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Investigation on Effective Parameters on Mold Filling of Cast Iron Melt in EPC Process

Nematizad, Mojtaba | 2010

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 40301 (07)
  4. University: Sharif University of Technology
  5. Department: Materials Science and Engineering
  6. Advisor(s): Varahram, Naser
  7. Abstract:
  8. Casting process with foam is a relatively new process which because of having multiple benefits (like elimination of muscle and segregation line, high dimensional precision and using sand without using glue) in recent years has been considered. Considering that during pouring, melt replaces with sand surrounded foam, successfulness of this method depends on complete elimination of foam model during Pouring for preventing formation of some defects like carbon defects in cast irons, or cold work and porosity in aluminum alloys. Parameters like Pouring temperature, alloy type, foam type, density of foam model, type of gating system, and some other parameters are affecting the way of filling of mold with molten metal in this method. In this work, effects of these parameters were investigated. Results showed that at very small sizes of gate, it does not affect time and rate of mold filling and the balance between decomposed foam products and passing gases of coating, controls mold filling. At critical size, (which in this work calculated about 0.6 square centimeters), Gate works as Chock. Also, the effect of number and position of gate is not such important. The effect of density of model foam on time and rate of mold filling is more important than pouring temperature, but the most important factor is the thickness of coating. By varying coating thickness from 0.5 to 1 millimeter, mold filling will change two times. For comparing mold filling time of conventional casting and EPC, we used SUTCAST software and results showed that this time is 89 percent higher in conventional casting. Considering that formation of most of defects in this method is directly related to decomposition condition of foam and mold filling, with investigating of mold filling mechanism and knowing role of above mentioned parameters, we can avoid defects formation in this method
  9. Keywords:
  10. Gating System ; Coating Thickness ; Density Current ; Evaporative Pattern Casting ; Photography Technique ; Themperature

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