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SHAPE CASTING: 6th International Symposium
Cover Image: Fracture surface of an AZ91 Mg alloy casting, supplied by Dr. Paul D. Eason, Associate Professor of Mechanical Engineering at the University of North Florida.
TIIS2016 145"' Annual Meeting & Exhibition
FEBRUARY 14-18 DOWNTOWN NASHVILLE
Tf NNf SSEE MUSIC CITY CENTER
New proceedings volumes from the TMS2016 Annual Meeting:
o 7th International Symposium on High-Temperature Metallurgical Processing
o CFD Modeling and Simulation in Materials Processing 2016
o Characterization of Minerals, Metals, and Materials 2016
o Energy Technology 2016: Carbon Dioxide Management and Other Technologies
o EPD Congress 2016
o light Metals 2016
o Magnesium Technology 2016
o Rare Metal Technology 2016
o REWAS2016
o Shape Casting: 6th International Symposium
o TMS 2016 Supplemental Proceedings
SHAPE CASTING: 6th International Symposium
Proceedings of a symposium sponsored by
the Aluminum Committee of the Light Metals Division
and the Solidification Committee of the Materials
Processing & Manufacturing Division of
The Minerals, Metals & Materials Society (TMS)
held during
TMS2016 145'" Annual M-tlng &. Exhibition
FEBRUARY 14-lBooWNTOWN NASHVILLE,
TENNESSEE MUSIC CITY CENTER
Edited by: Murat Tiryakioglu, Mark Jolly,
and Glenn Byczynski
Editors Murat Tiryakioglu Mark Jolly Glenn Byczynski
ISBN 978-3-319-48622-2 DOT I 0.1007/978-3-319-48166-1
Chemistry and Materials Science: Professional
ISBN 978-3-319-48166-1 ( eBook)
Copyright© 2016 by The Minerals, Metals & Materials Society Published by Springer International Publishers, Switzerland, 2016 Reprint of the original edition published by John Wiley & Sons, Inc., 2016,978-1-119-22582-9
This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made.
Printed on acid-free paper
This Springer imprint is published by Springer Nature The registered company is Springer International Publishing AG The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland
TABLE OF CONTENTS Shape Casting: 6th International Symposium
Preface ..................................................................................................................... ix Symposium Organizers/Editors .............................................................................. xi
Engineering High Quality Castings I
Bifilms and Hot Tearing of Al-Si Alloys .................................................................. 3
Muhammet Uluda*, Remzi ~etin, and Derya DiHJinar
Crack Susceptibility of Binary Aluminum Alloys: Analytical Equations .............. 11
Jiangwei Liu and Sindo Kou
The Unidirectional Solidification of Ti-46Al-8Nb Alloy with BaZr03 CoatedA120 3 Mould .............................................................................................. l9
Chao Wei, Mingyang Li, Guangyao Chen, Hongbin Wang, Xionggang Lu, and Chonghe Li
Analytical Model of Filling Fine Features and Sharp Comers in Investment Casting of CMSX-4 ............................................................................................... 27
L.P. Kroneman, M.J.M. Krane, and K.P. Trumble
Real-Time Radiography and Modeling of Porosity Formation in an A356 Aluminum Alloy Wedge Casting .................................................................. 35
Vahid Khalajzadeh, David D. Goettsch, and Christoph Beckermann
Modeling of Distortion of a Steel Bracket Sand Casting ...................................... .43 D. Galles and C. Beckermann
SiC Particle Reinforced A1 Matrix Composite by SIMA ....................................... 51 Emirhan Aydzn, Caglar Yuksel, Eray Eni, and Derya Dispinar
Evolution of Primary Fe-Rich Compounds in Secondary Al-Si-Cu Alloys ........... 59
Alberto Fabrizi, Stefano Capuzzi, and Giulio Timelli
v
Casting Perfonnance and Innovation
Methods of Reducing Materials' Waste and Saving Energy in Investment Casting ................................................................................................. 69
H.A. Mahrabi, M.R. Jolly, and K. Salonitis
Quality Assessment of A356 Ingots from Different Suppliers in
Wheel Production ................................................................................................... 77 Emre K.oca, Caglar Yukse~ Eray Erzi, and Derya Df~pznar
On the Relationship between Quality Index and Fatigue Life Distributions in B201 and D357 Alloy Aerospace Castings ............................................................ 85
Hiiseyin Ozde~ and Murat Tiryakioglu
On the Properties and Performance of Ablation Cast Components ....................... 93 Murat Tiryakiogtu and John Grassi
The Reliability of Ductile Casting Iron Dependent on Runner System Design: An Example of Support Bracket of Brake Caliper .............................................. 101
Fu-lUan Hsu, Kuo-Nien Wang, and Cheng-Lung Li
Corrosion Resistance of Stainless Steels in Biodiesel ......................................... 109 Alejandra S. Roman, Claudia M. Mendez. and Alicia E. Ares
Characterization of Tensile Deformation in AZ91D Mg Alloy Castings ............. 117 Ogtm Unal and Murat Tiryakioglu
On the Mean Stress Correction in Fatigue Life Assessment in Cast
AlunrinumAlloys ................................................................................................. 125 Hiiseyin Ozde~ and Murat Tiryakiogtu
Effects of Sr on the Microstructure of Electromagnetically Stirred Semi Solid Hypoeutectic Al-Si Alloys ................................................................................... 133
G. Eisaabadi, M. Nouri, R. Beygi, M. Zarezadeh Mehrizi, A. Nouri, and
M. Ebrahimi
Engineering High Quality Castings II
Grain Refinement of Al-Si Hypoeutectic Alloys by A13Ti1B Master Alloy and Ultrasonic Treatnlent. .................................................................................... 143
Gui Wang, Eric Qiang Wang, Arvind Prasad, Matthew Dargusch, and
David H StJohn
Vl
Influence of Process Parameters on the Microstructure and Casting Defects of a LPDC Engine Block ..................................................................................... 151
Giulio Timelli and Daniele Caliari
Preliminary Investigation of the Grain Refinement Mechanism in CuAlloys ............................................................................................................. 159
A.K. Cziegler and P. Schu11Ulcher
Solidification Analysis of a Magnesium-Zinc Alloy Using In-Situ Neutron Diffraction .............................................................................................. 167
Abdallah Elsayed, Dimitry Sediako, and Comondore Ravindran
Change in Silicon Morphology with Time and Temperature in Sr Modified A356 ................................................................................................. 175
Sadik Kaan Ipek, Caglar Yuksel, Eray Erzi, and Derya Dispinar
Effects of Casting Conditions on End Product Defects in Direct Chill Casted Hot Rolling Ingots .................................................................................... 185
Arda Yorulmaz, f;aglar Yaksel, Eraz Erzi, and Derya Dispinar
A Coupled Thermal-Stress Model of A319 Alloy Chilled Sand Casting ............ 195
Farzaneh Farhang Mehr, Steve Cockcroft, and Daan Maijer
Effect of Duration on 11 Grain Refinement of A356 and Melt Quality ............... 203
Ozen Gursoy, Eray Erzi, f;aglar YUksel, and Derya Dispinar
Author Index ........................................................................................................ 209
Subject Index ....................................................................................................... 211
Vll
PREFACE
This is the 6th in the series of International Shape Casting Symposia to be held at the annual TMS meeting and exhibition. Professor John Campbell has been on the organizing committee since the series inception in 2005 but has decided not to continue. I would like to thank John for all his work involved in the previous conferences. I am very pleased to be John's successor on the committee and it complements the role I will be taking on in February 2016 as Chair of the TMS Solidification Committee.
Over the last 10 years a wide range of topics has cropped up, some of which remain as significant aspects in the symposium. Oxide films have become hi-films, modeling is now not just fashionable but essential, and the provenance of defects will always be argued about Other topics are now becoming hot Energy in manufacturing, sustainability, and the circular economy-none of which were discussed in the first symposium-are now in everyday conversations in manufacturing plants as climate change and the overheating globe becomes more of a concern and energy process begin to rise.
The casting industry hasn't yet been hit by resource constraints, but inevitably this will come. Water, energy, and the materials we cast may well become scarcer and then we, as foundry engineers and scientists, have to work in smarter and more efficient ways with what we have. High quality and yield will be drivers for all in the sector and that can only be achieved by carrying out the research in liquid metal engineering that we all do. Understanding the science and applying it as an engineer is the only way forward in this very challenging environment.
Mark Jolly
lX
SYMPOSIUM ORGANIZERS/EDITORS
Murat Tiryaldoglu is the director of the School of Engineering and a professor of mechanical engineering at the University of North Florida. He received his B.Sc. in mechanical engineering from Bogazi~i University (1990), M.S. (1991) and Ph.D. (1993) in engineering management from the University of Missouri-Rolla, and another Ph.D in metallurgy and materials (2002), from the University of Birmingham. England.
Dr. Tiryakioglu grew up around his family's foundry, which continues to thrive in Istanbul, Turkey. This has
led to research interests in process design for high quality castings, aluminum heat treatment modeling and optimization, process-structure-property relationships in metals, statistical modeling and quality and reliability improvement, on which he has written a chapter, published over 100 technical papers, and edited nine books.
Dr. Tiryakioglu was awarded the inaugural John Campbell Medal from the Institute of Cast Metals Engineers (U.K.), and the Eugene Merchant Outstanding Young Manufacturing Engineer by the Society of Manufacturing Engineers. He was also selected a TMS Young Leader in Light Metals. He is a member of TMS, ASM International, and ASQ, and is an ASQ Certified Quality Engineer.
Mark Jolly is Professor of Sustainable Manufacturing and Head of the Sustainable Manufacturing Systems Centre at Cranfield University. He has 30 years' experience in manufacturing, process modeling, and the foundry industry as suppliers to aerospace, automotive, and medical sectors. He has a degree in metallurgy from Sheffield University and Ph.D. from Cambridge. Mark spent four years working for a tier 1 automotive supplier before spending two years in Switzerland managing industrial research contracts. Moving back to the U.K. he worked for seven years for Foseco. In 1995 he moved back into academia spending 17
years at University of Birmingham and setting up the Castings Centre and Process Modelling Group. In May 2012 he took up his current position at Cranfield. His current research is focused on reducing energy and materials usage in casting processes and glass manufacturing. Generally he has research interests in helping manufacturers improve the sustainability of their processes by improving their resource efficiency.
xi
Dr. Jolly is Chartered Engineer, a Chartered Environmentalist, a Fellow of the Institute of Materials, Minerals and Mining (IOMMM), a Fellow of the Institute of Cast Metals Engineers (ICMB) and a member of TMS and the American Foundry Society. He was the 2008 recipient of the Oliver Stubbs Gold Medal (ICME} and the University ofBirmingbam 's 2010 Josiah Mason Award for Business Achievement.
Glenn Byezyn.skl is Technical ManagerofNemak Canadian Operations. He received his Ph.D. in metallurgy and materials science from the University of Birmingham in U.K. in 2002. His masters (materials science in 1997) and bachelor's (mechanical engineering in 1994) degrees were conducted at the University of Windsor. In his 20-year career in metal casting he has held several R&D and engineering positions within Nemak and Ford Motor Company including R&D Manager ofNemak Europe based in Germany (2007-2009), manager of the Nemak Engineering Centre (Wmdsor) and Engineering Manager at
Nemak's Wmdsor Aluminum Plant. He was chairman of the Detroit-Wmdsor Chapter of the American Foundry Society (AFS} in 2006-2007, is a director and regional chairman of the Foundry Educational Foundation, and is a registered professional engineer in the Province of Ontario.
xii
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