This collection presents papers on the science, engineering, and technology of shape castings, with contributions from researchers worldwide. Among the topics that are addressed are structure-property-performance relationships, modeling of casting processes, and the effect of casting defects on the mechanical properties of cast alloys.
Table of Contents:
Preface ix
About the Editors xi
Process Design and Innovation
A Draft Melting Procedure for Al Alloys 3
J. Campbell
Effect of Casting Condition in Semi-solid Aluminum Alloy Injection Process on Distribution of Defects and Density 11
Y. Murakami, K. Miwa, M. Kito, T. Honda, N. Kanetake, and S. Tada
Reliability-based Casting Process Design Optimization 19
R. Hardin, K. Choi, and C. Beckermann
Influence of Process Parameters on Blistering during T6 Heat Treatment of Semi-solid Castings 27
Y. He, X. Xu, F. Zhang, D. Li, S. Midson, and Q. Zhu
Integrated Casting-heat Treatment Process Route for Near Net Shape ADI Casting Production 35
A. Meena and M. El Mansori
Swage Casting of A356 (AlSi7Mg0.3) Alloy 43
H. Lus
Additive Manufacturing Supports the Production of Complex Castings 51
A. Druschitz, C. Williams, D. Snelling, and M. Seals
Evolution of Filling System Design for an A356-T6 Aluminum Housing Casting 59
J. Chvala, M. Tiryakioglu, N. Hudyma, and P. Eason
Recent Advances on the Solidification Processing of Cast Energetic Materials 67
R. Mudryy, S. Jia, and L. Nastac
Solidification and Microstructure I
Thermodynamics-based Computational Approach to Al-Cu Alloys: Grain Refinement 77
J. Li, C. Promer, A. Jahn, B. Oberdorfer, S. Wurster, F. Martin, and P. Schumacher
Control Diffusion Solidification (CDS): An Overview of Mechanism and Application 89
R. Ghiaasiaan, S. Shankar, and D. Apelian
Correlation between Melt Quality and Fluidity of A356 99
B. Akkaya, E. Ertürk, and D. Dispinar
Fluidity Characteristics of A356 Alloy with Various Thickness Sectioned New Test Mould 105
M. Colak, R. Kayikci, and D. Dispinar
Effect of Feeder Configuration on the Microstructure of Ductile Cast Iron 113
N. Vedel-Smith and N. Tiedje
Analysis of Heterogeneous Nucleation in Ductile Iron 121
S. Lekakh
The External and Internal Shrinkages in Aluminum Gravity Castings 129
F. Hsu, S. Wang, and H. Lin
Effect of Si and Cu Content on the Size of Intermetallic Phase Particles in Al-Si-Cu-Mg-Fe Alloys 137
T. Sivarupan, J. Taylor, and C. Caceres
Efficient Use of Titanium and Boron in Grain Refining of a Die-cast Strontium-modified A356 145
S. Fischer, R. Boras, A. Bührig-Polaczek, and M. Bünck
Studying on the Effects of Quenching Rate on Residual Stress in Al-5Mg and Al-Mg-Cu Alloys 153
I. Kalkan and D. Dispinar
Mechanical Properties
Metallurgy without Bifilms: No More Fractures 163
J. Campbell
Correlation between Bifilm Index and Toughness of Aluminum Alloys 171
D. Dispinar, C. Kahruman, and J. Campbell
Impact of Section Thickness on the Microstructure and Mechanical Properties of Semi-solid Castings 177
S. Midson, Y. He, X. Hu, D. Li, F. Zhang, and Q. Zhu
The Relationship between Elongation and Fatigue Life in A206 Aluminum Castings 185
M. Tiryakioglu
Magnesium Casting Processes:The HIMAC Project Re-assessed 193
J. Campbell and M. Tiryakioglu
Manufacturing Cost Modeling of Castings Produced with CRIMSON Process 201
B. Zeng, M. Jolly, and K. Salonitis
On Weibull Mixtures in Mechanical Properties of Castings 209
M. Tiryakioglu
Microstructure and Mechanical Properties of Automotive Components Die Cast with Secondary Al Alloys by SEED Semi-solid Process 217
G. Timelli, S. Capuzzi, S. Ferraro, A. Fabrizi, and L. Capra
The Effect of Grain Structure on Casting Durability Assessment in Al-Si Alloys 225
G. Byczynski and R. Mackay
Near-net-shape Processing of 2024 Aluminium Alloy by SIMA Method 233
H. Özdes, I. Erdeniz, E. Erzi, and D. Dispinar
Solidification and Microstructure II
Reduced Pressure Test (RPT) for Bifilm Assessment 243
D. Dispinar and J. Campbell
Prediction of Misruns in Thin Wall Castings Using Computational Simulation 253
J. Jakumeit, E. Subasic, and M. Bünck
Shaping of Metals with Magnetic Fields 261
M. David, C. Monroe, and J. Griffin
The Formation of Hydrogen Related Porosity by Double Oxide Film Defects in Al Alloys 269
A. Gerrard and W. Griffiths
The Influence of Fe, Mn and Cr Additions on the Formation of Iron-rich Intermetallic Phases in an Al-Si Die-casting Alloy 277
A. Fabrizi, S. Ferraro, and G. Timelli
Thermal Analysis of Solidifying Secondary Phases in the Eutectic Al-Si Alloy and the Effect of Sr and Fe 285
J. Manickaraj, A. Gorny, and S. Shankar
Thin-wall Model for Use in Multiple Casting Conditions 293
A. Noble, C. Monroe, and A. Monroe
Electrochemical Behavior of Al-1wt.%Cu and Al-4.5wt.%Cu Alloys 301
A. Roman, C. Méndez, C. Schvezov, and A. Ares
Author Index 309
Subject Index 311
About the Author :
Murat Tiryakioglu, University of North Florida. John Campbell, University of Birmingham, United Kingdom.
Glenn Byczynski, Nemak.
