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Effects of Different Parameters on Porosity Defects Between the Horizontal and Vertical Shot Sleeve Processes

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Abstract

The effects of different casting parameters on porosity defects between the horizontal and vertical shot sleeve processes are quantitatively studied based on experiments and simulations. The castings made using the two processes are characterized in terms of porosity defects by X-ray radiographic inspection and blistering formation by T4 heat treatment process. Experimental results indicate that much fewer porosities and blisters are formed in the castings made using the vertical process than those made using the horizontal one. Meanwhile, numerical simulations have been performed to quantitatively investigate the flow dynamics behavior of molten metal in the horizontal and vertical shot sleeves. The simulation results demonstrate that compared with the conventional horizontal process, the vertical shot sleeve process is more efficient in elimination of waves and reduction of air entrapment and oxide formation. Moreover, the vertical process needs a lower pouring temperature which can decrease hydrogen solubility in the molten metal; it has a smaller temperature gradient of molten melt which can reduce the formation of cold flakes and pre-solidified materials. Therefore, the vertical shot sleeve process is more competitive in improving the internal integrity of die castings.

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Acknowledgements

The authors gratefully acknowledge financial support from Fiat Chrysler Automobiles LLC under the R&D project Agreement No. 00059689.

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Authors and Affiliations

  1. Department of Plasticity Technology, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, China

    Dashan Sui

  2. Department of Mechanical Engineering Technology, Purdue University, West Lafayette, IN, USA

    Dashan Sui & Qingyou Han

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  1. Dashan Sui
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  2. Qingyou Han
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Correspondence to Dashan Sui.

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Sui, D., Han, Q. Effects of Different Parameters on Porosity Defects Between the Horizontal and Vertical Shot Sleeve Processes. Inter Metalcast 13, 417–425 (2019). https://doi.org/10.1007/s40962-018-0267-7

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  • DOI: https://doi.org/10.1007/s40962-018-0267-7

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