• Title/Summary/Keyword: sand casting

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Application of Bulk Talc to Molding Material (주형재료로서 덩어리 활석의 이용)

  • Ha, Man-Jin;Lee, Zin-Hyoung;Lee, Sang-Soo;Eun, Hee-Joon
    • Journal of Korea Foundry Society
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    • v.14 no.1
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    • pp.45-51
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    • 1994
  • The possibility of using bulk talc as molding material was reviewed and tested with the measurement of thermal properties and computer simulations. The measured thermal conductivity and heat diffusivity($k{\rho}c$) of talc were $2.4W/m^{\circ}C$ and $6.6{\times}10^6J^2/m^4^{\circ}C^2s$, respectively. Thermal properties of talc could be ranked between those of sand mold and iron mold. Talc transforms into cristobalite and enstatite at $910^{\circ}C$, During the transformation volume and structure change, cracks appear on the surface and distortion occurs. Therefore talc can be used for molding material below $910^{\circ}C$ if carefully treated. Computer simulation was carried out to test whether talc insert could promote directional solidification in sand mold and iron mold. In sand mold, it was possible to achieve directional solidification of thin plate casting with the length to thickness ratio of 15, if both iron insert and talc insert were used. In iron mold, it was possible to achieve directional solidification only with talc insert.

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Effects of Alloying Element and Grain Refinement on the Tensile Properties of Mg-Alloy Casted with Sand Mold (사형 주조 마그네슘 합금의 인장 특성에 미치는 합금 원소와 결정립 미세화의 영향)

  • Han, Jae-Jun;Kwon, Hae-Wook
    • Journal of Korea Foundry Society
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    • v.31 no.4
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    • pp.212-217
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    • 2011
  • The effects of alloying element and grain refinement on the tensile properties of magnesium alloy poured into sand mold were investigated. The strength of magnesium alloy was greatly increased by the addition of aluminium and that was increased with the increased aluminum content added up to 8.10 wt% and decreased beyond that. Even though the strength of Mg-8.10 wt%Al alloy was rather decreased by the addition of zinc, that was increased with increased zinc content added up to 0.50 wt% and decreased with the increased one beyond that. The maximum tensile strength was obtained with 0.50 wt%Mn added. The strength and elongation were simultaneously increased with grain refinement and the optimum amount of strontium addition for this was 0.30 wt%. The optimum chemical composition was obtained and the yield strength, tensile strength and elongation of the alloy with this composition were 90.2, 176.3MPa and 4.43%, respectively.

Control of Abnormal graphite Structure in Heavy Section Ductile Cast Iron (후육 구상흑연주철의 이상흑연 제어)

  • Lee, Sang-Mok;Shin, Ho-Chul;Shin, Je-Sik;Moon, Byung-Moon
    • Journal of Korea Foundry Society
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    • v.25 no.1
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    • pp.40-50
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    • 2005
  • A series of heavy section ductile cast iron ingots with the cube length of 250mm were systematically investigated as functions of casting parameters of sand casting. Abnormal graphite formation was specially observed with the variation of Si content and Bi or Sb addition. Effects of chilling during casting and adaptation of riserless system were also examined, and proved to be effective for the prevention of both shrinkage and abnormal graphite such as chunky one. The formation of chunky graphite was effectively prevented by low Si content despite the promotion of pearlite matrix structure. The ferritic matrix was encouraged to form by high Si content and chunky graphite formation was effectively suppressed by the addition of Bi and Sb. Bi addition, however, was not good enough to control the microstructure owing to the sensitive cooling rate dependent inoculation behavior and relative low ability of nodulization. Sb addition, on the other hand, was proved to be effective for the microstructural control and enhancement of various mechanical properties such as strength, elongation, and impact energy. It may be suggested that optimized casting parameters should be applied to produce heavy section ductile cast iron with reliability.

Changed in Growth and Chemical Properties of Plastic Film House by Earthworm Cast on Gymnocalycium mihanovichii var. 'Ihong' (비모란 선인장(Gymnocalycium mihanovichii var. 'Ihong') 시설재배에서 지렁이분변토시용에 따른 생육특성 및 토양 화학성 변화)

  • Choi, I-Jin;Cho, Sang-Tae;Kim, Young-Mun;Kim, Mi-Seon;Lee, Sang-Kweon
    • Korean Journal of Organic Agriculture
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    • v.22 no.4
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    • pp.731-742
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    • 2014
  • In the current study, we investigated effects of a combination of earthworm casting, environment-friendly by-product fertilizer, and cultivation soil of Gymnocalycium mihanovichii in a heavy fertilizing culture on diameter, height, numbers of tubercles, and chemical properties of soil thereby elucidating optimal mixture ratio for securing production as well as providing nutrients throughout cultivation period. The Gymnocalycium mihanovichii var 'Ihong', one of grafted cactus for export (Rootstock: 9 cm, Scion: $1.5{\times}1.3cm$ grafted cactus) was cultured in plastic houses of Agricultural Technology Center located in Naegok-dong, Seocho-gu, Seoul from June, 2013 through December, 2013. For the control group, a mixture of sand and fertilizer (50:50) was used as this ratio is widely utilized in farmhouses. In contrast, a variety mixtures of sand and earthworm casting that was produced with food wastes was compared; the mixture ratios were 80:20, 60:40, 40:60, 20:80, and 0:100 and pH for these mixtures were found to be similar each other (ranging between 7.1 and 7.4) which is in an appropriate range (pH 6.5-7.5) for cultivation of G. mihanovichii. The organic content was increasing along with increasing contents of earthworm casting ratio while it was lower than the treatment practice group (32-43 mg/kg vs. 55 mg/kg). The content of exchangeable cation was also increasing as the ratio of earthworm casting was elevated; although levels of $K^+$, $Na^+$, and $Mg^{2+}$ were lower than the treatment practice group, the level of $Ca^{2+}$ was higher ($9.1cmol^+/kg$ and $11.5-33.7cmol^+/kg$ in the treatment practice group and the earthworm casting group, respectively). Three months after grafting, diameters of G. mihanovichii were compared with the control group; consequently, there was a significant difference noted in between the earthworm casting group and the control group (31.39 mm vs. 32.46-37.59 mm). After 5 months, growth characteristics of G. mihanovichii were evaluated. Similarly, the diameter of G. mihanovichii was significantly increasing in the group with higher ratio of earthworm casting treatment (32.63 mm vs. 32.49-37.59 mm). The height of tubercles was 2.63 mm in the control group while it was significantly elevating along with the ratio of earthworm casting mixture. The more numbers of tubercles, the more incomes for farm-houses; as results, higher mixture ration of earthworm casting resulted more numbers of tubercles compared to the control group (2.7 vs. 3.2-8.3 ea). In particular, in the earthworm casting groups with 80% and 100% ratios, the numbers of tubercles were 6.2 and 8.3 ea, respectively, which is 2.5 times more than those of the control group. These results indicate that earthworm casting treatment may be utilized in G. mihanovichii farming houses for short term production of tubercles. In the group with 40% and 60% of earthworm casting mixture, the numbers of tubercles were found to be 4.5 and 4.8 ea, respectively which is higher than the control group as well; in these groups, there were no issues with soil drainage as well as moss formation. Given the analysis results of growth characteristics of G. mihanovichii, it was concluded that 40% and 60% of earthworm casting mixture might be the optimal ratios.

Applicability of Air Cooling Heat-treatment for a Duplex Stainless Steel Casting (2상 스테인레스 주강의 공냉 열처리 적용 가능성)

  • Kim, Bong-Whan;Yang, Sik;Shin, Je-Sik;Lee, Sang-Mok;Moon, Byung-Moon
    • Journal of Korea Foundry Society
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    • v.26 no.1
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    • pp.17-26
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    • 2006
  • The substitution of cooling method from water quenching to air cooling after solution heat treatment was aimed for the development of a convenient and economical heat treatment process of duplex stainless steels without deterioration of mechanical and corrosion resistant properties for the industry. In order to achieve this goal, the mechanical properties and corrosion properties of a ASTM A890-4A duplex stainless steel were systematically investigated as functions of casting condition and cooling method after solution heat treatment. A 3-stepped sand mold and a permanent Y-block mold were used to check the effects of solidification structure and cooling rate after solution heat treatment. The microstructural characteristics such as the ferrite/austenite phase ratio and the precipitation behavior of ${\sigma}$ phase and carbides were investigated by combined analysis of OM and SEM-EDX with an aid of TTT diagram. Hardness and tension test were performed to evaluate the mechanical properties. Impact property at $-40^{\circ}C$ and corrosion resistance were also examined to check the possibility of the industrial application of this basic study. Throughout this investigation, air-cooling method was proved to effectively substitute for water-quenching process after the solution heat treatment, when the duplex stainless steel was sand mold cast with a thickness below 15 mm or permanent mold cast with a thickness below 20 mm.

Three Dimensional Solidification Analysis in Large Steel Castings by Modified Finite Difference Method (개량차분법에 의한 대형주강품의 3차원 응고해석)

  • Yoo, Seung-Mog;Lee, Doo-Ho;Kim, Jong-Ki;So, Chan-Young;Hong, Chun-Pyo
    • Journal of Korea Foundry Society
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    • v.11 no.1
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    • pp.54-62
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    • 1991
  • A computer program which consists of pre-processor, main solidification simulator and post-processor has been developed for three dimensional solidification analysis of steel castings. The pre-processor is used for mesh generation in a small personal computing system. The modified finite difference method is adopted for the main solidification simulation algorithm. The post -processor graphically presents the simulation results and shows the formation of shrinkage defects. Several experiments on large steel castings in sand mold were carried out. The temperature variations in casting and mold with time are measured experimentally, and the results are compared with calculation results. Several numerical examples for the prediction of shrinkage cavity in large steel casting of SC42 and SCNCrM2 alloys are compared with experimental results. The effect of sleeve and chills on solidification patterns are also studied. Formation of shrinkage defects for the three cases of experimental castings are relatively well predicted by present model.

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Development of Ternary Inorganic Binder System for Manufacturing High-Functional Ceramic Molds and Core (고기능성 세라믹 주형 및 중자 제작을 위한 3원계 무기 바인더 시스템 개발)

  • Hye-Yeong Park;Geun-Ho Cho;Hyun-Hee Choi;Bong Gu Kim;Eun-Hee Kim;SeungCheol Yang;Yeon-Gil Jung
    • Korean Journal of Materials Research
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    • v.32 no.12
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    • pp.538-544
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    • 2022
  • In existing ceramic mold manufacturing processes, inorganic binder systems (Si-Na, two-component system) are applied to ensure the effective firing strength of the ceramic mold and core. These inorganic binder systems makes it possible to manufacture a ceramic mold and core with high dimensional stability and effective strength. However, as in general sand casting processes, when molten metal is injected at room temperature, there is a limit to the production of thin or complex castings due to reduced fluidity caused by the rapid cooling of the molten metal. In addition, because sodium silicate generated through the vitrification reaction of the inorganic binder is converted into a liquid phase at a temperature of 1,000 ℃. or higher, it is somewhat difficult to manufacture parts through high-temperature casting. Therefore, in this study, a high-strength ceramic mold and core test piece with effective strength at high temperature was produced by applying a Si-Na-Ti three-component inorganic binder. The starting particles were coated with binary and ternary inorganic binders and mixed with an organic binder to prepare a molded body, and then heat-treated at 1,000/1,350/1,500 ℃ to prepare a fired body. In the sample where the two-component inorganic binder was applied, the glass was liquefied at a temperature of 1,000 ℃ or higher, and the strength decreased. However, the firing strength of the ceramic mold sample containing the three-component inorganic binder was improved, and it was confirmed that it was possible to manufacture a ceramic mold and core via high temperature casting.

Strength development of ground perlite-based geopolymer mortars

  • Celikten, Serhat;Isikdag, Burak
    • Advances in concrete construction
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    • v.9 no.3
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    • pp.227-234
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    • 2020
  • Raw perlite is a volcanic alumino-silicate and is used as aggregate in the construction industry. The high silica and alumina contained in the raw perlite allows the production of geopolymer mortar with the help of alkaline solutions. In this study, different geopolymer mortars are obtained by mixing ground perlite (GP), sodium hydroxide (NaOH), water and CEN standard sand and the strength and microstructure of these mortars are investigated. Mortar specimens are placed in the oven 24 hours after casting and kept at different temperatures and times, then the specimens are cured under laboratory conditions until the day of strength tests. After curing, unit weight, ultrasound pulse velocity, flexural and compressive strengths are determined. Experimental results indicate that the mechanical properties of the mortars enhance with increasing oven-curing period and temperatures as well as increasing NaOH molarity. In addition, SEM/EDS and XRD analyses are performed on the mortar specimens and the results are interpreted.

Guided wave analysis of air-coupled impact-echo in concrete slab investigation on the use of waste tyre crumb rubber in concrete paving blocks

  • Murugan, R. Bharathi;Natarajan, C.
    • Computers and Concrete
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    • v.20 no.3
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    • pp.311-318
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    • 2017
  • This paper investigates the utilization of waste tyre crumb rubber as the fine aggregate in precast concrete Paving block (PCPB). PCPB's are generally preferred for city roads, pedestrian crosswalk, parking lots and bus terminals. The main aim of this paper is to evaluate the mechanical properties of wet cast PCPB containing waste tyre crumb rubber. The mechanical properties were investigated using a density, compressive strength, split tensile strength and flexural strength tests at 7, 28 56 days according to the IS 15688:2006 and EN1338. The wet cast method was followed for producing PCPB samples. The fine aggregate (river sand) was replaced with waste tyre crumb in percentage of 5%, 10%, 15%, 20% and 25% by volume. All the test results were compared with the conventional PCPB (Without rubber). The test results indicate its feasibility for incorporating waste tyre crumb rubber in the production of PCPB by the wet cast method.

Effects of Process and Casting Variables on the Results of Degassing AC4C Aluminum Alloy Melt by Using Rotary Degasser (공정 및 주조 변수의 AC4C 알루미늄 합금 용탕의 로터리 degasser를 이용한 탈가스 처리 결과에 미치는 영향)

  • Lee, Ki-Joon;Kwon, Hae-Wook
    • Journal of Korea Foundry Society
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    • v.20 no.6
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    • pp.407-418
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    • 2000
  • The effect of various factors on the results of degassing of AC4C aluminum alloy melt by using rotary degasser were investigated. The difference between the effects of nitrogen gases of commercial pure and high purity grades on the degassing results was not significant. The optimum degassing condition was obtained. The effect of holding and degassing temperature was not significant, either. The result of degassing was deteriorated by the modification treatment of eutectic silicon, meanwhile improved by the grain refining. The effect of the latter was stronger than that of the former when the melt was treated simultaneously. The volume fractions of hydrogen porosity of the castings obtained from the molds with water moisture such as natural and green sand molds were much higher than those from the molds without that such as pep-set and $CO_2$ molds.

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