Casting yield improvement in graphite iron castings

A well designed runner and feeding system should produce castings with minimal defects and low pour weight. This thesis investigates how the filling regime and solidification of the mould influences defects in the castings produced from that mould. Design guidelines to reduce such defects are proposed and tested. An existing shrinkage fault in a Grey Iron disc brake casting is simulated using a commercial finite-difference computer program. Three criteria are used to predict the defect and the effect of changes to the feeder geometry. Critical Fraction Solidification analysis is used to determine whether the feeder remains in liquid contact with the casting during solidification and this approach is shown to correctly predict the presence or absence of porosity* The feeder block is extended below the ingate of the casting to improve liquid contact between the casting and feeder without significantly increasing the feeder mass. Plant trials confirm the change to the feeder eliminates the porosity defect. The runner system and mould venting for a thin walled Ductile Iron casting are investigated. Trials show that by setting the total mould vent area to be greater than the net ingate area of the castings, the cold-shut frequency is halved. A method for runner system design based on peak linear flow velocity in the runner during mould filling is proposed. A new pressurised runner system produces castings with significantly fewer defects and reduced pour weight when runner areas are designed to maintain peak velocity below 1 m/s. Peak velocity and magnesium levels are demonstrated to be critical factors in the elimination of cold-shut defects. A pressurised runner system is also shown to isolate inclusion defects from castings more effectively than an unpressurised system. From this work, a technique is proposed which allows the yield of an existing runner and feeder system for iron castings to be improved with confidence in the results.

Recrystallization kinetic behavior of copper-bearing strip cast steel

In the present study, copper-bearing low carbon steels were produced by direct strip casting (DSC) method on a pilot scale. The effects of copper on mechanical, microstructural, and recrystallization behavior were investigated. As-cast microstructure mainly consists of polygonal ferrite and Widmanstatten ferrite. The increase in Cu increases the amount of Widmanstatten ferrite and induces the formation of bainite in the as-cast condition. It was found that copper increases strength and hardness by solid solution strengthening, grain refinement, and precipitation hardening and the increment is significant above 1% Cu in as-cast condition. Six different compositions were selected for recrystallization study. All the samples were cold rolled to 70% reduction and annealed at three different temperatures, 600, 650, and 700°C for various times. Recrystallization responses were strongly dependent on initial microstructure and Cu content and the effect is dramatic between 1 and 2% Cu. Recrystallization time and temperature were found to be increased with increase in copper content.