 73
D. Eskin

The Fluid Flow and Solidification Phenomenon in Billet Continuous Casting Process with Mold and Final Electromagnetic Stirrings 81
D. Jiang and M. Zhu

Columnar-to-Equiaxed Transition in Zn-27wt.%Al Alloys: A Comparation Between Vertical and Horizontal Directional Solidifications 93
A. Ares and C. Schvezov

Microstructure Investigation of Aluminum Die-Cast Parts with Different Gating Conditions Tested in Fatigue 101
R. Ruxanda and R. Obara

Solidification Processing III

A Coupled Thermo-Mechanical Simulation on Squeeze Casting Solidification Process of Three-Dimensional Geometrically Complex Components 113
J. Tang, Z. Han, F. Wang, J. Sun, and S. Xu

Double Oxide Film Defects in Al Castings and the Effect of Different Element Additions 121
Q. Chen, A. Caden, and W. Griffiths

The Design of New Submerged Entry Nozzles for Beam-Blank Continuous Casting 129
M Zhu, M. Xu, and S. Luo

Effects of Ce on the Thermal Stability of the Ω Phase in a Cast Aluminum Metal Matrix Composite 137
F. Melotti, A. Dustan, T. Hirst, and W. Griffiths

Solidification Processing IV

Non-Metallic Ti Oxides and MnS/FeS2 Complex Precipitation in Ti-Killed Steel 147
J. Chen, D. Zhao, H. Li, and S. Zheng

Prediction of Surface Porosity Defects in High Pressure Die Casting 155
M. Saeedipour, S. Schneiderbauer, S. Pirker, and S. Bozorgi

Engineered Cooling Process for High Strength Ductile Iron Castings 165
S. Lekakh, A. Mikhailov, and J. Kramer

Numerical Simulation of Solidification Structure for YQ450NQR1 Steel Bloom in Continuous Casting Process 173
K. Dou, L. Wang, J. Qing, X Zhang, B. Wang, B. Liu, and Q. Liu

Microstructure Evolution I

Modeling of Microstructure Evolution during Alloy Solidification 183
M Zhu, S. Pan, and D. Sun

A Lattice Boltzmann Model for Dendritic Growth under Natural Convection 191
M Hashemi, M. Eshraghi, and S. Felicelli

Modeling of Dendritic Structure and Microsegregation in Solidification of Al-Rich Quaternary Alloys 199
T. Dai, M. Zhu, S. Chen, and W. Cao

Microstructure Evolution II

In Situ Study on the Evolution of Dendrite Morphology Affected by Electric Field in Sn-Bi Alloy 209
F. Yang, F. Cao, R. Li, H. Kang, Y. Fu, T. Xiao, and T. Wang

Heterogeneous Strip Originated from Inclusions: Characterization and Physical Mechanism 215
X Ma and D. Li

An Investigation of Dendritic Segregation in Directionally Solidified CMSX-4 Superalloy 223
G. Matache, D. Stefanescu, C. Puscasu, andE. Alexandrescu

Modeling of Casting Defects in an Integrated Computational Materials Engineering Approach 231
A. Sab au

X-ray Observations Showing the Effect of Fluid Flow on Dendritic Solidification in Ga-In Alloys 241
N. Shevchenko, O. Roshchupkina, and S. Eckert

Cast Iron I

Defect Formation Mechanisms in Lamellar Cast Iron Related to the Casting Geometry 251
A. Diôszegi, P. Svidrô, L. Elmquist, and I. Dugic

Characterization of Directionally Solidified Gray Iron 261
E. Rivera, T. Christiansen, A. Genau, and A. Catalina

Age-Strengthening of Cast Iron and Its Effects on Machinability: Review of the Literature 269
V. Richards

Examination of Austenite Solidification and Spheroidal Graphite Growth in Ni-Fe-C Alloys 277
J. Qing, V. Richards, and D. Van Aken

Production of Selected Key Ductile Iron Castings Used in Large-Scale Windmills 287
Y Pan, H. Lin, C. Lin, and R. Chang

An Overview of Isothermal Coarsening in Hypoeutectic Lamellar Cast Iron 295
J. Hernando and A. Diôszegi

Cast Iron II

Experimental Studies of Gray Cast Iron Solidification with Linear Variable Differential Transformer 305
A. Tadesse and H. Fredriksson

Undercooling, Cooling Curves and Nodule Count for Hypo- Hyper- and Eutectic Thin-Walled Ductile Iron Castings 313
W. Kapturkiewicz and A. Burbelko

Graphite Growth Morphologies in High Al Cast Iron 323
H. Muhmond and H. Fredriksson

Thermophysical Properties of Thin Walled Compacted Graphite Iron Castings 331
M Gôrny, J. Lelito, and M. Kawalec

Understanding Cast Iron Materials and Components: A Never Ending Story 339
I. Svensson and J. Olofsson

Understanding Superfine Graphite Iron Solidification through Interrupted Solidification Experiments 347
G. Alonso, D. Stefanescu, P. Larrahaga, E. De la Fuente, E. Aguado, and R. Suarez

Novel Casting and Molding Processes

Counter Gravity Casting 357
J. Campbell

A Numerical Model for Predicting the Gas Evolution in Silica Sand (Furan Binder) Mold Castings 363
L. Nastac, S. Jia, M. Nastac, and R. Wood

Solidification Processing V

Evaluation of the Casting/Chill Interface Thermal Behaviour during A319 Alloy Sand Casting Process 373
F. Mehr, S. Cockcroft, C. Reilly, and D. Maijer

Dependence of Hardness on Microstructure of a Directionally Solidified Sn-40wt.%Bi-0.7wt.%Cu Alloy 381
B. Silva and J. Spinelli

Contributions on Optimizing Approximations in the Study of Melting and Solidification Processes that Occur in Processing by Electro-Erosion 391
F. Potra, T. Potra, and V. Soporan

Investigation of Thin-Walled IN718 Castings by Counter-Gravity Investment Casting 399
A. Dong, N. Yan, J. Zhang, J. Wang, B. Sun, H. Gao, and D. Shu

Thermal Test of Nodular Cast Iron Cooling Stave 407
J. Zheng, H. Zuo, J. Zhang, and F. Li

Author Index 413

Subject Index 415