Fabrication Technology Of Metals - Foundry an der RWTH Aachen | Karteikarten & Zusammenfassungen

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TESTE DEIN WISSEN

Name the necessary Cooling Conditions of Permanent Mold casting.

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TESTE DEIN WISSEN

• High heat conductivity of the mold material 

• Forming of a solidified shell as an effect of chill factor 

• Gap forming by heat contraction of the solidified shell 


=> The gap forming during solidification is a major factor on the heat transfer and the solidification time

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TESTE DEIN WISSEN

Which two types of gas can be used for rotary degassing? Give an example for each type of gas.

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TESTE DEIN WISSEN

• Inert gas 

→ Argon 

→ Nitrogen 


• Reactive gas 

→ Chlorine 

→ Sulfur Hexafluoride

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TESTE DEIN WISSEN

Why are we using permanent molds?

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TESTE DEIN WISSEN

• high productivity 

• long tool life 

• high mechanical properties 

• excellent tightness 

• smooth surfaces, good polishing capability 

• near-net-shape 

   ->  less mechanical machining required 


Nearly all casting alloys are processed in permanent mold casting, if it is economically (and geometrically) justifiable!

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TESTE DEIN WISSEN

How differs the solidification time of a sand casting and a permanent mold?

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TESTE DEIN WISSEN

Solidification time for sand casting is 3 - 10 times longer than for die casting

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TESTE DEIN WISSEN

What are typical grain refiners for hypo- and hypereutectic Al-Si-Alloys?

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TESTE DEIN WISSEN

Hypoeutectic (for primary α-Al-phase):

• Ti 

• B 

• AlTi5 

• AlTi5B1 

• AlB4 

• KBF 

• KTiF


Hypereutectic (for primary Si-phase): 

• P (typically 0.02 wt.-%)  

Lösung ausblenden
TESTE DEIN WISSEN

What properties should a moulding material have for its use in a foundry?

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TESTE DEIN WISSEN

• Formability/compressibility 

• Flowability 

• Stability of the green sand mould 

• High temperature resistance 

• Good collapsibility 

• Reusability

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TESTE DEIN WISSEN

Name at least 5 typical castings made from Al-Alloy.

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TESTE DEIN WISSEN

Engine blocks, Metal bearing, Cylinder head, Car door frame, Gear housing, Pistons

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TESTE DEIN WISSEN

Name the hardening mechanisms for organic-chemically bound moulding materials. Give one example of a representative binding system each!

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TESTE DEIN WISSEN

Warm/Hot hardening Moulding Materials 

− Hot-Box Process 

− Croning Process 


Gas hardening Moulding Materials 

− Polyurethane-Cold-Box Process 

− Beta-Set Process 


• Cold hardening Moulding Materials 

− Furan Resin 

− Phenolic Resin

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TESTE DEIN WISSEN

What are the benefits of grain refinement?

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TESTE DEIN WISSEN

• Higher mechanical properties (tensile strength, ductility) 

• Better fluidity and mold-filling properties 

• Lower susceptibility of hot tears 

• Better internal feeding effectiveness 

• Reduction of porosity within the microstructure 

• Better resistance against surface corrosion 

• Economical machining 

• Good decorative appearance

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TESTE DEIN WISSEN

Name the advantages and disadvantages of inorganic Hot-Box binders in comparison to conventional gas and warm hardening organic binders!

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TESTE DEIN WISSEN

Advantages: 

• Low staff and environmental impact 

• High strength 


Disadvantages: 

• Energy-intensive 

• Poor flowability 

• Bad core collapsibility after casting 

• Limited storage capability

Lösung ausblenden
TESTE DEIN WISSEN

Name the Functions of Moulding Material Coatings.

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TESTE DEIN WISSEN

• Compensation of irregularities of the mould surface 

      ► Smoothing of mould, core and casting 

• Separation of moulding material and casting 

      ► Improved demoldability 

• Prevention of reactions between mould and liquid metal 

      ► Boundary effects in the microstructure and the formation of gas porosity is prevented 

• Prevention of abrupt thermal exposure to the moulding material 

      ► Sufficient heat resistance of the moulding material is ensured 

• Adjustment of the heat exchange from melt to the moulding material 

      ► Regulation of the heat distribution of the mould

Lösung ausblenden
TESTE DEIN WISSEN

Why do we preheat our molds?

Lösung anzeigen
TESTE DEIN WISSEN

• Reducing the thermal shock intensity => Increasing life time 

• Quickly obtaining a stationary process (regulating temperature profile of the mold) 

• Avoiding cold shuts (Fluidity increases) 

• Reducing the possibility of cracks (product and die) 

• Increasing the life time of coatings

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Q:

Name the necessary Cooling Conditions of Permanent Mold casting.

A:

• High heat conductivity of the mold material 

• Forming of a solidified shell as an effect of chill factor 

• Gap forming by heat contraction of the solidified shell 


=> The gap forming during solidification is a major factor on the heat transfer and the solidification time

Q:

Which two types of gas can be used for rotary degassing? Give an example for each type of gas.

A:

• Inert gas 

→ Argon 

→ Nitrogen 


• Reactive gas 

→ Chlorine 

→ Sulfur Hexafluoride

Q:

Why are we using permanent molds?

A:

• high productivity 

• long tool life 

• high mechanical properties 

• excellent tightness 

• smooth surfaces, good polishing capability 

• near-net-shape 

   ->  less mechanical machining required 


Nearly all casting alloys are processed in permanent mold casting, if it is economically (and geometrically) justifiable!

Q:

How differs the solidification time of a sand casting and a permanent mold?

A:

Solidification time for sand casting is 3 - 10 times longer than for die casting

Q:

What are typical grain refiners for hypo- and hypereutectic Al-Si-Alloys?

A:

Hypoeutectic (for primary α-Al-phase):

• Ti 

• B 

• AlTi5 

• AlTi5B1 

• AlB4 

• KBF 

• KTiF


Hypereutectic (for primary Si-phase): 

• P (typically 0.02 wt.-%)  

Mehr Karteikarten anzeigen
Q:

What properties should a moulding material have for its use in a foundry?

A:

• Formability/compressibility 

• Flowability 

• Stability of the green sand mould 

• High temperature resistance 

• Good collapsibility 

• Reusability

Q:

Name at least 5 typical castings made from Al-Alloy.

A:

Engine blocks, Metal bearing, Cylinder head, Car door frame, Gear housing, Pistons

Q:

Name the hardening mechanisms for organic-chemically bound moulding materials. Give one example of a representative binding system each!

A:

Warm/Hot hardening Moulding Materials 

− Hot-Box Process 

− Croning Process 


Gas hardening Moulding Materials 

− Polyurethane-Cold-Box Process 

− Beta-Set Process 


• Cold hardening Moulding Materials 

− Furan Resin 

− Phenolic Resin

Q:

What are the benefits of grain refinement?

A:

• Higher mechanical properties (tensile strength, ductility) 

• Better fluidity and mold-filling properties 

• Lower susceptibility of hot tears 

• Better internal feeding effectiveness 

• Reduction of porosity within the microstructure 

• Better resistance against surface corrosion 

• Economical machining 

• Good decorative appearance

Q:

Name the advantages and disadvantages of inorganic Hot-Box binders in comparison to conventional gas and warm hardening organic binders!

A:

Advantages: 

• Low staff and environmental impact 

• High strength 


Disadvantages: 

• Energy-intensive 

• Poor flowability 

• Bad core collapsibility after casting 

• Limited storage capability

Q:

Name the Functions of Moulding Material Coatings.

A:

• Compensation of irregularities of the mould surface 

      ► Smoothing of mould, core and casting 

• Separation of moulding material and casting 

      ► Improved demoldability 

• Prevention of reactions between mould and liquid metal 

      ► Boundary effects in the microstructure and the formation of gas porosity is prevented 

• Prevention of abrupt thermal exposure to the moulding material 

      ► Sufficient heat resistance of the moulding material is ensured 

• Adjustment of the heat exchange from melt to the moulding material 

      ► Regulation of the heat distribution of the mould

Q:

Why do we preheat our molds?

A:

• Reducing the thermal shock intensity => Increasing life time 

• Quickly obtaining a stationary process (regulating temperature profile of the mold) 

• Avoiding cold shuts (Fluidity increases) 

• Reducing the possibility of cracks (product and die) 

• Increasing the life time of coatings

Fabrication Technology of Metals - Foundry

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