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Designing the Least Expensive Charge Mix Using Data Analytics and Optimization for Gray Cast Iron (Grade FG 220) 利用数据分析和优化设计成本最低的灰铸铁(FG 220 级)炉料组合
IF 2.6 3区 材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2024-08-19 DOI: 10.1007/s40962-024-01418-1
Deepak Chowdhary, V. Rahul, Nilanjan Banerjee

In a foundry, optimizing the charge mix is critical to achieving consistent quality, cost-efficiency, and desired qualities in the final metal or alloy product. This paper describes a data analytics-driven strategy for optimizing the charge mix by lowering the cost of the scrap used to prepare the molten metal while maintaining the required chemical composition, tensile strength, and hardness required by the foundry for manufacturing gray cast iron products (Grade FG 220). The linear programming approach is used for this purpose where all the constraints are strictly met. Three categories of constraints are used for this purpose, i.e., composition constraint, foundry constraint, and material grade constraint. In the linear programming approach, the feasible region is considered as an ellipsoidal region and the developed convex optimization problem is iteratively solved. The result showed potential cost savings could be obtained, accompanied by the needed alloy chemical composition and quality.

在铸造厂中,优化炉料组合对于实现稳定的质量、成本效益以及最终金属或合金产品的预期质量至关重要。本文介绍了一种数据分析驱动的炉料组合优化策略,通过降低用于制备熔融金属的废料成本,同时保持铸造厂生产灰铸铁产品(FG 220 级)所需的化学成分、抗拉强度和硬度。为此采用了线性规划方法,严格满足所有约束条件。为此使用了三类约束条件,即成分约束条件、铸造厂约束条件和材料等级约束条件。在线性规划方法中,可行区域被视为一个椭圆形区域,并对开发的凸优化问题进行迭代求解。结果表明,在满足所需合金化学成分和质量的同时,还能节省潜在的成本。
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引用次数: 0
Performance of Resins for Stereolithography Printers in Jewelry Casting Applications: A Qualitative Assessment 立体光刻打印机树脂在珠宝铸造应用中的性能:定性评估
IF 2.6 3区 材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2024-08-19 DOI: 10.1007/s40962-024-01440-3
Ferrufino-Rojas Juan-Manuel, Ruiz-Calleja Tamara

This research analyzes the technical feasibility of manufacturing jewelry castings using the lost wax technique, substituting wax by the use of resins within the framework of 3D stereolithography printers. To achieve this goal, a pair of distinct 3D ring designs have been crafted: a robust signet ring and an intricate filigree ring. The purpose behind this decision is to determine whether the unique features of these two different designs have any noticeable effect on the result. Five different commercial resins have been utilized, with one of them explicitly formulated for casting purposes. Non-castable resins generate a unique, weathered appearance, due to the variability in ash residue within the mold after resin combustion, yielding unpredictable outcomes and diverse sample characteristics such as grainy texture, cracks, and a corroded effect. Examining the castable resin reveals its optimal performance for smaller elements like the filigree ring, showcasing remnants of supports or layers originating from the resin's printer curing process. On the contrary, larger resin-abundant objects like the signet ring result in notable flaws, attributed to gas accumulation within the mold, exerting internal pressure and causing mold rupture, leading to metal leakage.

Graphical Abstract

这项研究分析了使用失蜡技术制造珠宝铸件的技术可行性,即在三维立体光刻打印机框架内使用树脂替代蜡。为了实现这一目标,我们制作了一对独特的三维戒指设计:一个坚固的标志戒指和一个复杂的花丝戒指。做出这一决定的目的是为了确定这两种不同设计的独特性是否会对结果产生明显的影响。我们使用了五种不同的商用树脂,其中一种是专门为铸造目的而配制的。由于树脂燃烧后模具内残留灰烬的变化,不可浇铸树脂产生了独特的风化外观,产生了不可预测的结果和不同的样品特征,如颗粒纹理、裂缝和腐蚀效果。通过对可浇注树脂的研究,我们可以发现,对于像花丝环这样的较小部件来说,可浇注树脂具有最佳的性能,因为树脂在打印机固化过程中会残留支撑物或层。相反,像印章戒指这样树脂含量较高的大型物件则会出现明显的缺陷,原因是模具内气体积聚,产生内部压力,导致模具破裂,从而导致金属泄漏。
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引用次数: 0
Hybrid Filler Actions on Functional Performance Evaluation of Magnesium Alloy (AZ61) Hybrid Nanocomposites 混合填料对镁合金(AZ61)混合纳米复合材料功能性能评估的影响
IF 2.6 3区 材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2024-08-19 DOI: 10.1007/s40962-024-01431-4
R. Venkatesh, K. Logesh, Pradeep Kumar Singh, Mohanavel Vinayagam, Ismail Hossain, Manzoore Elahi M. Soudagar, Sami Al Obaid, Sulaiman Ali Alharbi, V. K. Ramachandaramurthy

The proposed research of magnesium alloy (AZ61) hybrid nanocomposites followed by advanced liquid-state processing associated with the squeeze die-cast process overcomes the drawbacks (micro-voids, agglomerated particles, and oxidation during open melting) of conventional liquid stir gravity die casting. The boron nitride (BN) and silicon carbide (SiC) nanoparticles are the source of hybrid filler material for composing the AZ61 alloy hybrid nanocomposites. Finding the role of hybrid filler materials during the squeeze casting processing on surface morphological, mechanical, and tribological performance is evaluated by the ASTM standard, and its outcomes are compared with cast AZ61 alloy and AZ61/3 wt% of BN nanocomposites. The advanced liquid-state processing features with squeeze die cast proved void-free structure composite surface and homogenous particle distribution was confirmed by scanning electron microscope analysis. The crystal peaks are confirmed with the support of X-ray diffraction analysis. Besides, the actions of hybrid filler material in AZ61 alloy matrix provided significant results and the composite contained with 3 wt% of BN 7.5 wt% SiC offered improved density (1.851 g/cc), reduced porosity (0.54%), optimum yield, and ultimate tensile strength performance of 184.7 ± 9 and 307.1 ± 6 MPa, maximum hardness (84.6 ± 4 HV), hiked impact strength (24.2 ± 1 J/mm2), reduced volumetric wear loss (0.97 mm3/m) and improved coefficient of friction (0.47). The best functional performance of composite sample (AZ61/3 wt% BN/7.5 wt% SiC) is advised for automotive top roof frame applications.

拟议的镁合金(AZ61)混合纳米复合材料研究采用与挤压压铸工艺相关的先进液态加工方法,克服了传统液态搅拌重力压铸工艺的缺点(微空洞、颗粒团聚和开放熔化过程中的氧化)。氮化硼(BN)和碳化硅(SiC)纳米颗粒是构成 AZ61 合金混合纳米复合材料的混合填充材料来源。根据 ASTM 标准评估了挤压铸造过程中混合填充材料对表面形貌、机械和摩擦学性能的作用,并将其结果与铸造的 AZ61 合金和 AZ61/3 wt% BN 纳米复合材料进行了比较。通过扫描电子显微镜分析,证实了挤压铸造的先进液态加工特点,即复合材料表面无空隙结构,颗粒分布均匀。X 射线衍射分析证实了晶体峰值。此外,混合填料在 AZ61 合金基体中的作用效果显著,含有 3 wt% BN 7.5 wt% SiC 的复合材料密度提高(1.851 g/cc),孔隙率降低(0.54% ),最佳屈服强度和极限拉伸强度分别为 184.7 ± 9 MPa 和 307.1 ± 6 MPa,最大硬度(84.6 ± 4 HV),冲击强度提高(24.2 ± 1 J/mm2),体积磨损损失降低(0.97 mm3/m),摩擦系数提高(0.47)。复合材料样品(AZ61/3 wt% BN/7.5 wt% SiC)的最佳功能性能建议用于汽车顶棚框架。
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引用次数: 0
Polynomial Description of the Fe–C–Si Stable Phase Diagram for up to 4.5 wt% Si, Including the Effect of Cr, Cu, Mn and P 硅含量高达 4.5 wt% 的铁-碳-硅稳定相图的多项式描述,包括铬、铜、锰和磷的影响
IF 2.6 3区 材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2024-08-15 DOI: 10.1007/s40962-024-01428-z
Jon Sertucha, Jacques Lacaze, Anna Regordosa, Ramon Suarez

Knowledge of the relevant stable equilibrium phase diagram is a prerequisite for taking account of deviations from equilibrium when modeling the solidification of silicon cast irons. While a linear description is practical for silicon contents up to 3 wt%, the curvature of the austenite liquidus at higher silicon contents necessitates the use of second-order polynomials. This study was carried out with the aim of obtaining an accurate description up to 4.5 wt% silicon, representative of today’s emerging high-silicon cast irons. In addition, alloying with up to 1 wt% copper, 0.5 wt% manganese and 0.25 wt% chromium and phosphorus was considered. In parallel to a description of the liquidus of austenite and graphite, the austenite-liquid partition coefficients of all alloying elements have been described. This paves the way for future work aimed at providing an accurate description of microsegregation and other non-equilibrium phenomena occurring during the solidification of silicon cast irons.

了解相关的稳定平衡相图是建立硅铸铁凝固模型时考虑偏离平衡的先决条件。虽然线性描述适用于硅含量不超过 3 wt%的情况,但硅含量较高时奥氏体液面的曲率要求使用二阶多项式。本研究的目的是准确描述硅含量高达 4.5 wt%(代表当今新兴的高硅铸铁)时的情况。此外,还考虑了最高 1 wt%的铜、0.5 wt%的锰、0.25 wt%的铬和磷合金。在描述奥氏体和石墨液相的同时,还描述了所有合金元素的奥氏体-液体分配系数。这为今后旨在准确描述硅铸铁凝固过程中发生的微偏析和其他非平衡现象的工作铺平了道路。
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引用次数: 0
Benchmarking Permeability of Investment Casting Shell Molds Used for High-Value Segments Using Smart Measurement 利用智能测量技术为用于高价值部件的熔模铸造外壳模具的透气性设定基准
IF 2.6 3区 材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2024-08-14 DOI: 10.1007/s40962-024-01435-0
Sanket Pandya, Nikunj Maheta, Mahek Rathod, Abhilash Edacherian, Amit Sata

Permeability of shell molds for investment castings used in high-valu segments including aerospace, biomedical and defense plays a very important role in achieving better quality castings especially free from filling-related defects. Though, guidelines related to permeability measurement techniques have been established for twenty years, the permeability measurement device is not available in most investment casting foundries. This can lead to issues when establishing foundries to supply investment castings for high-value segments. A specific permeability measurement device has been developed by following guidelines published by a globally accepted standard body that further has been facilitated with the fundamentals of the Internet of Things. Different mold materials (using zirconium sand, aluminum silicate and fused silica) that are used in shell mold making for high-valued segments have been tested for establishing benchmark values of permeability. These values of permeability were observed in the range of 8 × 10-11–37 × 10-11 cm2 to achieve better quality shells as well as investment castings.

用于航空航天、生物医学和国防等高价值领域的熔模铸造壳模的透气性对于提高铸件质量,尤其是避免出现与填充相关的缺陷具有非常重要的作用。虽然有关渗透性测量技术的指导原则已经制定了二十年,但大多数熔模铸造铸造厂都没有渗透性测量设备。这可能导致在建立铸造厂为高价值领域提供熔模铸造产品时出现问题。根据全球公认的标准机构发布的指导方针,我们开发了一种特定的渗透性测量设备,并进一步利用物联网的基本原理进行了改进。为确定透气性基准值,对高价值部件外壳模具制造中使用的不同模具材料(使用锆砂、硅酸铝和熔融石英)进行了测试。据观察,这些渗透率值的范围为 8 × 10-11-37 × 10-11 cm2,以获得质量更好的壳体和投资铸件。
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引用次数: 0
Effect of Zn Addition on the Structural, Mechanical and Tribological Properties of Al12Si (EN AC 44100) Alloy 添加锌对 Al12Si(EN AC 44100)合金的结构、机械和摩擦学性能的影响
IF 2.6 3区 材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2024-08-13 DOI: 10.1007/s40962-024-01432-3
Ali Paşa Hekimoğlu, Ahsen Sönmezışık, Süha Zimitoğlu, Murat Hacıosmanoğlu, Temel Savaşkan

In this study, the effects of 10 wt% Zn addition on the microstructure and properties of Al12Si EN AC 44100 alloy were investigated. For this purpose, EN AC 44100 and EN AC 44100 + 10 wt%Zn alloys were fabricated by permanent mold casting. The microstructural examinations were performed using standard metallographic techniques. The phases in microstructures were identified by energy dispersive spectroscopy and X-ray diffraction analyses. The yield strength, ultimate tensile strength, and elongation to fracture of the alloys were determined by tensile testing after measuring their Brinell hardness. The tribological properties of the alloys were examined using a ball-on-disk type wear test apparatus. It was observed that the microstructure of the EN AC 44100 alloy consists of aluminum-rich α, primary silicon and β (Al–Fe–Si) phases together with the eutectic Si particles. The addition of zinc resulted in a significant increase in the hardness and the strength of EN AC 44100 alloy but a considerable decrease in its friction coefficient and wear volume by modifying the microstructure of it. The modification caused a reduction in the size of α grains and eutectic silicon particles. Effects of zinc addition on the mechanical and wear properties of the EN AC 44100 alloy were discussed in terms of the observed microstructural changes.

本研究探讨了添加 10 wt% Zn 对 Al12Si EN AC 44100 合金微观结构和性能的影响。为此,采用永久模铸造法制造了 EN AC 44100 和 EN AC 44100 + 10 wt%Zn 合金。采用标准金相技术进行了微观结构检测。通过能量色散光谱和 X 射线衍射分析确定了微结构中的相。合金的屈服强度、极限拉伸强度和断裂伸长率是在测量其布氏硬度后通过拉伸试验确定的。使用球盘式磨损试验装置检测了合金的摩擦学特性。结果表明,EN AC 44100 合金的微观结构由富铝α相、原始硅相和β(Al-Fe-Si)相以及共晶硅颗粒组成。添加锌后,EN AC 44100 合金的硬度和强度显著提高,但其摩擦系数和磨损量却因微观结构的改变而大大降低。这种改性导致 α 晶粒和共晶硅颗粒的尺寸减小。根据观察到的微观结构变化,讨论了加锌对 EN AC 44100 合金机械和磨损性能的影响。
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引用次数: 0
Highlights on the Role of Fe, Sr, and Solidification Time on Porosity Formation in Al–Si Cast Alloys 铁、锶和凝固时间对铝硅铸造合金中孔隙形成的作用要点
IF 2.6 3区 材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2024-08-12 DOI: 10.1007/s40962-024-01409-2
E. Samuel, A. M. Samuel, H. W. Doty, S. Valtierra, F. H. Samuel

The present study was undertaken to elaborate on the parameters controlling the microstructural characterization of A319.2 Al–Si alloys, as a function of iron content (0.12–0.8%), Sr addition (~250 ppm), and solidification time (586s vs 513s). For comparison, selected conditions were applied to A356.2 alloys. The use of a hot graphite mold and an end-chill mold provided different solidification rates along the liquid/solid interface, corresponding to DAS values in the range of ~23–85μm, corresponding to levels of 5, 10, 30, 50, and 100 mm above the chill end. Addition of strontium leads to fragmentation of β–Al5FeSi platelets. Under similar Fe level and solidification rate conditions, the A319.2 alloys exhibit larger pore sizes than the A356.2 alloys, due to the absence of the (Al–Al2Cu) reaction in the latter and hence longer solidification time. Four types of iron intermetallics were reported viz., δ-, α-, β-, and π-phases.

本研究旨在阐述控制 A319.2 Al-Si 合金微观结构特征的参数与铁含量(0.12-0.8%)、锶添加量(约 250 ppm)和凝固时间(586 秒与 513 秒)的函数关系。为了进行比较,对 A356.2 合金采用了选定的条件。使用热石墨模具和端冷模具时,沿液体/固体界面的凝固速率不同,DAS 值的范围为 ~23-85μm,对应于冷端上方 5、10、30、50 和 100 mm 的水平。锶的加入导致了β-Al5FeSi 小板的破碎。在类似的铁含量和凝固速率条件下,A319.2 合金比 A356.2 合金显示出更大的孔隙尺寸,这是因为后者不存在(Al-Al2Cu)反应,因此凝固时间更长。报告了四种类型的铁金属间化合物,即δ相、α相、β相和π相。
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引用次数: 0
The Effect of Al–5Ti–B Addition and Applying Helmholtz Coils Magnetic Field for Increasing Mechanical Properties of Investment Casting A356 Al–Si Alloys 添加 Al-5Ti-B 和施加亥姆霍兹线圈磁场对提高熔模铸造 A356 Al-Si 合金机械性能的影响
IF 2.6 3区 材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2024-08-11 DOI: 10.1007/s40962-024-01424-3
Muhamad Jalu Purnomo, Yu-Xin Hsu, Ing-Song Yu, Chao-Yu Lee

This study investigates the influence of magnetic fields on the microstructure and mechanical properties for the investment casting A356 Al–Si alloy. A356, known for its significant application in aerospace, defense, and automotive industries, was subjected to various intensities of magnetic fields generated by Helmholtz coils during the investment casting process. Additionally, the alloy was modified with the addition of Al–5Ti–B master alloy, and samples were subjected to T6 heat treatment. The aim was to explore the combined effects of magnetic field, grain refiner, and heat treatment on the alloy’s microstructural evolution and mechanical properties. The characterizations of A356 alloy included tensile strength, Vickers hardness, metallography, scanning electron microscopy, X-ray diffraction, and differential scanning calorimetry. The results indicated that magnetic fields applied during the casting process significantly influence the grain refinement of α-Al and the spheroidization of the eutectic silicon, leading to improve its mechanical properties. The study also examined the effects of magnetic fields on the distribution and morphology of eutectic silicon and Mg2Si phases after T6 heat treatment. The findings of this research provide valuable insights in optimizing investment casting processes and enhancing the material properties of A356 alloy, which will offer potential applications in improving the quality and performance of cast components in various industrial sectors.

本研究探讨了磁场对熔模铸造 A356 Al-Si 合金的微观结构和机械性能的影响。A356 因其在航空航天、国防和汽车工业中的重要应用而闻名,在熔模铸造过程中,我们将其置于亥姆霍兹线圈产生的不同强度的磁场中。此外,还添加了 Al-5Ti-B 母合金对合金进行改性,并对样品进行 T6 热处理。目的是探索磁场、晶粒细化剂和热处理对合金微观结构演变和机械性能的综合影响。对 A356 合金进行的表征包括拉伸强度、维氏硬度、金相学、扫描电子显微镜、X 射线衍射和差示扫描量热。结果表明,在铸造过程中施加的磁场对α-Al的晶粒细化和共晶硅的球化有显著影响,从而改善了其机械性能。研究还考察了磁场对 T6 热处理后共晶硅和 Mg2Si 相的分布和形态的影响。这项研究的结果为优化熔模铸造工艺和提高 A356 合金的材料性能提供了宝贵的见解,这将为提高各工业部门铸造部件的质量和性能提供潜在的应用。
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引用次数: 0
Effect of Combined Addition of Molybdenum and Tungsten on Continuous Cooling Transformation Behavior of High Chromium Cast Iron 钼和钨的联合添加对高铬铸铁连续冷却转变行为的影响
IF 2.6 3区 材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2024-08-10 DOI: 10.1007/s40962-024-01423-4
Kaoru Yamamoto, S. Inthidech, Y. Yokomizo, N. Sasaguri, Y. Matsubara
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引用次数: 0
Enhanced Particle Dispersion in Aluminum Melts Using Multi-source Ultrasonic Vibration: Simulation and Experiments 利用多源超声波振动增强铝熔体中的颗粒分散:模拟与实验
IF 2.6 3区 材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING Pub Date : 2024-08-06 DOI: 10.1007/s40962-024-01419-0
Yeliang Zhu, Xiaogang Fang, Shulin Lv, Shusen Wu, Shifeng Luo, Siliang Yan, Jiguang Liu, Youwen Yang, Yiqing Chen

Due to severe acoustic attenuation, the effectiveness of single-source ultrasonic vibration (SUV) in dispersing reinforcement particles within Al matrix composites is limited, particularly when dealing with high weight fractions. In this study, a short-spacing multi-source ultrasonic vibration (MUV) technique, specifically quad-source ultrasonic vibration (QUV), was introduced to prepare SiCp/A356 composites with a high weight fraction of 15wt.% SiC particles. The characteristic of acoustic streaming and the dispersion of particles were systematically investigated through numerical simulations and physical experiments. The results reveal that QUV mitigates acoustic attenuation and expands the potential cavitation region (exceeding the cavitation threshold of 1.1 MPa) compared to single-source ultrasonic vibration (SUV). The synergistic effect of multiple ultrasonic waves not only elevates cavitation intensity but also enriches the structures of acoustic streaming, significantly reducing agglomeration and improving the dispersion of SiC particles within the Al matrix. Without ultrasonic treatment, only a small proportion of SiC particles are embedded in the Al matrix, with an SSiC/St ratio of merely 2.23%. However, as the number of ultrasonic sources increases, the agglomeration of SiC particles was relieved, and the resultant holes diminish. Remarkably, under QUV treatment, the holes in the composites virtually disappear, and the SSiC/St ratio increases to 9.82%. Additionally, the composites exhibit superior mechanical properties, with a tensile strength of 200 MPa and an elongation of 7.0%, which are 10.5% and 38.5% higher than those achieved using SUV, respectively.

由于声衰减严重,单源超声振动(SUV)在铝基复合材料中分散增强粒子的效果有限,尤其是在处理高重量分数时。在本研究中,引入了一种短间距多源超声振动(MUV)技术,特别是四源超声振动(QUV),用于制备 SiCp/A356 复合材料,其中 SiC 颗粒的重量分数高达 15wt.%。通过数值模拟和物理实验系统地研究了声流特性和颗粒的分散性。结果表明,与单源超声振动(SUV)相比,QUV 可减轻声衰减并扩大潜在空化区域(超过 1.1 MPa 的空化阈值)。多个超声波的协同效应不仅提高了空化强度,还丰富了声流结构,显著减少了团聚,改善了碳化硅颗粒在铝基体中的分散。在未进行超声波处理的情况下,只有一小部分 SiC 颗粒嵌入铝基体中,SSiC/St 比率仅为 2.23%。然而,随着超声源数量的增加,SiC 颗粒的聚集现象得到缓解,由此产生的孔洞也随之减少。值得注意的是,在 QUV 处理过程中,复合材料中的孔洞几乎消失,SSiC/St 比率增加到 9.82%。此外,复合材料还具有优异的机械性能,抗拉强度达到 200 兆帕,伸长率为 7.0%,分别比使用 SUV 时提高了 10.5%和 38.5%。
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引用次数: 0
期刊
International Journal of Metalcasting
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