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| 1 | Advanced casting technologies for lightweight automotive applications显示文摘This paper provides an overview of alloy and process developments in aluminum and magnesium castings for lightweight automotive applications. Wear-resistant aluminum alloys, creep-resistant and high strength/ductility magnesium alloys have been developed for automotive applications. On the process front, vacuumassisted die casting and high vacuum die casting technologies have been developed for high-integrity body and chassis applications. Thin-wall and hollow casting components are being produced by low-pressure die casting processes for structural applications. Overcasting technology is gaining traction and has enabled mixed material designs for automotive sub-systems such as engine cradles and instrument panel beams. Simulation tools developed to predict the interfacial interactions of the dissimilar components and the structural integrity of the overcast systems are being validated in the casting trials. | Alan A.Luo Anil K.Sachdev Bob R.Powell | 2010 | China Foundry2010，7，4： | 29 |
| 2 | Application and study in aluminum melt degassing technologies显示文摘The classification, characteristics and current situation of aluminum melt hydrogen-removal methods and technologies have been summarized. The latest studies and research results of aluminum melt degassing technology have been summed up. The tendency and prospect of aluminum degassing technology was discussed. | ~*H. J. Ni~(1,2), M. Y. Huang~1, Y. Zhu~1, P. Liao~1, R. Z. WU~2, B. D. Sun~2(1. Department of Mechanical Engineering, Nantong Institute of Technology, Nantong 226007, Jingsu, P. R. China 2. School of Material Science and Engineering, Shanghai Jiaotong University, Shanghai 200030, P. R. China) | 2004 | China Foundry2004，1，S1： | 27 |
| 3 | Microstructure and mechanical properties of NZ30K alloy by semi-continuous direct chill and sand mould casting processes显示文摘The Mg-3.0Nd-0.2Zn-0.4Zr (NZ30K) alloys were prepared by direct-chill casting (DCC) and sand mould casting (SMC) processes,respectively and their microstructures and mechanical properties were investigated.The results indicate that casting method plays a remarkable influence on the microstructure and mechanical properties of as-cast NZ30K alloy.The grain size increases from 35-40μm in the billets made by the DCC to about 100-120μm in the billets by the SMC.The aggregation of Mg12Nd usually found at the triple joints of grain boundaries in the billets prepared by SMC while is not observable from the billets by DCC.The tensile strengths and elongations of the billets are 195.2 MPa and 15.5% by DCC,and 162.5 MPa and 3.2% by SMC,respectively.The tensile strength of the alloy by DCC is remarkably enhanced by T6 heat treatment,which reached 308.5 MPa.Fracture surfaces of NZ30K alloy have been characterized as intergranular fracture by SMC and quasi-cleavage fracture by DCC,respectively. | Zheng Xingwei Dong Jie Liu Wencai Ding Wenjiang | 2011 | China Foundry2011，8，1： | 25 |
| 4 | The role and impact of 3D printing technologies in casting显示文摘3D printing is such a magical technology that it extends into almost every sector relating to manufacturing, not to mention casting production. In this paper, the past, present and future of 3D printing in the foundry sector are profoundly reviewed. 3D printing has the potential to supplement or partially replace the casting method. Today, some castings can be directly printed by metal powders, for example, titanium alloys, nickel alloys and steel parts. Meanwhile, 3D printing has found an unique position in other casting aspects as well, such as printing the wax pattern, ceramic shell, sand core, sand mould, etc. Most importantly, 3D printing is not just a manufacturing method, it will also revolutionize the design of products, assemblies and parts, such as castings, patterns, cores, moulds and shells in casting production. The solid structure of castings and moulds will be redesigned in future into truss or spatially open and skeleton structures. This kind of revolution is just sprouting, but it will bring unimaginable impact on manufacturing including casting production. Nobody doubts the potential of 3D printing technologies in manufacturing, but they do have limitations and drawbacks. | Jin-wu Kang Qiang-xian Ma | 2017 | China Foundry2017，14，3： | 18 |
| 5 | Effects of laser energy density on forming accuracy and tensile strength of selective laser sintering resin coated sands显示文摘Baozhu sand particles with size between 75 μm and 150 μm were coated by resin with the ratio of 1.5 wt.% of sands. Laser sintering experiments were carried out to investigate the effects of laser energy density(E = P/v), with different laser power(P) and scanning velocity(v), on the dimensional accuracy and tensile strength of sintered parts. The experimental results indicate that with the constant scanning velocity, the tensile strength of sintered samples increases with an increase in laser energy density; while the dimensional accuracy apparently decreases when the laser energy density is larger than 0.032 J·mm-2. When the laser energy density is 0.024 J·mm-2, the tensile strength shows no obvious change; but when the laser energy density is larger than 0.024 J·mm-2, the sample strength is featured by the initial increase and subsequent decrease with simultaneous increase of both laser power and scanning velocity. In this study, the optimal energy density range for laser sintering is 0.024-0.032 J·mm-2. Moreover, samples with the best tensile strength and dimensional accuracy can be obtained when P = 30-40 W and v = 1.5-2.0 m·s-1. Using the optimized laser energy density, laser power and scanning speed, a complex coated sand mould with clear contour and excellent forming accuracy has been successfully fabricated. | Xu Zhifeng Liang Pei Yang Wei Li Sisi Cai Changchun | 2014 | China Foundry2014，11，3： | 17 |
| 6 | Research and application of enterprise resource planning system for foundry enterprises显示文摘PPDB issues-four aspects of current management issues of foundry enterprises are discussed in this paper,including Production Management,Process Control,Duration Monitoring and Business Intelligence Data Analysis.Also a whole Enterprise Resource Planning(ERP) solution for foundry enterprises is proposed.The solution contains many models,four of which are used to solve the PPDB issues.These are called SPDB models,which separately are the Single-piece management model(based on casting lifecycle),Process management model(based on task-driven technology),Duration monitoring model(based on surplus period),and Business intelligence data analysis model(based on data mining).An ERP system for foundry enterprises,named HZERP,was researched and developed,and applied to a sand casting company of single piece and small batch production.Qualitatively and quantitatively comparing the application effect before and after implementing the HZERP system,the result demonstrated that the foundry ERP system based on the SPDB models can help metal casting enterprises achieve the single-piece management,better regulate the production processes,improve production and delivery management,shorten the production cycle,reduce costs,and speed up the capital turnover to a large extent. | Zhou Jianxin Ji Xiaoyuan Liao Dunming Guan Bifeng Guan Bihong Pang Shengyong Tang Hongtao | 2013 | China Foundry2013，10，1： | 16 |
| 7 | Development of vacuum die-casting process显示文摘The vacuum die-casting process,started 25 years ago in Japan,has been widely applied.This technology contributes very much to improvement of castings quality.The main factor causing the defects of die castings is the trapped air in the mold cavity,while the key technology of vacuum die-casting process is to avoid the trapped air effectively by evacuating the cavity before casting.At the same time,due to the shot speed and the casting pressure reduced in half,the service life of the die is prolonged and the productivity is enhanced,as well.Vacuum die-casting process is of great signif icance in improving the die castings quality and making up the shortcomings of super-high-speed shot casting. | Masashi Uchida | 2009 | China Foundry2009，6，2： | 15 |
| 8 | Microstructure characteristics and solidification behavior of wrought aluminum alloy 2024 rheo-diecast with self-inoculation method显示文摘One important problem in casting wrought aluminum alloys is the high tendency to the formation of hot tears in the solidification process.By using semi-solid metal(SSM) processing,the hot tearing tendency of alloys can be minimized during casting.In the present research,the semi-solid slurry of wrought aluminum alloy 2024 was firstly prepared with a novel self-inoculation method(SIM),and then the microstructure characteristics of the semi-solid slurry and the rheo-diecastings cast with the semi-solid slurry were investigated.The results indicate that finer and more uniform globular primary α-Al particles can be obtained when the semi-solid slurry are isothermally held for a short period within the semi-solid temperature range,and the primary α-Al particles without entrapped liquid are uniformly fine,globular grains in the rheo-diecastings.The holding temperature and time affect the solid fraction,particle size,and shape factor.After the semi-solid slurry is held at 625 ℃ for 3 min and 5 min,the optimal values for the average equivalent diameter are 70.80 μm and 74.15 μm,and for the shape factor are 1.32 and 1.42,respectively.The solidification process of the rheo-diecastings is composed of the following two distinct stages:primary solidification process and secondary solidification process.The secondary solidification process consists further of the following three stages:(1) direct growth of secondary primary(α 2) phase from the surface of the primary α-Al phase particles without re-nucleation,(2) independent nucleation and growth of α 3 phase from the residual liquid,and(3) eutectic reaction at the end. | Li Yanlei Li Yuandong Li Chun Wu Huihui | 2012 | China Foundry2012，9，4： | 15 |
| 9 | Gating system optimization of low pressure casting A356 aluminum alloy intake manifold based on numerical simulation显示文摘To eliminate the shrinkage porosity in low pressure casting of an A356 aluminum alloy intake manifold casting, numerical simulation on fi lling and solidifi cation processes of the casting was carried out using the ProCAST software. The gating system of the casting is optimized according to the simulation results. Results show that when the gating system consists of only one sprue, the fi lling of the molten metal is not stable; and the casting does not follow the sequence solidifi cation, and many shrinkage porosities are observed through the casting. After the gating system is improved by adding one runner and two in-gates, the fi lling time is prolonged from 4.0 s to 4.5 s, the fi lling of molten metal becomes stable, but this casting does not follow the sequence solidifi cation either. Some shrinkage porosity is also observed in the hot spots of the casting. When the gating system was further improved by adding risers and chill to the hot spots of the casting, the shrinkage porosity defects were eliminated completely. Finally, by using the optimized gating system the A356 aluminum alloy intake manifold casting with integrated shape and smooth surface as well as dense microstructure was successfully produced. | Jiang Wenming Fan Zitian | 2014 | China Foundry2014，11，2： | 14 |
| 10 | Effect of ultrasonic melt treatment on degassing of Mg-6Zn-1Ca alloy显示文摘The effect of ultrasonic power and treatment time on degassing of Mg-6Zn-1Ca alloy was studied in this paper. The degassing effect was characterized by measuring densities of ingots. The results show that proper ultrasonic treatment can remove hydrogen from the melt of the Mg-6Zn-1Ca alloy. The ultrasonic degassing effect is closely related to the ultrasonic power density and treatment time. The degassing efficiency increases with an increase in ultrasonic power density when the melt is treated at 690 °C for 120 s, reaching its highest value at 1.2 W·cm-3. When the power density is 1.2 W·cm-3, with an increase in ultrasonic treatment time, the degassing efficiency increases at first, reaches its peak value at 120 s, then decreases as the ultrasonic treatment is further prolonged. In this experiment, the optimum degassing effect with an efficiency of 67.5 % is obtained by ultrasonic treatment with the power density of 1.2 W·cm-3 for 120 s. The maximum density of ingot can be increased from 1.8069 g·cm-3 to 1.8146 g·cm-3(increased by 0.43%). | Zheng Jia Wen-ming Zhang Fu Yang Zhi-qiang Zhang Qi-chi Le Jian-zhong Cui | 2015 | China Foundry2015，12，1： | 14 |
| 11 | Digital management technology and its application to investment casting enterprises显示文摘With the advent of Industry 4.0, more and more investment casting enterprises are implementing production manufacturing systems, especially in the last two years. This paper summarizes three new common requirements of the digital management aspect in precision casting enterprises, and puts forward three corresponding techniques. They are: the production process tracking card technology based on the main-sub card mode; the workshop site production process processing technology based on the barcode; and the equipment data integration technology. Then, this paper discusses in detail the principle, application and effect of these technologies; to provide the reference for enterprises to move towards digital casting and intelligent casting. | Xiao-yuan Ji Hu Ye Jian-xin Zhou Wei-lin Deng | 2016 | China Foundry2016，13，5： | 14 |
| 12 | Recent development of ductile cast iron production technology in China显示文摘Recent progress in the production and technology of ductile cast iron castings in China is reviewed. The manufacture and process control of as-cast ductile iron are discussed. The microstructure, properties and application of partial austenitization normalizing ductile iron and austempered ductile iron (ADI) are briefly depicted. The new development of ductile iron production techniques, such as cored-wire injection (wire-feeding nodularization) process, tundish cover ladle nodularizing process, horizontal continuous casting, and EPC process (lost foam) for ductile iron castings, etc., are summarized. | Cai Qizhou Wei Bokang | 2008 | China Foundry2008，5，2： | 13 |
| 13 | Tensile properties of high strength cast Mg alloys at room temperature:A review显示文摘As most Mg alloy products are now produced by a casting process,the development of high strength cast Mg alloys can promote their further applications and has already become one of the hot research areas of Mg alloys.The present paper reviews the strengthening mechanisms,tensile properties and modification results of commercial high strength cast Mg alloys;as well as the development of Mg-Gd,Mg-Nd and Mg-Sn based alloys.It concludes that precipitation strengthening is the most important strengthening mechanism in high strength cast Mg alloys,which contributes more than 60%of yield strength in solution&peak-aged(T6)cast Mg alloys.For the yield strength,the alloys follow the sequence of Mg-Gd(Y)-Ag>Mg-Gd(Y)-Zn>Mg-Gd-Y/Sm/Nd>Mg-Y-Nd(WE series)>ZK61>Mg-Nd>AZ91>Mg-Sn.Mg-Gd(Y)-Ag based alloys are the strongest cast Mg alloys at present,followed by Mg-Gd(Y)-Zn based alloys.The high yield strengths of Mg-Gd(Y)-Ag and Mg-Gd(Y)-Zn cast alloys are due to the co-precipitation of basal and prismatic meta-stable phases. | Fu Penghuai Peng Liming Jiang Haiyan Ding Wenjiang Zhai Chunquan | 2014 | China Foundry2014，11，4： | 12 |
| 14 | Development tendencies of moulding and core sands显示文摘Further development of the technology for making moulding and core sands will be strictly limited by tough requirements due to protection of the natural environment. These tendencies are becoming more and more tense, so that we will reach a point when even processes, that from technological point of view fulfill high requirements of the foundry industry, must be replaced by more ecologically-friendly solutions. Hence, technologies using synthetic resins as binding materials will be limited. This paper presents some predictable development tendencies of moulding and core sands. The increasing role of inorganic substances will be noticed, including silicate binders with significantly improved properties, such as improved knock-out property or higher reclamation strength. Other interesting solutions might also be moulding sands bonded by geo-polymers and phosphate binders or salts and also binders based on degradable biopolymers. These tendencies and the usefulness of these binders are put forward in this paper. | Stanisaw M.Dobosz Petr Jelinek Katarzyna Major-Gabry | 2011 | China Foundry2011，8，4： | 11 |
| 15 | Tensile behavior of Ti-6Al-4V alloy fabricated by selective laser melting: effects of microstructures and as-built surface quality显示文摘Selective laser melting(SLM) is a powerful additive manufacturing(AM) technology, of which the most prominent advantage is the ability to produce components with a complex geometry. The service performances of the SLM-processed components depend on the microstructure and surface quality. In this work, the microstructures, mechanical properties, and fracture behaviors of SLM-processed Ti-6 Al-4 V alloy under machined and as-built surfaces after annealing treatments and hot isostatic pressing(HIP) were investigated. The microstructures were analyzed by optical microscope(OM), scanning electron microscope(SEM) and transmission electron microscopy(TEM). The mechanical properties were measured by tensile testing at room temperature. The results indicate that the as-deposited microstructures are characterized by columnar grains and fine brittle martensite and the asdeposited properties present high strength, low ductility and obvious anisotropy. After annealing at 800-900°C for 2-4 h and HIP at 920°C/100 MPa for 2 h, the brittle martensite could be transformed into ductile lamellar(α+β) microstructure and the static tensile properties of SLM-processed Ti-6 Al-4 V alloys in the machined condition could be comparable to that of wrought materials. Even after HIP treatment, the as-built surfaces could decrease the ductility and reduction of area of SLM-processed Ti-6 Al-4 V alloys to 9.2% and 20%, respectively. The crack initiation could occur at the columnar grain boundaries or at the as-built surfaces. The lamellar(α+β) microstructures and columnar grains could hinder or distort the crack propagation path during tensile tests. | pan tao huai-xue li bai-ying huang quan-dong hu shui-li gong qing-yan xu | 2018 | China Foundry2018，15，4： | 11 |
| 16 | Influencing factors on as-cast and heat treated 400-18 ductile iron grade characteristics显示文摘As-cast and heat-treated 400-18 ductile iron(DI)grade was obtained in different foundry conditions,as metallic charge,Mg-treatment alloy and inoculation.It was found that the Pearlitic Influence Factor(Px)and Anti-nodulizing Complex Factor(K1)have an important influence on property of DI,depending on the Mn and P level,the metallurgical quality of iron melt,rare earth(RE)and inoculation.It was also found that the influence of Mn is depended on the phosphorus and residual elements level in ductile iron.Less than 0.03%P and 0.2%Mn and Px<2.0 are the basic conditions to obtain as-cast ferritic structure.At the same lower level of Mn and P,the increasing of residual elements(Px>2.0)determines presence of pearlite in as-cast structure,while ferrite structure is obtained after a short annealing heat treatment.Lower level of phosphorus(P<0.025%)and residual elements(Px<2.0)allow to use relative high Mn content(0.32%-0.38%),in condition of ferritic structure,including in as-cast state.High P(0.04%-0.045%)and Mn(0.25%-0.35%)content stabilized pearlite,especially at lower level of residual elements(Px <2.0).Anti-nodulizing action of elements was counteracted up to K1=2.0 level,by RE included in Mg-treatment alloy,which are beneficial for K1<1.2 and compulsory for K1>1.2.Si has a significant influence on the mechanical properties of heat treated ductile irons:an important decreasing of elongation level and a moderate increasing of yield and tensile strength and their ratio in 150-170 HB typical hardness field.A typical final chemical composition for as-cast 400-18 ductile iron could include 3.5%-3.7%C,2.4%-2.5%Si,max.0.18%Mn,max.0.025%P,max.0.01%S,0.04%-0.05%Mgres.for Px<1.5 and K1<1.1.High purity pig iron,RE-bearing FeSiMg and powerful inoculant are also recommended. | I.Riposan M.Chisamera S.Stan | 2007 | China Foundry2007，4，4： | 11 |
| 17 | Formation law and criterion of nebulous macroscopic segregation in ZL205A alloy castings显示文摘The appearance of macroscopic segregation in ZL205A alloy castings bears a super resemblance to theappearance of shrinkage porosity, and the chemical composition of the segregation is Al2Cu whose microstructure isin the form of dentrite or skeleton crystal. According to the characteristic of nebulous segregation, the formationprocess could be divided into two steps by the eutectic temperature of Al2Cu. Then a criterion for each of the twosteps is brought forward on the basis of the shrinkage porosity criterion of low pressure casting. | Li Yusheng Zhai Hu Feng Zhijun Qu Xuahui | 2008 | China Foundry2008，5，1： | 11 |
| 18 | Numerical simulation of low pressure die-casting aluminum wheel显示文摘The FDM numerical simulation software,ViewCast system,was employed to simulate the low pressure die casting(LPDC)of an aluminum wheel.By analyzing the mold-filling and solidification stage of the LPDC process,the distribution of liquid fraction,temperature field and solidification pattern of castings were studied.The potential shrinkage defects were predicted to be formed at the rim/spoke junctions,which is in consistence with the X-ray detection result.The distribution pattern of the defects has also been studied.A solution towards reducing such defects has been presented.The cooling capacity of the mold was improved by installing water pipes both in the side mold and the top mold.Analysis on the shrinkage defects under forced cooling mode proved that adding the cooling system in the mold is an effective method for reduction of shrinkage defects. | Mi Guofa Liu Xiangyu Wang Kuangfei Fu Hengzhi | 2009 | China Foundry2009，6，1： | 11 |
| 19 | Manufacture technique of semi-solid slurry of hypoeutectic Al-Si alloy by low superheat pouring and weak electromagnetic stirring显示文摘The semi-solid slurry of hypoeutectic Al-Si alloy was manufactured by low superheat pouring and weak electromagnetic stirring. The effects of pouring temperature and stirring power on the semi-solid slurry making process were investigated. The results indicate that the semi-solid slurry to satisfy rheocasting requirement can be made by a combination of low superheat pouring and weak electromagnetic stirring. The pouring temperature (or superheat) and the stirring power significantly affect the morphology and the size of primary α-Al, while there is no obvious effect of the stirring time on primary α-Al. Compared with the samples made by low superheat pouring without stirring, the nucleation rate, particle morphology and grain size of primary α-Al in A356 Al alloy are markedly improved by a process of applying both low superheat pouring and weak electromagnetic stirring. Under the condition of weak electromagnetic stirring applied, the pouring temperature with low superheat can be equivalently to reach the effectiveness obtained from the even lower pouring temperature without stirring. | LIU Zheng MAO Wei-ming ZHAO Zheng-duo | 2006 | China Foundry2006，3，2： | 11 |
| 20 | Effects of hot top pulsed magneto-oscillation on solidification structure of steel ingot显示文摘Achieving a uniform structure with few defects in heavy steel ingot is of high commercial importance. In this present work, in order to verify the potential of pulsed magneto-oscillation(PMO) applied in the production of heavy ingot, an induction coil was located at the hot top of the steel ingot to develop a novel technique, named hot top pulsed magneto oscillation(HPMO). The influences of HPMO on the solidification structure, macro segregation and compactness of a cylindrical medium carbon steel ingot with the weight of 160 kg were systematically investigated by optical microscope(OM) and laser induced breakdown spectroscopy original position metal analyzer(LIBSOPA-100). The results show that HPMO not only causes significant grain refinement and promotes the occurrence of columnar to equiaxed transition(CET) but also can homogenize the carbon distribution and enhance the compactness of the steel ingot. Therefore, HPMO technique has the potential to be applied in the production of heavy steel ingots on an industrial scale. | Hui-cheng Li Yu-xiang Liu Yun-hu Zhang Zhen Liu Qi-jie Zhai | 2018 | China Foundry2018，15，2： | 11 |
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