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The porosity casting defects in aluminum

The database was developed pyrolysis pattern property using the pyrolysis Pattern apparatus. The database for materials currently used pattern covered in detail in REPORT NO. 527985-2004 – Project Final Report submitted by DOE CONTRACT N0. DE-FC07-99ID13840. The data include gas fraction, liquid fraction, energy consumption, and pressure for different velocities, foam densities and temperatures. This was considered to be complete database; However, further evaluations were performed on patterns with different levels of three types of additives in the current program. Was meant to focus the effort to maximize the effect of different amounts of additives reduce the molecular weight of patterns.

It was intended to properties of data that GM could use the code provided. Given that the pyrolysis Pattern apparatus was idle for hours entended (2001 to 2005) the device was inspected and recalibrated. Experiments were expanded polystyrene (EPS) of 0.75 bars. Wide, 1.5 in. Tall, and 20 to 24 in. Long to about 1.4 PCF density. The bars were modeled using three types of add-ons developed by GM R & D (GM Research and Development Center) (see Table 1.2.1) and two levels of molecular weight. Add bromide used in producing beads functions to reduce the molecular weight more rapidly during heating, hence the viscosity of the liquid pyrolysis products are moved to the shield more quickly. Experience has shown that plug foundry bromide in the amount of 0.36% significantly reduced times and defects in aluminum casting porosity.

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Casting to avoid defects being introduced

Another process involving intense heat, precautions must be taken to make the cut at a sufficient distance from the body of the casting to avoid defects being introduced in casting due to local heating. Such an operation must be done before the final heat treatment. 10.3 in the case of casting prove defective causes of foundry in preparation, machining or erection, such casting may be rejected notwithstanding any previous certification test andtor satisfactory inspection.

NOTES 1 the austenitization temperature relatively high in combination with a content of high canses of labeled carbon decarburization of surface by the furnace atmosphere and a certain loss of manganese. The skin can therefore be Martensitic partiafly which can lead to the formation of cracks fine and little deep surface. These cracks for most applications are not functionally harmful ordirmzy, less than serious constraints impact or traction ate involved. This is for informatidrr only.

2. changes that occur in the surface composition of castings during heat treatment can produce a magnetic skin. This surface magnetism developed is generally not dangerous. It can be significantly reduced by grinding, if necessary. This is for information only.

3 (a) after heat treatment, the microstructure of the material is usually fully austenitic. However, in the case of a high section thickness, due to the relatively slow building ground speed and cooling, a significant amount of carbides separate during casting of origin. These carbides are quite slow to dissolve back into the austenite during heat treatment. Try to eliminate carbides of microstructure, especially in the interior regions of thick-walled castings can call for sustained periods of soaking very at a temperature of austenitizatioa. [Such prolonged, in turn, immersion coa] D result to some extent of the degradation of the surface, in the nature of the level, decarbonization, etc. growth as also of grain that may be harmful. Sailandra, the presence of a small percentage uf carbides of heavy castings section thickness, especially in the Interior, is tolerated as a practical compromise and is generally not dangerous. It is open to the parties to agree on the extent of the presence of carbides for a given section thickness. However, unless specifically agreed between the pafiics, or then stipulated in the investigation and the agenda, examination of the microstructure 51 is not a criterion for acceptance of castings to thk standard. 3 (b) to overcome or at least reduce, the problem of the presence of carbides in the condition of heat treatment and the loss of the endurance to some degree, for applications involving heavy thicknesses and high impact grades 4 and 5 are recommended.

If specified at the time of the investigation and order, the analysis of the product can be made from a test piece or of a representative flow melt everyone. Drilling for the analysis must be taken from pitch less than 6 mm under the surface of the melt, and so as to not harm the usefulness of any casting selected. The variation permitted in the analysis of the product of the limits specified in table 1 is ‘ be given in IS 6601.

NOTE – Contamination of drilling by drilling chips should be avoided. Drills BAUKJE’s best high speed steel, or exercises some of new tool materials, will be generally satisfactory for drilling of manganese steel. Manganese steel can be drilled better after annealing for several hours at 500 to 600 “C.

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The Root Cause of Casting Defects

The quality of castings mainly depends on the level of manufacturing, and the defect of metal material is one of the difficult problems to overcome in the process of casting. At present, a lot of jewelry manufacturing metal materials are used by alloy materials, compared with metal simple substance it has a certain difference, so the material defect is also different. From the perspective of comprehensive benefits, many enterprises still use the conventional casting machinery with moderate price; therefore a thorough understanding of the casting defects formation mechanism to minimize defects and improve the production efficiency is beneficial.

casting defects

So far, studies have shown that the unreasonable casting process is the main factor for the formation of casting defects. The process of casting forms casting defects most easily. The most easily observed material defects are cavity defects and surface defects, followed by mixed plant-based defects, shrinkage cavity defects etc. These are typical casting defects. The shape of the accessories is largely a potential cause of the casting defects. At the production site, the maker and the operator of the accessories meet the gap that the operator often lays particular stress on jewelry’s brightness and fastness, and easily ignore the shape of the accessories which may lead to casting defects problem. This may mainly cause randomness of casting defects.

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copper-castings-1

Considerations for Copper Castings Defects Repair

Cold welding material using method:

First clean copper castings surface, make sure rust and oil were completely eliminated, otherwise it will cause protection layer off. Rough treatment is best, which will increase the binding force between the molecules and greatly enhance the service life of the product after repair.

Also, remember to choose cold welding materials according to copper castings itself, such as casting copper parts must choose cast iron cold welding materials, steel, aluminum, iron, etc, need corresponding special cold welding materials to reach the best effect as well.

copper castings

Copper castings products: Copper (pure copper), aluminum bronze, tin bronze, brass, special brass (brass silicon manganese brass), lead brass (brass rail) and Cu-Zn binary alloy ordinary brass.

Difference between copper castings and aluminum castings

Process and use of aluminum castings and copper castings are the same. The only difference is material, in a word, aluminum casting made by aluminum material, and copper castings made by cast copper material, on the other hand the colors are also respectively, aluminum casting is silver, copper castings are golden yellow. Both of them have their own characteristics and value. From the consumer point of view, choose what kind of material mainly depends on consumer preferences and demand to some extend.

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steel-casting-process

The Defects of High Manganese Steel Casting Process

In the high manganese steel casting process, it inevitably exists all kinds of casting defects, such as osteoporosis, shrinkage cavity, micro cracks and composition segregation, etc. these disadvantages are easy to cause longitudinal cracks, vertical cracks, collapse, stripping impellers in the steel casting process which may lead to early failure. Thus high manganese steel castings possess low service life.

Steel Casting Process (1)At present, in order to improve the service life of the frog, there are many new technologyand structures in the steel casting process to reduce casting defects, as well as in design .The new steel casting process is adopted to eliminate the casting defects of high manganese steel frog and ultimately achieve the goal of prolonging the service life of the frog high manganese steel. But these measures can not fundamentally clear away the presence of steelcasting defects. So the degree of the service life of the frog they can increase is limited.

The average service life of high manganese steel frog in our country is more than 100 million tons, and the service life is extremely unstable. These problems are related to the existence of casting defects.

In order to find out the high manganese steel castings with better mechanical properties forsteel casting process, it is necessary to research and develop the casting process with high manganese steel casting samples.

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