Shape Casting: 7th International Symposium Celebrating Prof. John Campbell's 80th Birthday PDF
Preview Shape Casting: 7th International Symposium Celebrating Prof. John Campbell's 80th Birthday
SHAPE CASTING: 7th International Symposium Celebrating Prof. John Campbell’s 80th Birthday EDITED BY Murat Tiryakiog˘lu, William Griffiths, and Mark Jolly The Minerals, Metals & Materials Series ğ fi Murat Tiryakio lu William Grif ths (cid:129) (cid:129) Mark Jolly Editors Shape Casting 7th International Symposium Celebrating ’ Prof. John Campbell s 80th Birthday 123 Editors Murat Tiryakioğlu William Griffiths University of NorthFlorida University of Birmingham Jacksonville, FL,USA Birmingham, UK Mark Jolly Cranfield University Cranfield,UK ISSN 2367-1181 ISSN 2367-1696 (electronic) TheMinerals, Metals& Materials Series ISBN978-3-030-06033-6 ISBN978-3-030-06034-3 (eBook) https://doi.org/10.1007/978-3-030-06034-3 LibraryofCongressControlNumber:2018964679 ©TheMinerals,Metals&MaterialsSociety2019 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpart 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 orinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilar methodologynowknownorhereafterdeveloped. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfrom therelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. The publisher, the authors, and the editorsare safeto assume that the adviceand informationin this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authorsortheeditorsgiveawarranty,expressorimplied,withrespecttothematerialcontainedhereinor for any errors or omissions that may have been made. The publisher remains neutral with regard to jurisdictionalclaimsinpublishedmapsandinstitutionalaffiliations. Coverillustration:FromCao,Xinjin,“HeatTreatmentofLiquidMetal:PrecipitationandSedimentation Processing of Liquid Al-11.5Si-0.4Mg Cast Alloy”, Ph.D. Thesis, University of Birmingham, 2001; Supervisor:Prof.JohnCampbell ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSwitzerlandAG Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland Preface This is seventh in the series of International Shape Casting Symposia held at the TMS Annual Meeting. The 2019 symposium has been organized to celebrate the 80th birthday of Prof. John Campbell, who served on the organizing committee between2005and2015.ProfessorCampbellhasbeenastrongadvocateforsolving the challenges facing the casting industry through the scientific method and incorporating physical fundamentals into solutions. He has been not only the leadingexpertoncastingsworldwide,butalsoanadvisor,ateacher,amentor,anda friend to many of us working on castings. Overall, he has been an inspiration for thoseofuswhotrytomakeacontributiontothefield.John,thankyouforallyou have done. Happy 80th birthday! As in previous volumes, we continue to explore the leading edge technologies and the latest innovations in casting process design and quality improvements relative to shape casting through presentations by researchers from around the world. We have given special emphasis to the contributions of Prof. Campbell, especially bifilms in castings. Murat Tiryakioğlu Lead Organizer v Contents Part I Entrainment and Bifilms Update on Bifilms—The Fundamental Defect in Metals. . . . . . . . . . . . . 3 John Campbell Entrainment Defects in Cast Iron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Zakareya Nashwan and W. D. Griffiths Measurement of Air Entrainment During Pouring of an Aluminum Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Lucas Archer, F. V. Guerra and Christoph Beckermann Connecting Oxide Bifilms’ Properties from Atomistic Simulations with Virtual Casting of Aluminum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Jialin Liu, Qigui Wang and Yue Qi Numerical Process Modelling and Simulation of Campbell Running Systems Designs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Chengcheng Lyu, Michail Papanikolaou and Mark Jolly Synchrotron X-Ray Real-Time Studies of the Nucleation and Growth of Intermetallic Phases in Solidification . . . . . . . . . . . . . . . 65 Jiawei Mi Determination of Liquid Metal Quality with Deep Etching Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Furkan Tezer, Özen Gürsoy, Eray Erzi, Mert Zorağa and Derya Dışpınar Effect of Fe-Rich Intermetallics on Tensile Behavior of Al–Cu 206 Cast Alloys at Solid and Near-Solid States. . . . . . . . . . . . 85 K. Liu, X. Cao, A. Bolouri and X.-G. Chen vii viii Contents Part II Casting Defects and Their Characterization Determining Casting Defects in Thixomolding Mg Casting Part by Computed Tomography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Jiehua Li, Bernd Oberdorfer and Peter Schumacher The Effect of the Addition of Transition Metals on Double Oxide Film Defects in an Al–Si–Mg Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 W. D. Griffiths, A. J. Caden and Q. Chen On Estimating Largest Defects in Castings . . . . . . . . . . . . . . . . . . . . . . 115 Murat Tiryakioğlu and Irisi Nini Ti Grain Refinement Myth and Cleanliness of A356 Melt . . . . . . . . . . . 125 Özen Gürsoy, Eray Erzi and Derya Dışpınar On the Effects of Defects and Imperfections on Tensile Toughness of a Secondary Aluminium Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Jakob Olofsson, Anton Bjurenstedt and Salem Seifeddine The Myth of Hydrogen Pores in Aluminum Castings. . . . . . . . . . . . . . . 143 Murat Tiryakioğlu Casting Defect Analysis on Fracture Surface of 356 Aluminium Alloy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Özen Gürsoy, Eray Erzi and Derya Dispinar Investigation of Casting Quality Change of A356 by Duration in Liquid State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Muhammet Uludağ, Mikdat Gurtaran and Derya Dispinar Characterization of the Effect of Sr and Ti on Liquid Quality in Al8Si3Cu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Muhammet Uludağ, Derya Dispinar and Murat Tiryakioğlu Part III Process Innovation and Modelling The Nemak Cosworth Casting Process Latest Generation . . . . . . . . . . . 179 Glenn Byczynski and Robert Mackay Campbellology for Runner System Design . . . . . . . . . . . . . . . . . . . . . . . 187 Fu-Yuan Hsu A Solidification Model with Application to AlSi-Based Alloys . . . . . . . . 201 Adrian V. Catalina, Liping Xue and Charles A. Monroe Physical Modeling of Transport Phenomena in Asymmetrical Multi-strand Tundish with Retaining Wall. . . . . . . . . . . . . . . . . . . . . . . 215 Wei Xiao and Yanping Bao Contents ix The Validation of Feeder Modeling for Ductile Iron Castings . . . . . . . . 227 Fu-Yuan Hsu and Yu-Hung Chen The Contactless Electromagnetic Sonotrode. . . . . . . . . . . . . . . . . . . . . . 239 Koulis A. Pericleous, Valdis Bojarevics, Georgi Djambazov, Agnieszka Dybalska, William Griffiths and Catherine Tonry Simulation Analysis Techniques for Investment Casting Process of Ni-Base Superalloy Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Kosuke Fujiwara, Hidetaka Oguma, Masaki Taneike, Ikuo Okada, Kyoko Kawagishi, Tadaharu Yokokawa and Hiroshi Harada ImprovementinMetallurgicalPropertiesofGravityDieCast2024-T6 Aluminum Alloy via Cryogenic Process . . . . . . . . . . . . . . . . . . . . . . . . . 263 Engin Tan, Sinan Aksöz, Yavuz Kaplan, Hilal Can and Derya Dışpınar Melt Cleaning Efficiency of Various Fluxes for A356 Alloy . . . . . . . . . . 273 Çağlar Yüksel, Uğur Aybarc, Eray Erzi, Derya Dispinar and Mustafa Cigdem Part IV Properties of Castings Characterisation of Lead Sheet Manufactured Using Traditional Sand-Casting Technique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 Arun Prabhakar, Konstantinos Salonitis and Mark Jolly On the Intrinsic and Extrinsic Microstructure-Property Effects in Cast Aluminum Alloys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 Murat Tiryakioğlu Measurement of Residual Strain in the Cylinder Bridge of High- Pressure Die Cast A383 Engine Blocks Using Neutron Diffraction. . . . . 303 T. Liu, L. N. Brewer, Jeffrey R. Bunn, Chris M. Fancher, L. Nastac, V. Arvikar and I. Levin Relation Between Microstructure and Tensile Properties of V and B Added Al-7Si Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Özkan Kesen, Ahmet Can Filiz, Selim Temel, Özen Gürsoy, Eray Erzi and Derya Dispinar The Effect of Friction Stir Processing on Bifilms and Structural Quality in A356 Alloy Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 Nelson Netto, Murat Tiryakioğlu, Paul D. Eason, Boğaçhan Őndeş and Eray Erzi Effect of Copper and Nickel Addition on Mechanical Properties of A356 Alloy and Assessment of Mechanism of Pore Formation . . . . . 329 Kerim Yildirim, Johannes Brachmann, Derya Dispinar, Andreas Bührig-Polaczek and Uwe Vroomen x Contents Aluminum Alloy with High Mg Content: Casting Studies for Microstructural Evolution, Phase Formation and Thermophysical Properties with Different Alloying Elements. . . . . . . . . . . . . . . . . . . . . . 337 Armagan Gul, Özen Gürsoy, Eray Erzi, Derya Dispinar and Eyup Kayali Correlation Between Melt Quality and Machinability of Al9Si3Cu HPDC Alloy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 Ibrahim Halil Kalkan, Omer Vardar, Ibrahim Göksel Hızlı, Eray Erzi, Ozen Gürsoy and Derya Dışpınar Change in Sr Modification by Duration and Its Effect on Mechanical Properties of A360 and A413 Alloy . . . . . . . . . . . . . . . . 353 Inal Kaan Duygun, Ozen Gursoy, Eray Erzi and Derya Dispinar Part V Poster Session Aluminum Matrix Graphene-Reinforced Composite Materials . . . . . . . 365 Okan Aydın, Aziz Kocaveli, Özen Gürsoy, Eray Erzi and Derya Dışpınar Influence of Melt Quality on the Fluidity of AlSi12Fe . . . . . . . . . . . . . . 373 İbrahim Göksel Hızlı, Meltem Salkır, İbrahim Halil Kalkan and Derya Dışpınar Author Index.. .... .... .... ..... .... .... .... .... .... ..... .... 381 Subject Index.. .... .... .... ..... .... .... .... .... .... ..... .... 383 About the Editors Murat Tiryakioğlu is a Professor of Mechanical Engineering and Advanced Manufacturing and Materials Innovation at the University of North Florida. He received his B.Sc. in mechanical engineer- ing from Boğaziçi University (1990); M.S. (1991) and Ph.D. (1993) in engineering management from the University of Missouri, Rolla; and another Ph.D. in metallurgyandmaterials (2002)fromtheUniversityof Birmingham, England. He 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 opti- mization, process–structure–property relationships in metals, and statistical modeling and quality and relia- bility improvement, on which he has written a chapter, published over 100 technical papers, and edited ten books. HewasawardedtheinauguralJohnCampbellMedal, from the Institute of Cast Metals Engineers (UK), and the Eugene Merchant Outstanding Young Man- ufacturing 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,andASQandisanASQCertifiedQuality Engineer. xi
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