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Shape Casting: 5th International Symposium 2014

Shape Casting: 5th International Symposium 2014

Murat Tiryakioǧlu, John Campbell, Glenn Byczynski

ISBN: 978-1-118-88809-4

Dec 2013

320 pages



This collection presents papers on the science, engineering, and technology of shape castings, with contributions from researchers worldwide.  Among the topics that are addressed are structure-property-performance relationships, modeling of casting processes, and the effect of casting defects on the mechanical properties of cast alloys.

Preface ix

About the Editors xi

Process Design and Innovation

A Draft Melting Procedure for Al Alloys 3
J. Campbell

Effect of Casting Condition in Semi-solid Aluminum Alloy Injection Process on Distribution of Defects and Density 11
Y. Murakami, K. Miwa, M. Kito, T. Honda, N. Kanetake, and S. Tada

Reliability-based Casting Process Design Optimization 19
R. Hardin, K. Choi, and C. Beckermann

Influence of Process Parameters on Blistering during T6 Heat Treatment of Semi-solid Castings 27
Y. He, X. Xu, F. Zhang, D. Li, S. Midson, and Q. Zhu

Integrated Casting-heat Treatment Process Route for Near Net Shape ADI Casting Production 35
A. Meena and M. El Mansori

Swage Casting of A356 (AlSi7Mg0.3) Alloy 43
H. Lus

Additive Manufacturing Supports the Production of Complex Castings 51
A. Druschitz, C. Williams, D. Snelling, and M. Seals

Evolution of Filling System Design for an A356-T6 Aluminum Housing Casting 59
J. Chvala, M. Tiryakioglu, N. Hudyma, and P. Eason

Recent Advances on the Solidification Processing of Cast Energetic Materials 67
R. Mudryy, S. Jia, and L. Nastac

Solidification and Microstructure I

Thermodynamics-based Computational Approach to Al-Cu Alloys: Grain Refinement 77
J. Li, C. Promer, A. Jahn, B. Oberdorfer, S. Wurster, F. Martin, and P. Schumacher

Control Diffusion Solidification (CDS): An Overview of Mechanism and Application 89
R. Ghiaasiaan, S. Shankar, and D. Apelian

Correlation between Melt Quality and Fluidity of A356 99
B. Akkaya, E. Ertürk, and D. Dispinar

Fluidity Characteristics of A356 Alloy with Various Thickness Sectioned New Test Mould 105
M. Colak, R. Kayikci, and D. Dispinar

Effect of Feeder Configuration on the Microstructure of Ductile Cast Iron 113
N. Vedel-Smith and N. Tiedje

Analysis of Heterogeneous Nucleation in Ductile Iron 121
S. Lekakh

The External and Internal Shrinkages in Aluminum Gravity Castings 129
F. Hsu, S. Wang, and H. Lin

Effect of Si and Cu Content on the Size of Intermetallic Phase Particles in Al-Si-Cu-Mg-Fe Alloys 137
T. Sivarupan, J. Taylor, and C. Caceres

Efficient Use of Titanium and Boron in Grain Refining of a Die-cast Strontium-modified A356 145
S. Fischer, R. Boras, A. Bührig-Polaczek, and M. Bünck

Studying on the Effects of Quenching Rate on Residual Stress in Al-5Mg and Al-Mg-Cu Alloys 153
I. Kalkan and D. Dispinar

Mechanical Properties

Metallurgy without Bifilms: No More Fractures 163
J. Campbell

Correlation between Bifilm Index and Toughness of Aluminum Alloys 171
D. Dispinar, C. Kahruman, and J. Campbell

Impact of Section Thickness on the Microstructure and Mechanical Properties of Semi-solid Castings 177
S. Midson, Y. He, X. Hu, D. Li, F. Zhang, and Q. Zhu

The Relationship between Elongation and Fatigue Life in A206 Aluminum Castings 185
M. Tiryakioglu

Magnesium Casting Processes:The HIMAC Project Re-assessed 193
J. Campbell and M. Tiryakioglu

Manufacturing Cost Modeling of Castings Produced with CRIMSON Process 201
B. Zeng, M. Jolly, and K. Salonitis

On Weibull Mixtures in Mechanical Properties of Castings 209
M. Tiryakioglu

Microstructure and Mechanical Properties of Automotive Components Die Cast with Secondary Al Alloys by SEED Semi-solid Process 217
G. Timelli, S. Capuzzi, S. Ferraro, A. Fabrizi, and L. Capra

The Effect of Grain Structure on Casting Durability Assessment in Al-Si Alloys 225
G. Byczynski and R. Mackay

Near-net-shape Processing of 2024 Aluminium Alloy by SIMA Method 233
H. Özdes, I. Erdeniz, E. Erzi, and D. Dispinar

Solidification and Microstructure II

Reduced Pressure Test (RPT) for Bifilm Assessment 243
D. Dispinar and J. Campbell

Prediction of Misruns in Thin Wall Castings Using Computational Simulation 253
J. Jakumeit, E. Subasic, and M. Bünck

Shaping of Metals with Magnetic Fields 261
M. David, C. Monroe, and J. Griffin

The Formation of Hydrogen Related Porosity by Double Oxide Film Defects in Al Alloys 269
A. Gerrard and W. Griffiths

The Influence of Fe, Mn and Cr Additions on the Formation of Iron-rich Intermetallic Phases in an Al-Si Die-casting Alloy 277
A. Fabrizi, S. Ferraro, and G. Timelli

Thermal Analysis of Solidifying Secondary Phases in the Eutectic Al-Si Alloy and the Effect of Sr and Fe 285
J. Manickaraj, A. Gorny, and S. Shankar

Thin-wall Model for Use in Multiple Casting Conditions 293
A. Noble, C. Monroe, and A. Monroe

Electrochemical Behavior of Al-1wt.%Cu and Al-4.5wt.%Cu Alloys 301
A. Roman, C. Méndez, C. Schvezov, and A. Ares

Author Index 309

Subject Index 311