The present article deals with the possibility of using the reverse engineering method for the production of prototype molds by Patternless process technology. Article describes method how to obtain virtual model by using a 3D scanner. Article also explains principle of the Patternless process technology, which is based on the milling mold cavity using CNC machining equipment. The aim of the research is the use of advanced technologies that speed up and facilitate the process of production prototype mold. The practical result of the presented experiment is bronze casting, which serves as a foot rest bracket on historic bike.
The work deals with technology Patternless process that combines 3 manufacturing process mold by using rapid prototyping technology, conventional sand formation and 3D milling. It's unconventional technology that has been developed to produce large-sized and heavyduty castings weighing up to several tons. It is used mainly in prototype and small batch production, because eliminating production of models. The work deals with the production of blocks for making molds of gypsum and gypsum drying process technology Thermomold. Into blocks, where were made cavities by milling were casted test castings from AlSi10MgMn alloy by gravity casting. At machining of the mold cavity was varied feed rate of tool of cemented carbide. Evaluated was the surface roughness of test castings, that was to 5 micrometers with feed from 900 to 1300 mm/min. The dimensional accuracy of castings was high at feed rate of 1000 and 1500 mm/min did not exceed 0.025 mm.
The paper deals with the impact of technological parameters on the mechanical properties and microstructure in AlSi12 alloy using squeeze casting technology. The casting with crystallization under pressure was used, specifically direct squeeze casting method. The goal was to affect crystallization by pressure with a value 100 and 150 MPa. From the experiments we can conclude that operating pressure of 100 MPa is sufficient to influence the structural characteristics of the alloy AlSi12. The change in cooling rate influences the morphology of the silicon particles and intermetallic phases. A change of excluded needles to a rod-shaped geometries with significantly shorter length occurs when used gravity casting method. At a pressure of 100 MPa was increased of tensile strength on average of 20%. At a pressure of 150 MPa was increased of tensile strength on average of 30%. During the experiment it was also observed, that increasing difference between the casting temperature and the mold temperature leads to increase of mechanical properties.
Pouring of liquid aluminium is typically accompanied by disturbance of the free surface. During these disturbances, the free surface oxide films can be entrained in the bulk of liquid, also pockets of air can be accidentally trapped in this oxide films. The resultant scattering of porosity in castings seems nearly always to originate from the pockets of entrained air in oxide films. Latest version of ProCast software allows to identify the amount of oxides formed at the free surface and where they are most likely to end-up in casts. During a filling calculation, ProCast can calculate different indicators which allow to better quantify the filling pattern. The fluid front tracking indicator “ Free surface time exposure” has the units [cm2*s]. At each point of the free surface, the free surface area is multiplied by the time. This value is cumulated with the value of the previous timestep. In addition, this value is transported with the free surface and with the fluid flow.Experiments to validate this new functions were executed.
This paper deals with production of safety inlay for steam locomotive valve by the Patternless Process method. For the moulds creation was used moulding mixtures of II. generation, whereas binder was used a water glass. CNC miller was used for creation of mould cavity. Core was created also by milling into block made of moulding compound. In this article will be presented also making of 3D model, setting of milling tool paths and parameters for milling.
The paper deals with squeeze casting technology. For this research a direct squeeze casting method has been chosen. As an experimental material, the AlSi12 and AlSi7Mg0.3 alloys were used. The influence of process parameters variation (pouring temperature, mold temperature) on mechanical properties and structure will be observed. For the AlSi7Mg0.3 alloy, a pressure of 30 MPa was used and for the AlSi12 alloy 50 MPa. The thicknesses of the individual walls were selected based on the use of preferred numbers and series of preferred numbers (STN ISO 17) with the sequence of 3.15 mm, 4 mm, 5 mm, 6.3 mm and 8 mm. The width of each wall was 22 mm and length 100 mm. The mechanical properties (Rm, A5) for individual casting parameters and their individual areas of different thicknesses were evaluated. For the AlSi7Mg0.3 alloy, the percentage increase of the tensile strength was up to 37% and the elongation by 400% (at the 8 mm thickness of the casting). For the AlSi12 alloy, the strength increased from 8 to 20% and the tensile strength increased from 5 to 85%. The minimum thickness of the wall to influence the casting properties by pressure was set to 5 mm (based on the used casting parameters). Due to the effect of the pressure during crystallization, a considerable refinement and uniformity of the casting structure occured, also a reduction in the size of the eutectic silicate-eliminated needles was observed.
The paper deals with the influence of manganese in AlSi7Mg0.3 alloy with higher iron content. Main aim is to eliminate harmful effect of intermetallic – iron based phases. Manganese in an alloy having an iron content of about 0.7 wt. % was graded at levels from 0.3 to 1.4 wt. %. In the paper, the effect of manganese is evaluated with respect to the resulting mechanical properties, also after the heat treatment (T6). Morphology of the excluded intermetallic phases and the character of the crystallisation of the alloy was also evaluated. From the obtained results it can be concluded that the increasing level of manganese in the alloy leads to an increase in the temperature of the β-Al5FeSi phase formation and therefore its elimination. Reducing the amount of β-Al5FeSi phase in the structure results in an improvement of the mechanical properties (observed at levels of 0.3 to 0.8 wt. % Mn). The highest addition of Mn (1.4 wt.%) leads to a decrease in the temperature corresponding to the formation of eutectic silicon, which has a positive influence on the structure, but at the same time the negative sludge particles were also present
Main aim of submitted work is evaluation and experimental verification of inoculation effect on Al alloys hot-tear sensitivity. Submitted work consists of two parts. The first part introduces the reader to the hot tearing in general and provides theoretical analysis of hot tearing phenomenon. The second part describes strontium effect on hot tearing susceptibility, and gives the results on hot tearing for various aluminium alloys. During the test, the effect of alloy chemical composition on hot tearing susceptibility was also analyzed. Two different Al-based alloys were examined. Conclusions deals with effect of strontium on hot tearing susceptibility and confirms that main objective was achieved.
The paper deals with squeeze casting technology. For this research a direct squeeze casting method has been chosen. The influence of process parameters variation (casting temperature, mold temperature, pressure) on mechanical properties and structure will be observed. The thicknesses of the individual walls were selected based on the use of preferred numbers and series of preferred numbers (STN ISO 17) with the sequence of 3.15, 4.00, 5.00, 6.00 and 8.00 mm. The width of each wall was 22 mm with a length of 100 mm. As an experimental material was chosen the AlSi12 and AlSi7Mg0.3 alloys. The mechanical properties (UTS, E) for individual casting parameters and their individual areas of different thicknesses were evaluated. In the structure the influence of pressure on the change of the eutectic morphology, the change of the volume of eutectic and the primary alpha phase, the effect of the pressure on the more fine-grain and the regularization of the structure were evaluated.
The paper deals with the impact of technological parameters on the heat transfer coefficient and microstructure in AlSi12 alloy using squeeze casting technology. The casting with crystallization under pressure was used, specifically direct squeeze casting method. The goal was to affect crystallization by pressure with a value 100 and 150 MPa. The pressure applied to the melt causes a significant increase of the coefficient of heat transfer between the melt and the mold. There is an increase in heat flow by approximately 50% and the heat transfer coefficient of up to 100-fold, depending on the casting conditions. The change in cooling rate influences the morphology of the silicon particles and intermetallic phases. A change of excluded needles to a rod-shaped geometry with significantly shorter length occurs when used gravity casting method. By using the pressure of 150 MPa during the crystallization process, in the structure can be observed an irregular silica particles, but the size does not exceed 25 microns.
Casting industry has been enriched with the processes of mechanization and automation in production. They offer both better working standards, faster and more accurate production, but also have begun to generate new opportunities for new foundry defects. This work discusses the disadvantages of processes that can occur, to a limited extend, in the technologies associated with mould assembly and during the initial stages of pouring. These defects will be described in detail in the further part of the paper and are mainly related to the quality of foundry cores, therefore the discussion of these issues will mainly concern core moulding sands. Four different types of moulding mixtures were used in the research, representing the most popular chemically bonded moulding sands used in foundry practise. The main focus of this article is the analysis of the influence of the binder type on mechanical and thermal deformation in moulding sands.