Construction and analysis of dynamic solidification curves for non-equilibrium solidification process in lost-foam casting hypoeutectic gray cast iron

Most lost-foam casting processes involve non-equilibrium solidification dominated by kinetic factors, while construction of a common dynamic solidification curve is based on pure thermodynamics, not applicable for analyses and research of non-equilibrium macro-solidification processes, and the construction mode can not be applied to nonequilibrium solidification process. In this study, the construction of the dynamic solidification curve(DSC) for the nonequilibrium macro-solidification process included: a modified method to determine the start temperature of primary austenite precipitation(T_(AL)) and the start temperature of eutectic solidification(T_(ES)); double curves method to determine the temperature of the dendrite coherency point of primary austenite(T-(AC)) and the temperature of eutectic cells collision point(T_(EC)); the "technical solidus" method to determine the end temperature of eutectic reaction(T_(EN)). For this purpose, a comparative testing of the non-equilibrium solidification temperature fields in lost-foam casting and green sand mold casting hypoeutectic gray iron was carried out. The thermal analysis results were used to construct the DSCs of both these casting methods under non-equilibrium solidification conditions. The results show that the transformation rate of non-equilibrium solidification in hypoeutectic gray cast iron is greater than that of equilibrium solidification. The eutectic solidification region presents a typical mushy solidification mode. The results also indicate that the primary austenite precipitation zone of lost-foam casting is slightly larger than that of green sand casting. At the same time, the solid fraction(f_s) of the dendrite coherency points in lost-foam casting is greater than that in the green sand casting. Therefore, from these two points, lost-foam casting is more preferable for reduction of shrinkage and mechanical burntin sand tendency of the hypoeutectic gray cast iron. Due to the fact that the solidification process(from the surface to center) at primary austenite growth area in the lost-foam cylinder sample lags behind that in the green sand casting, the mushy solidification tendency of lost-foam casting is greater and the solidification time is longer.

A novel approach to investigate effect of magnetic field on dynamic properties of natural rubber based isotropic thick magnetorheological elastomers in shear mode

The preparation of natural rubber based isotropic thick magnetorheological elastomers(MRE) was focused on by varying the percentage volume concentration of carbonyl iron powder and developing a test set up to test the dynamic properties. Effect of magnetic field on the damping ratio was studied on the amplification region of the transmissibility curve. The viscoelastic dynamic damping nature of the elastomer was also studied by analyzing the force-displacement hysteresis graphs. The results show that MR effect increases with the increase in magnetic field as well as carbonyl iron powder particle concentration. It is observed that softer matrix material produces more MR effect. A maximum of 125% improvement in the loss factor is observed for the MRE with 25% carbonyl iron volume concentration. FEMM simulation shows that as carbonyl iron particle distribution becomes denser, MR effect is improved. FEMM analysis also reveals that if the distance between the adjacent iron particles are reduced from 20 μm to 10 μm, a 40% increase in stored energy is observed.