Sharif Digital Repository

During solidification and casting in metallic molds, the heat flow is controlled by the thermal resistance at the casting-mold interface. Thus heat transfer coefficient at the metal-mold interface has a predominant effect on the rate of heat transfer. In some processes such as low pressure and die-casting, the effect of pressure on molten metal will affect the rate of heat transfer at least at initial steps of solidification. In this study interfacial heat transfer coefficient at the interface between A356 alloy casting and metallic mold during the solidification of casting under pressure were obtained using the IHCP (Inverse Heat Conduction Problem) method. Temperature measurements are then... 

In this investigation, a computational-model has been developed, including heat transfer and the effects of the resistance of a metal-mold interface and pressure, for simulation of the solidification process. Simulation of the interface resistance is based on the Zero Thickness Element (ZTE), utilizing the Finite Element Method (FEM). Solid boundary conditions, including contact resistances, have been modified by a pressure gradient in each of the ZTE. The pressure gradient has been modeled, based on experimental data. In order to verify the computational results, an Al-11.5 wt% Si alloy was poured into a permanent mold and the temperature of the interface was measured by a data acquisition... 

Purpose - Dimensional accuracy analysis of wax model created by room temperature vulcanization (RTV) silicone rubber molding to be used in investment casting is presented. The purpose of this paper is to discuss the effective parameters of dimensional accuracy in RTV tooling technique. Design/methodology/approach - After producing a pattern by stereolithography (SLA) and then creating the RTV silicone rubber mold by the SLA pattern, dimensional accuracy of wax models produced by RTV tool are analyzed. Design of experiments (DOE) using the Taguchi approach is used for analysis and determination of optimum condition. Findings - Experiments show that the dimensional accuracy in RTV technique is... 

Surface turbulence during the filling of the mold triggers the entrainment of oxide films, which appears to be detrimental to the soundness of the final casting. Nonpressurized and bottom-gating systems have been employed in order to avoid such casting defects by reducing the surface velocity of the liquid metal. However, recent studies have shown that the melt front velocity in the mold entrance may exceed the critical value in the nonpressurized and bottom-gating systems. Therefore, a study was conducted on numerical simulation melt flow pattern in nonpressurized and bottom-gating systems. It was noted that the liquid metal enters the gate and then mold cavity with a higher velocity by... 

An experimental rheological study has been performed to evaluate the influence of TiC addition on the rheological behavior and stability of 316L stainless steel powder injection molding (PIM) feedstock. The effects of TiC concentration, solid loading, shear rate and temperature were investigated via capillary rheometer method. The stability of feedstocks was evaluated quantitatively using "instability index", which describes the threshold beyond which the variation of viscosity becomes unacceptable for PIM purposes. The results show that the rheological behavior of PIM feedstocks highly depends on the blend composition. The addition of TiC particles to the stainless steel powder increases... 

The rheological behaviour of powder injection moulding feedstock comprising of 316L stainless steel and 3 wt-%TiC powders was studied using a capillary rheometer. The flowability and the sensitivity of viscosity to shear rate and temperature of the feedstock were investigated and compared with those of the binder system and the 316L SS PIM feedstock. The general rheological indexes were examined through relevant equations and the influence of TiC addition on the mouldability of the 316L SS feedstock was determined. It was found that all the feedstocks are basically pseudoplastic but the values of flow behaviour index n are influenced by the TiC addition, the solid volume fraction and the... 

Gas porosities and Fe-rich phases and entrapped double oxide films (hereafter: oxides) are known to be the most detrimental defects in cast Al-Si-Mg alloys. The effects of H (gas porosities) and Fe (Β-Al5FeSi phase) on reproducibility of tensile properties in Al-7Si-0.35Mg alloy have been investigated in this study. Four different casting conditions (Low H-Low Fe, Low H-High Fe, High H-Low Fe and High H-High Fe) were studied. In each case, 30 tensile test samples were prepared by casting in a metallic mold and machining (total of 120 tensile test samples). Results of tensile test were analyzed by Weibull three-parameter analyses. The microstructures of samples were studied by optical... 

Double oxide films (hereafter: oxides), inclusions and Fe-rich phases are known to be the most detrimental defects in cast Al-Si-Mg alloys. The effects of these defects on reproducibility of tensile properties in Al-7Si-0.35Mg alloy have been investigated in this study. Four different casting conditions (low oxide-low Fe, high oxide-low Fe, low oxide-high Fe and high oxide-high Fe) were studied. In each case, 30 tensile test samples were prepared by casting in a metallic mold and machining (total of 120 tensile test samples). Results of tensile test were analyzed by Weibull three-parameter and mixture analyses. The microstructure and fracture surface of samples were studied by optical and... 

The aim of this paper is to correlate interfacial heat transfer coefficient (IHTC) to applied external pressure, in which IHTC at the interface between A356 aluminum alloy and metallic mold during the solidification of casting under different pressures were obtained using the inverse heat conduction problem (IHCP) method. The method covers the expedient of comparing theoretical and experimental thermal histories. Temperature profiles obtained from thermocouples were used in a finite difference heat flow program to estimate the transient heat transfer coefficients. The new simple formula was presented for correlation between external pressure and heat transfer coefficient. Acceptable... 

Gas porosities and entrapped double oxide film (hereafter: oxides) are known to be the most detrimental defects in cast Al-Si-Mg alloys. This study investigated the effects of dissolved hydrogen (hereafter: H) and oxides on reproducibility of tensile properties in Al-7Si-0.35 Mg alloys. Also the effects of H and oxides content on the morphology of defects were studied. Four different casting conditions (low oxide-low H, low oxide-high H, high oxide-low H, high oxide-high H) were tested using tensile test bars that were cast in a metallic mold. Results of tensile test that were obtained for each casting condition were analyzed using Weibull two-parameter analysis. Microstructure and fracture...