Sharif Digital Repository

Process of casting with evaporative patterns and unbonded sand is a new method that due to different economic, environmental and technological benefits is considered to large and small industrial parts manufacturing in recent years. Different parameters are effective on the surface and metallurgical quality in this process, such as foam density, sand type and size, level and mode of vibration, sand compaction, coating and pouring time and temperature. If coating permeability that is function of type, thickness and concentration of coating is chosen improper, pyrolysis vapor of foam don’t exit completely and in this condition carbon of vapor deposit on the metal surface and produces defect... 

In this research the effect of Si, Cu and Ni alloying elements on the structure and mechanical properties of the A336 alloy is investigated. Expriments were done in two situations, casting and heat treated and the results for all samples with different amount of alloying elements are compared and the effect of heat treating is also investigated. Results show that with increasing the amount of Si and Cu and decreasing the amount of Ni strength and hardness of the cast alloy are 134 MPa and 65 HB and they increase to 187 MPa and 89 HB in heat treated alloy. The elongation and coefficient of linear expansion are decreased from 2.3% and 21.94 μm/m.K to 1.1% and 21.62 μm/m.K. Also the T6 heat... 

The Ni-based superalloy GTD-111 possesses excellent hot corrosion resistance, high stability and strength at elevated temperature; accordingly, the alloy is used in manufacturing of the first stage blades of powerful gas turbines. In this study, effect of withdrawal rate from Bridgman furnace and precipitation hardening on the microstructure and microhardness of this superalloy were investigated. To this end, several experiments were carried out under growth rates of 1, 6 and 10 mm/min using Bridgman process under vacuum. Afterwards, the effects of homogenization treatment, partial dissolution with two different cooling rates (air and water) along with aging on the microstructure were... 

LM13 Aluminum alloys contain Silicon, Copper, magnesium and Nickel. This alloys have been widely used in automobile pistons. For this application thermal expansion coefficient is one important characteristics other than mechanical properties. In this project replacing Cobalt with Nickel to improve alloy thermal and mechanical properties in piston applications by different cobalt contents. Cobalt contents is 0, 0.15, 0.55 and 0.77 Wt%. Because of oxidation magnesium content decrease into 0.98, 0.74, 0.61 and 0.48 Wt%. Thermal expansion coefficient and UTS first increase and after 0.55 Cobalt Wt% show decrease But yield strength and hardness increase as cobalt content increase. Microscopic... 

Al-4.5% Cu alloy, an age-hardenable alloy, is an important alloy in industry due to such unique characteristics as high strength-to-weight ratio and considerable strength at elevated temperatures. In this study, the aim was to evaluate the combined effect of cooling rate and heat treatment on an A206 alloy having more impurities—especially iron—than the nominal specifications. To this end, the melt was poured in a five-step mold. Afterwards, each step was subjected to T4 and T6 treatments in order to study the changes compared to the as-cast samples. Ultimate tensile strength, yield strength, elongation, and grain size were determined by using tensile tests and optical microscopy,... 

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... 

AS5U3G and AS7U3G are two prevalent types of alloy which are used in producing cylinder head. In this research AS5U3G alloy is studied. Gravity casting is one of the method of producing this part. Produced porosities in cylinder head casting process, cause leakage in this part. In order to solve this problem, some actions have been taken that we can divide them into quality operations improvement of melt and making changes in casts. The sampling is done in four levels to evaluate the gas porosity and shrinkage. In these levels, pressure and degassing duration and strontium's modifying in a fixed temperature have been evaluated. Based on reports by comparing density of relative samples, it... 

In this study, the influence of eutectic modification, grain refining and cooling rate on amount of shrinkage porosity in aluminium A356 alloy were investigated. Modification process for changing the morphology of eutectic silicon from needle like to fibrous like, use in aluminium – silicon alloys. This process often leads to increasing porosity in melt and affect harmfully on mechanical properties. For studying shrinkage porosity, the melt degassed completely to minimizing amount of gas in the melt. For modification, strontium in Al-10Sr master alloy and sodium in NaF salt used and for grain refining Al-10Ti and Al-5Ti-1B master alloys used. To study the effect of cooling rate, three mold... 

Today, application of aluminium alloys in industries is developing. And this is because of some specification of these alloys like high proportion of the Strength per weight. One of the most useful alloys of this alloy group is A356 alloy that contain 7 % Silicon and 0.4 Percent of magnesium, this alloy because of cast ability, heat treat ability specification is use developing in air and automotive industries. But usage of this alloys combined with some difficulties like low fluidity and formation of shrinkage and gas porosities in this alloys. In present work with programmer software Visual Fortran, based on Finite difference method, a simulation model has been developed, can solve heat... 

Prevent shrinkage and porosity in the melting parts expensive attention has been cast as a piece of low cost healthy and free from defects in casting production. Calculated feeding distance and the required number of risers. Also ensure that more tests were done with computer simulation compared the results acceptable to have the cast and expensive to produce a piece has nearly no troubleshooting. Variety of factors can affect the riser effect is melting parts Read some of these factors include alloy melting, superheat and mold .... . Oxygen factor in the project as one of the molten factors between feeding distance for molten plain carbon steel melting components and parts reviews and... 

In this thesis the effects of some casting parameters on residual stress and strain in steel casting parts have been studied. An H shape model has been chosen in order to investigate effects of casting parameters such as mold and cast constraints and inhomogeneous cooling on residual stress formation during casting in sand mold. These aforementioned factors have been simulated and studied in this research. Cooling of casting parts in sand mold and coupled thermo mechanical analysis has been simulated with the help of commercial finite element package ABAQUS. The results of this study show that, the complex samples with different section area, because of mold and cast constraints and... 

Al-20Si-5Fe-3Cu-1Mg–xCr (X=0, X=1.5) ribbons were produced by melt-spinning technique at the rotating speed of 20 and 40 ms-1. The thickness of ribbons were 40 to 80 and 15 to 35 μm, respectively. The properties of as-melt spun and as-cast specimen were investigated by optical microscopy (OM), scanning electron microscopy (SEM), X-Ray diffractometry (XRD) and the microhardness method. It was found that at the air side of ribbons the microstructure was dendritic while at the wheel side it was featureless. The microstructure of ribbons at two rotating speed showed a homogenous distribution of Si particles embedded in an α-Al matrix. XRD investigations exhibited the absence of any intermetallic... 

A study has been carried out on the formation of TiB2 particles in an aluminum based in-situ metal matrix composite by mixing master alloys containing Ti and B i.e., Al-10Ti and Al-8B with a Ti:B weight ratio of 5:2. It was shown that the microstructure of the composite was greatly affected by the controlling factors of the in-situ reaction like temperature, reaction time and stirring of the melt. An increasing reaction time leads to the dissolusion of the primary phases (AlB2 and Al3Ti) and the increase in TiB2 volume fraction. Optical microscope and SEM images were used to study these changes and XRD analysis was applied to confirm these observations. The act of melt stirring in short... 

Pearlitic Ductile Iron are being used variously for producing different kinds of components in industry. For producing of Pearlitic structure in some kind of components such as crankshaft, copper and tin are being used. In many cases according to conditions and facilities of the replacement, these two elements normally have been used.Despite the fact that mostly components are influenced by the fatigue, the influence of these two elements on the fatigue properties of the components hasn’t been studied comprehensively.In this research, the influence of the copper and tin alloying elements on the fatigue limit of the Pearlitic Ductile Iron has been studied.The samples of ductile iron with... 

Real modeling of ceramic foam filters, because of their specific tortuosities is not possible and in case of possibility of real modeling of pores in filters, because of restriction of element’s dimensions, the number of elements increases and model can’t be run in a reasonable time with common computers which are accessible nowadays. The common computer simulation of filters in Computational Fluid Dynamic (CFD) and their effect on fluid flow pattern is done by use of permeability properties of porous media. In this research, ceramic foam filters which are used in casting are simulated by Forchhimer and Darcy models. SUT CAST software is used for simulation, because of its ability for... 

The use of exothermic and insulated materials is one of the most effective methods in increasing feed efficiency. In order to model performance of these materials, we need for information in connection with thermo physical properties, interface resistances and way for releasing heat in exothermic and insulated materials. Due to lack of published information in this area, the purpose of this study is for increasing information in this area and especially in the heat release in these materials. In this investigation first, physical model governing this phenomenon was found. At this stage in order to Model of heat transfer from one dimensional transient heat conduction equation, discreted by... 

In this research, solidification and microstructure of ductile cast iron was simulated using Fourier heat transfer equation. Using Fourier heat transfer equation, distribution of macroscopic temperature with heat transfer coefficient was obtained. The purpose of simulation, forecasting ductile iron microstructure, including grain size, number per unit volume of graphite (NC), microstructure including volume fractions of ferrite and pearlite and graphite phases. Knowing the phases of the microstructure and nodule count and the use of empirical relationships, we can estimate mechanical properties. In this regard, all transformations during cooling of molten ductile iron was simulated. Results... 

Aluminum alloys are one of the most economical light alloys that are used in automobile and aerospace industries. Application of Al-Si alloys are considerably used more than other Al alloys. Hypereutectic Al-Si alloys are well developed among Al-Si alloys due to their excellent properties such as high wear resistance and low thermal expansion coefficient. In these alloys formation of the primary silicon particles and hard intermetallic compounds in a ductile matrix provides a desirable wear properties. Coarsening of these particles in the structure of castings will reduce their mechanical properties. Moreover, oxidation of powders and difficulty in manufacturing complex parts in powder... 

One of the most important factors affecting the performance of the vehicle's brake disc is its stiffening coefficient. To improve this feature, many researches have been carried out by leading automotive companies, whose scientific aspects have not yet been widely disseminated. Brake discs are often made of cast iron and are more likely to produce gray iron with type A graphite. However, according to available resources, factors such as graphite morphology, their length-to-thickness ratios, cast iron and heat treatment on the piece affect this important feature. One of the most important factors that make changes in the above mentioned cases is the chemical composition and freezing rate. In... 

The computer simulation of freezing patterns in castings has done much to broaden our understanding of casting and mold system design. The structural integrity of shaped castings is closely related to the time–temperature history during solidification, and the use of casting simulation could do much to increase this knowledge in the foundry industry. However, some uncertainties must be eradicated, particularly heat transfer at the metal/mold interface. The accurate knowledge of interfacial heat transfer coefficients is necessary for accurate modeling of castings. The present work focuses on the determination of transient mold–environment and metal–mold heat transfer coefficients during...