Sharif Digital Repository

In this study, the effects of mold constraints and cooling rate on residual stress were analyzed during the shaped casting process. For this purpose, an H-shaped sample was designed in which the contraction of its middle portion is highly restricted by the mold during the cooling process. The effects of an increasing cooling rate combined with mold constraints were analyzed by reducing the thickness of the middle portion in the second sample. A three-dimensional coupled temperature-displacement analysis was performed in finite-element code ABAQUS to simulate residual stress distribution, and then numerical results were verified by the hole-drilling strain-gauge method. It was concluded that... 

Aluminum matrix nano composites have become of great interest in the lightweight fields because of their high specific stiffness and high specific strength. Many processing techniques have been developed to manufacture metal matrix nano composites on the commercial scale. Compocasting is a relatively new technology for composite forming, different from the conventional composite shaping technologies that use either solid or liquid metals as the starting material. An investigation is carried out on the influence of applied load, sliding speed, wearing surface hardness, reinforcement fracture toughness and morphology as the critical parameters in relation to the wear regime. In general, EMS... 

The present study investigated the effects of initial Hydrogen level and cooling rate on ultimate tensile strength of commercial Al-A319 alloys. Three hydrogen levels (0.01, 0.2, and 0.41 mL/100 grams of melt) and five cooling rate were studied. Total of 45 tensile test bars was prepared (three hydrogen levels × five cooling rate × three repeats). The UTS of the samples was determined though uniaxial tension tests. Furthermore, the microstructures of the samples were studied by standard metallographic technique and image analysis software. Finally the relationship between UTS and microstructurai features—SDAS and fraction of porosity (Fp%)—of the alloys was investigated.Results of tensile... 

A 2-D numerical model was developed to predict the shape of weld pool in stationary GTA welding of commercial pure aluminium, without considering fluid flow in the weld pool. A Gaussian current density and heat input distribution on the surface of the workpiece were considered. The parameters of Gaussian distribution were modified by comparing calculated results with experimental ones. It was found that these distribution parameters are functions of applied current and arc length. Effects of arc length, applied current and welding time on the geometry of the weld pool were investigated. To check the validity of the model, a series of experiments were also conducted. In general, the agreement... 

In the present work, a mathematical model was developed based on finite difference method to predict the microporosity distribution in A356 aluminum alloy casting. Heat, mass, and gas conservation equations were solved in this model. Moreover, Darcy's equation was considered in the mushy zone. Results show that the distribution and concentration of microporosities in cast parts vary with both cooling rate and initial gas content. Simulation results were compared with experimental data where proportionally good agreement with experimental results was found. Finally, a complex cast part was simulated presenting the ability of the model to predict the porosities in industrial cast parts  

In the last few years, an increasing attention has been paid to the issues of saving energy and reducing the manufacturing costs in the transport industry which necessitates further efforts to replace traditional materials like steel with lightweight materials such as plastics, aluminum, magnesium, and composites. Metal matrix nanocomposites have turned into an established material in today's industry with an ongoing expansion in their field of applications. In this study, the formation of nanoparticle-aluminum metal matrix composites is described by compocast processing from nanoparticle Al2O3 and the A356 aluminum alloy. In order to optimize the processing parameters, a novel approach is... 

Effects of sprue base size and design on flow pattern during aluminum gravity casting have been investigated by employing different sprue base sizes and using computational fluid dynamics (CFD). Calculations was carried out using SUTCAST simulation software based on solving Navier-Stokes equation and tracing the free surface using SOLA-VOF algorithm. Flow pattern was analyzed with focusing on streamlines and velocity distribution in sprue base, runner and in-gate. Increasing well size was produced a vortex flow at the bottom of sprue base which increased the surface velocity of liquid metal in runner. Using a rather big sprue well could eliminate vena contracta, but in-gate velocity was... 

In this study, the feasibility of the synthesis of Fe-TiC-Al 2O3 hybrid nanocomposite via mechanical activation followed by carbothermal reduction was investigated. The raw materials including ilmenite, carbon black and aluminum powder were milled in a high energy planetary ball mill. At different time intervals, samples were taken for characterization. After phase evaluation with XRD, some samples were heat treated in an atmosphere controlled tube furnace. Studies proved that increasing the milling time of the raw materials resulted in the formation of more amorphous phase and more active materials. Furthermore, investigations showed that after carbothermal reduction, the synthesized TiC...