Intelligent casting:Empowering the future foundry industry

Emerging technological advances are reshaping the casting sector in latest decades.Casting technology is evolving towards intelligent casting paradigm that involves automation,greenization and intelligentization,which attracts more and more attention from the academic and industry communities.In this paper,the main features of casting technology were briefly summarized and forecasted,and the recent developments of key technologies and the innovative efforts made in promoting intelligent casting process were discussed.Moreover,the technical visions of intelligent casting process were also put forward.The key technologies for intelligent casting process comprise 3D printing technologies,intelligent mold technologies and intelligent process control technologies.In future,the intelligent mold that derived from mold with sensors,control devices and actuators will probably incorporate the Internet of Things,online inspection,embedded simulation,decision-making and control system,and other technologies to form intelligent cyber-physical casting system,which may pave the way to realize intelligent casting.It is promising that the intelligent casting process will eventually achieve the goal of real-time process optimization and full-scale control,with the defects,microstructure,performance,and service life of the fabricated castings can be accurately predicted and tailored.

Thermal and mechanical behavior of casting copper alloy wheel during wheel and belt continuous casting process

To investigate the thermal and mechanical behavior of casting wheel,a two-dimensional thermoelastic-plastic finite element model was used to predict the temperature,stress and distortion distribution of the casting wheel during the wheel and belt continuous casting process.The effects of grinding thickness and casting speed on the thermal and mechanical behaviors of the center of the hot face of the casting wheel were discussed in detail.In each rotation,the casting wheel passes through four different spray zones.The results show that the temperature distribution of the casting wheel in different spray zones is similar,the temperature of the hot face is the highest and the temperature reaches the peak in the spray zoneⅢ.The stress and distortion depend on the temperature distribution,and the maximum stress and distortion of the hot face are 358.2 MPa and 1.82 mm,respectively.The temperature at the center of the hot face decreases with increasing grinding thickness and increases with increasing casting speed.

基于ProCAST的铜合金通海阀铸造工艺优化

目的结合ZCuAl7-7-4-2合金的铸造特性,研究复杂薄壁铸件通海阀的铸造成形工艺,探究初始浇注方案下的充型、凝固规律,优化工艺并提出合理的铸造工艺方案。方法根据通海阀的结构特点,设计出底注雨淋式浇注系统,并利用流体力学理论和截面积比值法确定浇注系统的具体参数,使用ProCAST软件研究不同工艺参数、冒口尺寸对铸件质量的影响,以得到最优的浇注方案。结果在底注雨淋式浇注系统的充型过程中,金属液温度分布均匀、流速平稳,凝固顺序合理,所得铸件缺陷较少,其中疏松缩孔体积为0.63 mm3,且集中分布在阀盖处。优化浇注温度和浇注速度能够有效减少铸造缺陷,优化出的最佳浇注工艺参数组合如下:浇注温度为1180℃,浇注速度为3.5 kg/s。结合该模拟结果改进冒口尺寸后,彻底消除了铸件的铸造缺陷。结论优化工艺参数和浇注系统设计能够有效提高铸件的生产质量,便于铸件的一次成形,对实际生产提供指导。

Data-driven casting defect prediction model for sand casting based on random forest classification algorithm

The complex sand-casting process combined with the interactions between process parameters makes it difficult to control the casting quality,resulting in a high scrap rate.A strategy based on a data-driven model was proposed to reduce casting defects and improve production efficiency,which includes the random forest(RF)classification model,the feature importance analysis,and the process parameters optimization with Monte Carlo simulation.The collected data includes four types of defects and corresponding process parameters were used to construct the RF model.Classification results show a recall rate above 90% for all categories.The Gini Index was used to assess the importance of the process parameters in the formation of various defects in the RF model.Finally,the classification model was applied to different production conditions for quality prediction.In the case of process parameters optimization for gas porosity defects,this model serves as an experimental process in the Monte Carlo method to estimate a better temperature distribution.The prediction model,when applied to the factory,greatly improved the efficiency of defect detection.Results show that the scrap rate decreased from 10.16% to 6.68%.

Ultra-large aluminum shape casting:Opportunities and challenges

Ultra-large aluminum shape castings have been increasingly used in automotive vehicles,particularly in electric vehicles for light-weighting and vehicle manufacturing cost reduction.As most of them are structural components subject to both quasi-static,dynamic and cyclic loading,the quality and quantifiable performance of the ultra-large aluminum shape castings is critical to their success in both design and manufacturing.This paper briefly reviews some application examples of ultra-large aluminum castings in automotive industry and outlines their advantages and benefits.Factors affecting quality,microstructure and mechanical properties of ultra-large aluminum castings are evaluated and discussed as aluminum shape casting processing is very complex and often involves many competing mechanisms,multi-physics phenomena,and potentially large uncertainties that significantly influence the casting quality and performance.Metallurgical analysis and mechanical property assessment of an ultra-large aluminum shape casting are presented.Challenges are highlighted and suggestions are made for robust design and manufacturing of ultra-large aluminum castings.

基于Cast Designer的壳体铸件铸造工艺设计及智能优化

使用Cast Designer铸造仿真分析软件,通过可铸性评估系统DFM,完成浇冒系统的辅助设计,然后使用DOE技术和基于遗传算法GA的智能优化技术,评估不同工艺设计方案与铸造过程参数对壳体铸件质量的影响,分析在不同的冒口、冷铁和浇注温度条件下得料率和缩孔量的关系。根据对DOE模拟结果的分析,发现顶冒口和侧冒口尺寸是影响得料率和缩孔量的关键因数,再利用遗传算法GA选择最佳设计方案和参数。通过帕累托曲线得到了生产壳体铸件的最优工艺方案。

CAST池活性污泥除磷微生物群落特征研究

为掌握霞山水质净化厂CAST池各反应段活性污泥除磷微生物群落结构特征,特对CAST池内不同区活性污泥进行采样并DNA提取后高通量测序分析,结果表明CAST池各阶段活性污泥富集了丰富的具有良好除磷功能的菌。门水平上的优势除磷菌有变形杆菌门(Proteobacteria)、绿弯菌门(Chloroflexi)、放线菌门(Actinobacteriota)、酸杆菌门(Acidobacteriota)、厚壁菌门(Firmicutes)。属水平上的优势除磷菌为Norank_f_Caldilineaceae、Candidatus_Competibacter、Norank_f_norank_o_Saccharimonadales、Tetrasphaera、Norank_f_Blastocatellaceae等。该CAST池活性污泥中存在聚磷菌与聚糖菌共存的现象且两者相对丰度较高,两者的竞争及环境条件变化会导致除磷效果的波动。主反应区曝气使得好氧聚磷菌Tetrasphaera相对丰度远高于生物选择区和兼氧区。反硝化聚磷菌Streptococcus和Acinetobacter在生物选择区中相对丰度远高于兼氧区和主反应区。反硝化聚磷菌在生物选择区厌氧段更加适宜其生长导致其相对丰度较高,能增强该阶段除磷效果。在实际生产中应着力改善合适环境条件提升聚磷菌生物量以保障除磷效果。

Role of alloying and heat treatment on microstructure and mechanical properties of cast Al-Li alloys:A review

Due to the prominent advantages of low density,high elastic modulus,high specific strength and specific stiffness,cast Al-Li alloys are suitable metallic materials for manufacturing complex large-sized components and are ideal structural materials for aerospace,defense and military industries.On the basis of the microstructural characteristics of cast Al-Li alloys,exploring the role of alloying and micro-alloying can stabilize their dominant position and further expand their application scope.In this review,the development progress of cast Al-Li alloys was summarized comprehensively.According to the latest research highlights,the influence of alloying and heat treatment on the microstructure and mechanical properties was systematically analyzed.The potential methods to improve the alloy performance were concluded.In response to the practical engineering requirements of cast Al-Li alloys,the scientific challenges and future research directions were discussed and prospected.

Experimental observations on the nonproportional multiaxial ratchetting of cast AZ91 magnesium alloy at room temperature

The nonproportional multiaxial ratchetting of cast AZ91 magnesium (Mg) alloy was examined by performing a sequence of axial-torsional cyclic tests controlled by stress with various loading paths at room temperature (RT).The evolutionary characteristics and path dependence of multiaxial ratchetting were discussed.Results illustrate that the cast AZ91 Mg alloy exhibits considerable nonproportional additional softening during cyclic loading with multiple nonproportional multiaxial loading paths;multiaxial ratchetting presents strong path dependence,and axial ratchetting strains are larger under nonproportional loading paths than under uniaxial and proportional45°linear loading paths;multiaxial ratchetting becomes increasingly pronounced as the applied stress amplitude and axial mean stress increase.Moreover,stress-strain curves show a convex and symmetrical shape in axial/torsional directions.Multiaxial ratchetting exhibits quasi-shakedown after certain loading cycles.The abundant experimental data obtained in this work can be used to develop a cyclic plasticity model of cast Mg alloys.

Numerical simulation of melt flow and temperature field during DC casting 2024 aluminium alloy under different casting conditions

Casting speed,casting temperature and secondary cooling water flow rate are the main process parameters affecting the DC casting process.These parameters significantly influence the flow and temperature fields during casting,which are crucial for the quality of the ingot and can determine the success or failure of the casting operation.Numerical simulation,with the advantages of low cost,rapid execution,and visualized results,is an important method to study and optimize the DC casting process.In the present work,a simulation model of DC casting 2024 aluminum alloy was established,and the reliability of the model was verified.Then,the influence of casting parameters on flow field and temperature field was studied in detail by numerical simulation method.Results show that with the increase of casting speed,the melt flow becomes faster,the depths of slurry zone and mushy zone increase,and the variation of slurry zone depth is greater than that of mushy zone.With an increase in casting temperature,the melt flow rate increases,the depth of the slurry zone becomes shallower,and the depth of the mushy zone experiences only minor changes.The simulation results further indicate that the increase of the flow rate of the secondary cooling water slightly reduces the depths of both slurry and mushy zone.

Thin-walled and large-sized magnesium alloy die castings for passenger car cockpit:Application,materials,and manufacture

In order to effectively reduce energy consumption and increase range mile,new energy vehicles represented by Tesla have greatly aroused the application of integrated magnesium(Mg)alloy die casting technology in automobiles.Previously,the application of Mg alloys in automobiles,especially in automotive cockpit components,is quite extensive,while it has almost disappeared for a period of time due to its relatively high cost,causing a certain degree of information loss in the application technology of Mg alloy parts in automobiles.The rapid development of automotive technology has led to a higher requirement for the automotive components compared with those traditional one.Therefore,whatever the components themselves,or the Mg alloy materials and die casting process have to face an increasing challenge,needing to be upgraded.In addition,owing to its high integration characteristics,the application of Mg alloy die casting technology in large-sized and thin-walled automotive parts has inherent advantages and needs to be expanded urgently.Indeed,it necessitates exploring advance Mg alloys and new product structures and optimizing die casting processes.This article summarizes and analyzes the development status of thin-walled and large-sized die casting Mg alloy parts in passenger car cockpit and corresponding material selection methods,die casting processes as well as mold design techniques.Furthermore,this work will aid researchers in establishing a comprehensive understanding of the manufacture of thin-walled and large-sized die casting Mg alloy parts in automobile cockpit.It will also assist them in developing new Mg alloys with improved comprehensive performance and new processes to meet the high requirements for die casting automotive components.

To improve robustness of mechanical properties of semi-solid cast A356 alloy using taguchi design method

Mechanical properties of semi-solid casting are dependent on multiple processing parameters,and improper processing parameters will not only reduce mean data but also increase variations.The present study investigated the impact of parameters in slurry preparation and heat treatment on the yield strength and ductility of T6 heat-treated A356 Al-Si alloy using rapid slurry forming(RSF)semi-solid casting.The focus was primarily on the robustness of mechanical properties based on Taguchi design method.By analyzing signal-to-noise ratio and minimum value calculated from-3S,the optimum slurry preparation parameters and heat treatment parameters were determined to be no quench,enthalpy exchange material(EEM)temperature of 140℃,EEM-to-melt ratio of 6mass%,stirring time of 18 s,solution heat treated at 520℃ for 2 h,and ageing heat treated at 190℃ for 6 h.In a small batch validation,the-3S yield strength and-3S elongation reach 256.1 MPa and 5.03% respectively,showing a satisfactory robustness.The hardness and microstructure of heat-treated samples with the best and worst properties were characterized to gain insight into the underlying mechanisms affecting the mean value and variations of mechanical properties.

Microstructure and Hot Tearing Sensitivity Simulation and Parameters Optimization for the Centrifugal Casting of Al-Cu Alloy

Four typical theories on the formation of thermal tears:strength,liquid film,intergranular bridging,and solidifica-tion shrinkage compensation theories.From these theories,a number of criteria have been derived for predicting the formation of thermal cracks,such as the stress-based Niyama,Clyne,and RDG(Rapaz-Dreiser-Grimaud)criteria.In this paper,a mathematical model of horizontal centrifugal casting was established,and numerical simulation analysis was conducted for the centrifugal casting process of cylindrical Al-Cu alloy castings to investigate the effect of the centrifugal casting process conditions on the microstructure and hot tearing sensitivity of alloy castings by using the modified RDG hot tearing criterion.Results show that increasing the centrifugal rotation and pouring speeds can refine the microstructure of the alloy but increasing the pouring and mold preheating temperatures can lead to an increase in grain size.The grain size gradually transitions from fine grain on the outer layer to coarse grain on the inner layer.Meanwhile,combined with the modified RDG hot tearing criterion,the overall distribution of the castings’hot tearing sensitivity was analyzed.The analysis results indicate that the porosity in the middle region of the casting was large,and hot tearing defects were prone to occur.The hot tearing tendency on the inner side of the casting was greater than that on the outer side.The effects of centrifugal rotation speed,pouring temperature,and preheating temperature on the thermal sensitivity of Al-Cu alloy castings are summarized in this paper.This study revealed that the tendency of alloy hot cracking decreases with the increase of the centrifugal speed,and the maximum porosity of castings decreases first and then increases with the pouring temperature.As the preheating temperature increases,the overall maximum porosity of castings shows a decreasing trend.

A simple route for preparation of TRIP-assisted Si-Mn steel with excellent performance using direct strip casting

The complex producing procedures and high energy-consuming limit the large-scale production and application of advanced high-strength steels(AHSSs).In this study,the direct strip casting(DSC)technology with unique sub-rapid solidification characteristics and cost advantages was applied to the production of low-alloy Si-Mn steel with the help of quenching&partitioning(Q&P)concept to address these issues.Compared this method with the conventional compact strip production(CSP)process,the initial microstructure formed under different solidification conditions and the influence of heat treatment processes on the final mechanical properties were in-vestigated.The results show that the initial structure of the DSC sample is a dual-phase structure composed of fine lath martensite and bainite,while the initial structure of the CSP sample consists of pearlite and ferrite.The volume fraction and carbon content of retained austenite(RA)in DSC samples are usually higher than those in CSP samples after the same Q&P treatment.DSC samples typically demonstrate better comprehensive mechanical properties than the CSP sample.The DSC sample partitioned at 300℃ for 300 s(DSC-Pt300)achieves the best comprehensive mechanical properties,with yield strength(YS)of 1282 MPa,ultimate tensile strength(UTS)of 1501 MPa,total elongation(TE)of 21.5%,and product of strength and elongation(PSE)as high as 32.3 GPa·%.These results indicate that the excellent mechanical properties in low-alloy Si-Mn steel can be obtained through a simple process(DSC-Q&P),which also demonstrates the superiority of DSC technology in manufacturing AHSSs.

Research progress on semi-continuous casting of magnesium alloys under external field

High-performance magnesium alloys are moving towards a trend of being produced on a large scale and in an integrated manner.The foundational key to their successful production is the high-quality cast ingots.Magnesium alloys produced through the conventional semi-continuous casting process inevitably contain casting defects,which makes it challenging to manufacture high-quality ingots.The integration of external field assisted controlled solidification technology,which combines physical fields such as electromagnetic and ultrasonic fields with traditional semi-continuous casting processes,enables the production of high-quality magnesium alloy ingots characterized by a homogeneous microstructure and absence of cracks.This article mainly summarizes the technical principles of those external field assisted casting process.The focus is on elaborating the refinement mechanism of different types of electromagnetic fields,ultrasonic fields,and combined physical fields during the solidification of magnesium alloys.Finally,the development prospects of producing highquality magnesium alloy ingots through semi-continuous casting under the external field were discussed.

Irregular initial solidification by mold thermal monitoring in the continuous casting of steels:A review

Occasional irregular initial solidification phenomena,including stickers,deep oscillation marks,depressions,and surface cracks of strand shells in continuous casting molds,are important limitations for developing the high-efficiency continuous casting of steels.The application of mold thermal monitoring(MTM) systems,which use thermocouples to detect and respond to temperature variations in molds,has become an effective method to address irregular initial solidification phenomena.Such systems are widely applied in numerous steel companies for sticker breakout prediction.However,monitoring the surface defects of strands remains immature.Hence,indepth research is necessary to utilize the potential advantages and comprehensive monitoring of MTM systems.This paper summarizes what is included in the irregular initial solidification phenomena and systematically reviews the current state of research on these phenomena by the MTM systems.Furthermore,the influences of mold slag behavior on monitoring these phenomena are analyzed.Finally,the remaining problems of the formation mechanisms and investigations of irregular initial solidification phenomena are discussed,and future research directions are proposed.

Remaining Useful Life for Heavy-Duty Railway Cast Steel Knuckles Based on Crack Growth Behavior with Hypothetical Distributions

The current research on the integrity of critical structures of rail vehicles mainly focuses on the design stage,which needs an effective method for assessing the service state.This paper proposes a framework for predicting the remaining useful life(RUL)of in-service structures with and without visible cracks.The hypothetical distribution and delay time models were used to apply the equivalent crack growth life data of heavy-duty railway cast steel knuckles,which revealed the evolution characteristics of the crack length and life scores of the knuckle under different fracture failure modes.The results indicate that the method effectively predicts the RUL of service knuckles in different failure modes based on the cumulative failure probability curves for different locations and surface crack lengths.This study proposes an RUL prediction framework that supports the dynamic overhaul and state maintenance of knuckle fatigue cracks.

I-DCGAN and TOPSIS-IFP:A simulation generation model for radiographic flaw detection images in light alloy castings and an algorithm for quality evaluation of generated images

The intelligent detection technology driven by X-ray images and deep learning represents the forefront of advanced techniques and development trends in flaw detection and automated evaluation of light alloy castings.However,the efficacy of deep learning models hinges upon a substantial abundance of flaw samples.The existing research on X-ray image augmentation for flaw detection suffers from shortcomings such as poor diversity of flaw samples and low reliability of quality evaluation.To this end,a novel approach was put forward,which involves the creation of the Interpolation-Deep Convolutional Generative Adversarial Network(I-DCGAN)for flaw detection image generation and a comprehensive evaluation algorithm named TOPSIS-IFP.I-DCGAN enables the generation of high-resolution,diverse simulated images with multiple appearances,achieving an improvement in sample diversity and quality while maintaining a relatively lower computational complexity.TOPSIS-IFP facilitates multi-dimensional quality evaluation,including aspects such as diversity,authenticity,image distribution difference,and image distortion degree.The results indicate that the X-ray radiographic images of magnesium and aluminum alloy castings achieve optimal performance when trained up to the 800th and 600th epochs,respectively.The TOPSIS-IFP value reaches 78.7%and 73.8%similarity to the ideal solution,respectively.Compared to single index evaluation,the TOPSIS-IFP algorithm achieves higher-quality simulated images at the optimal training epoch.This approach successfully mitigates the issue of unreliable quality associated with single index evaluation.The image generation and comprehensive quality evaluation method developed in this paper provides a novel approach for image augmentation in flaw recognition,holding significant importance for enhancing the robustness of subsequent flaw recognition networks.

Effect of phosphorus content on interfacial heat transfer and film deposition behavior during the high-temperature simulation of strip casting

The interfacial wettability and heat transfer behavior are crucial in the strip casting of high phosphorus-containing steel.A hightemperature simulation of strip casting was conducted using the droplet solidification technique with the aims to reveal the effects of phosphorus content on interfacial wettability,deposited film,and interfacial heat transfer behavior.Results showed that when the phosphorus content increased from 0.014wt%to 0.406wt%,the mushy zone enlarged,the complete solidification temperature delayed from1518.3 to 1459.4℃,the final contact angle decreased from 118.4°to 102.8°,indicating improved interfacial contact,and the maximum heat flux increased from 6.9 to 9.2 MW/m2.Increasing the phosphorus content from 0.081wt%to 0.406wt%also accelerated the film deposition rate from 1.57 to 1.73μm per test,resulting in a thickened naturally deposited film with increased thermal resistance that advanced the transition point of heat transfer from the fifth experiment to the third experiment.

Extension of Flow Behaviour and Damage Models for Cast Iron Alloys with Strain Rate Effect

Cast iron alloys with low production cost and quite good mechanical properties are widely used in the automotive industry.To study the mechanical behavior of a typical ductile cast iron(GJS-450)with nodular graphite,uni-axial quasi-static and dynamic tensile tests at strain rates of 10^(-4),1,10,100,and 250 s^(-1)were carried out.In order to investigate the influence of stress state on the deformation and fracture parameters,specimens with various geometries were used in the experiments.Stress strain curves and fracture strains of the GJS-450 alloy in the strain rate range of 10^(-4)to 250 s^(-1)were obtained.A strain rate-dependent plastic flow model was proposed to describe the mechanical behavior in the corresponding strain-rate range.The available damage model was extended to take the strain rate into account and calibrated based on the analysis of local fracture strains.Simulations with the proposed plastic flow model and the damage model were conducted to observe the deformation and fracture process.The results show that the strain rate has obviously nonlinear effects on the yield stress and fracture strain of GJS-450 alloys.The predictions with the proposed plastic flow and damage models at various strain rates agree well with the experimental results,which illustrates that the rate-dependent plastic flow and damage models can be used to describe the mechanical behavior of cast iron alloys at elevated strain rates.The proposed plastic flow and damage models can be used to describe the deformation and fracture analysis of materials with similar properties.