Twin Gating System Design for Typical Thin Wall Stainless Steel Castings Based on Fast Pouring Mechanism

2013 ◽  
Vol 457-458 ◽  
pp. 1657-1660 ◽  
Author(s):  
Da Chun Yang ◽  
Sen Lin Li ◽  
Feng He
Keyword(s):  
Mechanical Properties ◽  
Stainless Steel ◽  
System Design ◽  
Directional Solidification ◽  
Thin Wall ◽  
Gating System ◽  
Steel Castings ◽  
Ordinary Steel ◽  
Wall Stainless Steel

The thin wall stainless steel castings is difference to ordinary steel castings in foundry technology. This paper discussed the problems of thin wall stainless steel castings which appearing in the flow controlling board for warm-air pipe, and put forward the foundry technology of this stainless steel castings based on the principle of directional solidification and fast pouring mechanism. According to the theory, twin gating system has been designed for the controlling board castings, and two ladles are pouring into the open twin gating system at the same time. The shrinkage of finally congealing part was fed by two risers. The practice has shown that the design is feasible, there is not cold shut, misrun, scab, and oxidizing for the castings, and the requirements of mechanical properties can be met.

Effect of Casting Design to Microstructure and Mechanical Properties of 1 mm TWDI Plate

2011 ◽  
Vol 110-116 ◽  
pp. 3301-3307 ◽  
Author(s):  
Johny Wahyuadi Soedarsono ◽  
Rianti Dewi Sulamet-Ariobimo
Keyword(s):  
Mechanical Properties ◽  
System Design ◽  
Cooling Rate ◽  
Skin Effect ◽  
Carbide Formation ◽  
Thin Wall ◽  
Gating System ◽  
Microstructure And Mechanical Properties ◽  
Minimal Standard ◽  
Casting Design

In producing thin wall ductile iron (TWDI) cooling rate must be strictly maintaned to prevent carbide formation. There are many ways to control cooling rate and one of these is through casting design, especially gating system design. This paper discusses the possibility to produce 1 mm TWDI plate and also to note the effect of gating system design to microstructure and mechanical properties. Casting design based on gating system design are made to produce 1 mm TWDI plate. The 1 mm TWDI plates will be used for fin. There are three design and coded as T1, T2, and T3. The moulds used were made from furan sand. Beside the experiment, casting design simulation with Z-Cast was also conducted to ensure the completion of producing 1 mm TWDI plate. Simulation result showed that all designs could produce 1 mm TWDI plate. Result from experiment showed that all the designs have microstructure consisting of nodule graphite in ferrite matrix and carbide. Apart from mentioned microstructure there is also skin effect. The difference between all designs lies in carbide content and skin effect width. All the nodularity exceeded 80% and nodule count exceeded 1000 nodule/mm2. Brinell hardness number for all design exceeded minimal standard given by JIG G5502. As for UTS only T2 design can exceed the minimal standard. There is a contradictive result between experiment and simulation in cooling rate.

Influence of Casting Process for Technological Yield of Thin Wall Steel Castings by Last Solidifying Feeding Mechanism

2012 ◽  
Vol 538-541 ◽  
pp. 1134-1137
Author(s):  
Da Chun Yang
Keyword(s):  
Mechanical Properties ◽  
Complex Structure ◽  
Casting Process ◽  
Thin Wall ◽  
Gating System ◽  
Pouring Temperature ◽  
Process Yield ◽  
Feeding Mechanism ◽  
Steel Castings

For the steel castings which is thin wall, uniform thickness, complex structure, and no special mechanical properties, it is feasible that the foundry technology was designed according to the last solidifying feeding mechanism. Adopting this process for the thin wall steel castings, the pouring temperature must be controlled and the gating system be designed rationally. Using self-feeding shrinkage in solidification, and the casting was poured and congealing at the same time. The shrinkage of finally congealing part was fed by small riser or gating system (no riser). Using this foundry technology, the casting process yield and surface quality of casting may be improved, the production cost is reduced, and the requirements of mechanical properties can be met.

Effect of Casting Design to Microstructure and Mechanical Properties of 3 Mm TWDI Plate

2011 ◽  
Vol 415-417 ◽  
pp. 831-837 ◽  
Author(s):  
Johny Wahyuadi Soedarsono ◽  
Bambang Suharno ◽  
Rianti Dewi Sulamet-Ariobimo
Keyword(s):  
Mechanical Properties ◽  
System Design ◽  
Cooling Rate ◽  
Skin Effect ◽  
Carbide Formation ◽  
Thin Wall ◽  
Gating System ◽  
Nodule Count ◽  
Microstructure And Mechanical Properties ◽  
Casting Design

The problem occurs in producing thin wall ductile iron (TWDI) is high cooling rate due to its thickness. Cooling rate must be strictly maintained to prevent carbide formation. There are many ways to control cooling rate. Casting design is one of these, especially gating system design. This parameter is often chosen because of its independence. Major changes in equipment and raw material used in the foundry are not needed when a casting design is chosen to deal with cooling rate. This paper discusses the effect of gating system design on microstructure and mechanical properties of 3 mm TWDI plate. A casting design based on gating system design is made to produce 1, 2, 3, 4, and 5 mm TWDI plates. There are three designs coded as T1, T2, and T3. These three designs were also used in making 1 mm TWDI plates of which the result has been published. The plate with thickness of 3 mm will be used for automotive component like the crankshaft made by Martinez. The moulds used were furan sand. Beside the experiment, casting design simulation with Z-Cast was also conducted to see the behaviour of solidification in 3 mm TWDI plate. Simulation result showed every design has its own solidification behaviour for 3 mm TWDI plate, especially for T2. Experiment result showed that all the designs have microstructure consisting of nodule graphite in ferrite matrix, no trace of carbide and skin effect are formed. Skin effect length is various for all designs. Nodularity exceeded 75% and nodule count exceeded 900 nodules/mm2. Brinell hardness number for all design is beyond standard given by JIG G5502. As for UTS and elongation none of the designs exceed the minimal standard. Experiment results confirmed simulation result. Compared to the previous result nodularity and nodule count decrease and curve trends for every result are not the same.

scholarly journals Research on on-line ultrasonic testing of small diameter thin wall stainless steel straight welded pipe

2021 ◽  
Vol 1820 (1) ◽  
pp. 012086
Author(s):  
Huaishu Hou ◽  
Ding Lu ◽  
Shiwei Zhang ◽  
Yi Zhang ◽  
Chaolei Cheng
Keyword(s):  
Stainless Steel ◽  
Ultrasonic Testing ◽  
Small Diameter ◽  
Thin Wall ◽  
On Line ◽  
Welded Pipe ◽  
Wall Stainless Steel

Effect of Casting Design to Microstructure and Mechanical Properties of 5 mm TWDI Plate

2012 ◽  
Vol 152-154 ◽  
pp. 1607-1611 ◽  
Author(s):  
Johny Wahyuadi Soedarsono ◽  
Bambang Suharno ◽  
Rianti Dewi Sulamet-Ariobimo
Keyword(s):  
Mechanical Properties ◽  
Cooling Rate ◽  
Skin Effect ◽  
Raw Material ◽  
Carbide Formation ◽  
Thin Wall ◽  
Gating System ◽  
Nodule Count ◽  
Microstructure And Mechanical Properties ◽  
Casting Design

In producing thin wall ductile iron (TWDI) cooling rate must be strictly maintained to prevent carbide formation. There are many ways to control cooling rate BUT the most independent one is by casting design. By choosing this parameter major changes in equipment and raw material used in the foundry can be avoided. This paper discusses the effect of gating system design on microstructure and mechanical properties of 5 mm TWDI plate. A casting design based on vertical gating system is made to produce 1, 2, 3, 4, and 5 mm TWDI plates. Plate with 5 mm thickness becomes an interesting subject due to its position as the thickest and furthest from ingate in casting design with a new concept. There are three designs coded as T1, T2, and T3. These three designs were also used in making 1 and 3 mm TWDI plates of which the result has been published. The plate with 5 mm thickness will be used for automotive components. Casting design simulation for filling flow and solidification were conducted with Z-Cast. Result of flow simulation shows that the filling flow happens in two kinds. Result of solidification shows that T3 has the highest solidification rate. In the experiment, the moulds used were furan sand. Experiment result shows that all the designs have microstructure consisting of nodule graphite in ferrite matrix, no trace of carbide and skin effect are formed. Skin effect length is various for all designs. The highest nodularity is only 72% and nodule count shows only 700 nodules/mm2. Brinell hardness number for all design is beyond standard given by JIG G5502. As for UTS and elongation none of the designs exceed the minimal standard. Experiment results confirms simulation result. Compared to the previous result nodularity and nodule count decrease and curve trends for every result are not similar.

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