SHAPE CASTING: 6th International Symposium

Cover Image: Fracture surface of an AZ91 Mg alloy casting, supplied by Dr. Paul D. Eason, Associate Professor of Mechanical Engineering at the University of North Florida.

TIIS2016 145"' Annual Meeting & Exhibition

FEBRUARY 14-18 DOWNTOWN NASHVILLE

Tf NNf SSEE MUSIC CITY CENTER

New proceedings volumes from the TMS2016 Annual Meeting:

o 7th International Symposium on High-Temperature Metallurgical Processing

o CFD Modeling and Simulation in Materials Processing 2016

o Characterization of Minerals, Metals, and Materials 2016

o Energy Technology 2016: Carbon Dioxide Management and Other Technologies

o EPD Congress 2016

o light Metals 2016

o Magnesium Technology 2016

o Rare Metal Technology 2016

o REWAS2016

o Shape Casting: 6th International Symposium

o TMS 2016 Supplemental Proceedings

SHAPE CASTING: 6th International Symposium

Proceedings of a symposium sponsored by

the Aluminum Committee of the Light Metals Division

and the Solidification Committee of the Materials

Processing & Manufacturing Division of

The Minerals, Metals & Materials Society (TMS)

held during

TMS2016 145'" Annual M-tlng &. Exhibition

FEBRUARY 14-lBooWNTOWN NASHVILLE,

TENNESSEE MUSIC CITY CENTER

Edited by: Murat Tiryakioglu, Mark Jolly,

and Glenn Byczynski

Editors Murat Tiryakioglu Mark Jolly Glenn Byczynski

ISBN 978-3-319-48622-2 DOT I 0.1007/978-3-319-48166-1

Chemistry and Materials Science: Professional

ISBN 978-3-319-48166-1 ( eBook)

Copyright© 2016 by The Minerals, Metals & Materials Society Published by Springer International Publishers, Switzerland, 2016 Reprint of the original edition published by John Wiley & Sons, Inc., 2016,978-1-119-22582-9

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TABLE OF CONTENTS Shape Casting: 6th International Symposium

Preface ..................................................................................................................... ix Symposium Organizers/Editors .............................................................................. xi

Engineering High Quality Castings I

Bifilms and Hot Tearing of Al-Si Alloys .................................................................. 3

Muhammet Uluda*, Remzi ~etin, and Derya DiHJinar

Crack Susceptibility of Binary Aluminum Alloys: Analytical Equations .............. 11

Jiangwei Liu and Sindo Kou

The Unidirectional Solidification of Ti-46Al-8Nb Alloy with BaZr03 CoatedA120 3 Mould .............................................................................................. l9

Chao Wei, Mingyang Li, Guangyao Chen, Hongbin Wang, Xionggang Lu, and Chonghe Li

Analytical Model of Filling Fine Features and Sharp Comers in Investment Casting of CMSX-4 ............................................................................................... 27

L.P. Kroneman, M.J.M. Krane, and K.P. Trumble

Real-Time Radiography and Modeling of Porosity Formation in an A356 Aluminum Alloy Wedge Casting .................................................................. 35

Vahid Khalajzadeh, David D. Goettsch, and Christoph Beckermann

Modeling of Distortion of a Steel Bracket Sand Casting ...................................... .43 D. Galles and C. Beckermann

SiC Particle Reinforced A1 Matrix Composite by SIMA ....................................... 51 Emirhan Aydzn, Caglar Yuksel, Eray Eni, and Derya Dispinar

Evolution of Primary Fe-Rich Compounds in Secondary Al-Si-Cu Alloys ........... 59

Alberto Fabrizi, Stefano Capuzzi, and Giulio Timelli

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Casting Perfonnance and Innovation

Methods of Reducing Materials' Waste and Saving Energy in Investment Casting ................................................................................................. 69

H.A. Mahrabi, M.R. Jolly, and K. Salonitis

Quality Assessment of A356 Ingots from Different Suppliers in

Wheel Production ................................................................................................... 77 Emre K.oca, Caglar Yukse~ Eray Erzi, and Derya Df~pznar

On the Relationship between Quality Index and Fatigue Life Distributions in B201 and D357 Alloy Aerospace Castings ............................................................ 85

Hiiseyin Ozde~ and Murat Tiryakioglu

On the Properties and Performance of Ablation Cast Components ....................... 93 Murat Tiryakiogtu and John Grassi

The Reliability of Ductile Casting Iron Dependent on Runner System Design: An Example of Support Bracket of Brake Caliper .............................................. 101

Fu-lUan Hsu, Kuo-Nien Wang, and Cheng-Lung Li

Corrosion Resistance of Stainless Steels in Biodiesel ......................................... 109 Alejandra S. Roman, Claudia M. Mendez. and Alicia E. Ares

Characterization of Tensile Deformation in AZ91D Mg Alloy Castings ............. 117 Ogtm Unal and Murat Tiryakioglu

On the Mean Stress Correction in Fatigue Life Assessment in Cast

AlunrinumAlloys ................................................................................................. 125 Hiiseyin Ozde~ and Murat Tiryakiogtu

Effects of Sr on the Microstructure of Electromagnetically Stirred Semi Solid Hypoeutectic Al-Si Alloys ................................................................................... 133

G. Eisaabadi, M. Nouri, R. Beygi, M. Zarezadeh Mehrizi, A. Nouri, and

M. Ebrahimi

Engineering High Quality Castings II

Grain Refinement of Al-Si Hypoeutectic Alloys by A13Ti1B Master Alloy and Ultrasonic Treatnlent. .................................................................................... 143

Gui Wang, Eric Qiang Wang, Arvind Prasad, Matthew Dargusch, and

David H StJohn

Vl

Influence of Process Parameters on the Microstructure and Casting Defects of a LPDC Engine Block ..................................................................................... 151

Giulio Timelli and Daniele Caliari

Preliminary Investigation of the Grain Refinement Mechanism in CuAlloys ............................................................................................................. 159

A.K. Cziegler and P. Schu11Ulcher

Solidification Analysis of a Magnesium-Zinc Alloy Using In-Situ Neutron Diffraction .............................................................................................. 167

Abdallah Elsayed, Dimitry Sediako, and Comondore Ravindran

Change in Silicon Morphology with Time and Temperature in Sr Modified A356 ................................................................................................. 175

Sadik Kaan Ipek, Caglar Yuksel, Eray Erzi, and Derya Dispinar

Effects of Casting Conditions on End Product Defects in Direct Chill Casted Hot Rolling Ingots .................................................................................... 185

Arda Yorulmaz, f;aglar Yaksel, Eraz Erzi, and Derya Dispinar

A Coupled Thermal-Stress Model of A319 Alloy Chilled Sand Casting ............ 195

Farzaneh Farhang Mehr, Steve Cockcroft, and Daan Maijer

Effect of Duration on 11 Grain Refinement of A356 and Melt Quality ............... 203

Ozen Gursoy, Eray Erzi, f;aglar YUksel, and Derya Dispinar

Author Index ........................................................................................................ 209

Subject Index ....................................................................................................... 211

Vll

PREFACE

This is the 6th in the series of International Shape Casting Symposia to be held at the annual TMS meeting and exhibition. Professor John Campbell has been on the organizing committee since the series inception in 2005 but has decided not to continue. I would like to thank John for all his work involved in the previous conferences. I am very pleased to be John's successor on the committee and it complements the role I will be taking on in February 2016 as Chair of the TMS Solidification Committee.

Over the last 10 years a wide range of topics has cropped up, some of which remain as significant aspects in the symposium. Oxide films have become hi-films, modeling is now not just fashionable but essential, and the provenance of defects will always be argued about Other topics are now becoming hot Energy in manufacturing, sustainability, and the circular economy-none of which were discussed in the first symposium-are now in everyday conversations in manufacturing plants as climate change and the overheating globe becomes more of a concern and energy process begin to rise.

The casting industry hasn't yet been hit by resource constraints, but inevitably this will come. Water, energy, and the materials we cast may well become scarcer and then we, as foundry engineers and scientists, have to work in smarter and more efficient ways with what we have. High quality and yield will be drivers for all in the sector and that can only be achieved by carrying out the research in liquid metal engineering that we all do. Understanding the science and applying it as an engineer is the only way forward in this very challenging environment.

Mark Jolly

lX

SYMPOSIUM ORGANIZERS/EDITORS

Murat Tiryaldoglu is the director of the School of Engineering and a professor of mechanical engineering at the University of North Florida. He received his B.Sc. in mechanical engineering from Bogazi~i University (1990), M.S. (1991) and Ph.D. (1993) in engineering management from the University of Missouri-Rolla, and another Ph.D in metallurgy and materials (2002), from the University of Birmingham. England.

Dr. Tiryakioglu grew up around his family's foundry, which continues to thrive in Istanbul, Turkey. This has

led to research interests in process design for high quality castings, aluminum heat treatment modeling and optimization, process-structure-property relationships in metals, statistical modeling and quality and reliability improvement, on which he has written a chapter, published over 100 technical papers, and edited nine books.

Dr. Tiryakioglu was awarded the inaugural John Campbell Medal from the Institute of Cast Metals Engineers (U.K.), and the Eugene Merchant Outstanding Young Manufacturing Engineer by the Society of Manufacturing Engineers. He was also selected a TMS Young Leader in Light Metals. He is a member of TMS, ASM International, and ASQ, and is an ASQ Certified Quality Engineer.

Mark Jolly is Professor of Sustainable Manufacturing and Head of the Sustainable Manufacturing Systems Centre at Cranfield University. He has 30 years' experience in manufacturing, process modeling, and the foundry industry as suppliers to aerospace, automotive, and medical sectors. He has a degree in metallurgy from Sheffield University and Ph.D. from Cambridge. Mark spent four years working for a tier 1 automotive supplier before spending two years in Switzerland managing industrial research contracts. Moving back to the U.K. he worked for seven years for Foseco. In 1995 he moved back into academia spending 17

years at University of Birmingham and setting up the Castings Centre and Process Modelling Group. In May 2012 he took up his current position at Cranfield. His current research is focused on reducing energy and materials usage in casting processes and glass manufacturing. Generally he has research interests in helping manufacturers improve the sustainability of their processes by improving their resource efficiency.

xi

Dr. Jolly is Chartered Engineer, a Chartered Environmentalist, a Fellow of the Institute of Materials, Minerals and Mining (IOMMM), a Fellow of the Institute of Cast Metals Engineers (ICMB) and a member of TMS and the American Foundry Society. He was the 2008 recipient of the Oliver Stubbs Gold Medal (ICME} and the University ofBirmingbam 's 2010 Josiah Mason Award for Business Achievement.

Glenn Byezyn.skl is Technical ManagerofNemak Canadian Operations. He received his Ph.D. in metallurgy and materials science from the University of Birmingham in U.K. in 2002. His masters (materials science in 1997) and bachelor's (mechanical engineering in 1994) degrees were conducted at the University of Windsor. In his 20-year career in metal casting he has held several R&D and engineering positions within Nemak and Ford Motor Company including R&D Manager ofNemak Europe based in Germany (2007-2009), manager of the Nemak Engineering Centre (Wmdsor) and Engineering Manager at

Nemak's Wmdsor Aluminum Plant. He was chairman of the Detroit-Wmdsor Chapter of the American Foundry Society (AFS} in 2006-2007, is a director and regional chairman of the Foundry Educational Foundation, and is a registered professional engineer in the Province of Ontario.

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