Identification of critical factors affecting shrinkage porosity in permanent mold casting using numerical simulations based on design of experiments

Journal of Materials Processing Technology

Volumn 209, Issue 3, 2009, Pages 1209-1219

  Gunasegaram, D R ^a   Farnsworth, D J ^b   Nguyen, T T ^a  

^a CSIRO   (Australia)

^b FORD MOTOR COMPANY   (United States)

Author keywords

Aluminum; Casting; Design of experiments (DOE); Numerical simulation; Permanent mold; Shrinkage porosity

Indexed keywords

ALUMINA; ALUMINUM; COMPENSATION (PERSONNEL); COMPUTER SIMULATION; COST ACCOUNTING; DENSITY (OPTICAL); DESIGN; DESIGN OF EXPERIMENTS; DIFFRACTIVE OPTICAL ELEMENTS; EMPLOYMENT; EXPERIMENTS; FOUNDRIES; FOUNDRY PRACTICE; JUST IN TIME PRODUCTION; LIGHT METALS; MATHEMATICAL MODELS; METAL CASTING; MOLDS; OPTICAL PROPERTIES; POROSITY; SHRINKAGE; WAGES;

CASTING PROCESSES; CRITICAL FACTORS; CRITICAL LOCATIONS; CRITICAL REGIONS; GEOMETRIC CONSTRAINTS; JUST-IN-TIME PRODUCTIONS; LABOR COSTS; LEAK TESTS; MASS PRODUCTIONS; MATERIAL YIELDS; MOLD TEMPERATURES; NUMERICAL SIMULATION; PERMANENT MOLD; POTENTIAL FACTORS; PROCESS PARAMETERS; SCRAP RATES; SECTION THICKNESSES; SHRINKAGE PORES; SHRINKAGE POROSITY; TEMPERATURE PROFILES; TWO PARAMETERS;

PERMANENT MOLD CASTING;

EID: 57949083609     PISSN: 09240136     EISSN: None     Source Type: Journal    
DOI: 10.1016/j.jmatprotec.2008.03.044     Document Type: Article

References (16)

1. Antony J. Training for design of experiments using a catapult. Qual. Reliab. Eng. Int. 18 (2002) 29-35
2. Campbell J. Castings (1991), Butterworth-Heinemann, London pp. 42, 49, 146-147 and 175-208
3. Chiesa F. Measurement of thermal conductance at the mold/metal interface of permanent molds. AFS Trans. 98 (1990) 193-200
4. Davies O.L. The Design and Analysis of Industrial Experiments. second ed. (1978), Longman, London pp. 247-289
5. Gunasegaram D.R., Dahle A.K., and Nguyen T.T. Mechanism of air gap formation during solidification of commercial Al-Si alloys. AFS Trans. 107 (1999) 257-263
6. Gunasegaram D.R., and Nguyen T.T. Effect of cooling rate on air gap formation in aluminium permanent mould casting. Int. J. Cast Met. Res. 19 (2006) 116-122
7. Gunasegaram D.R., and Smith B.J. MAGMASOFT helps assure quality in a progressive Australian iron foundry. Proceedings of the 32nd National Convention of the Australian Foundry Institute. Fremantle, Australia (2001) 99-104
8. Gunasegaram, D.R., 1998. A Thermo-mechanical Study of the Casting-Mould Interface. Ph.D. Thesis. The University of Queensland, Brisbane, Australia.
9. Gunasegaram D.R., and Nguyen T.T. Comparison of heat transfer parameters in two permanent molds. AFS Trans. 105 (1997) 551-556
10. Gunasegaram D.R., Celentano D.J., and Nguyen T.T. Effect of cooling a permanent composite mold on air gap formation and heat transfer. In: Viswanathan S., Reddy R.G., and Malas J.C. (Eds). Sensors and Modeling in Materials Processing: Techniques and Applications, 126th TMS Annual Meeting. Orlando, USA (1997) 101-116
11. Gupta A., Ding Y., Xu L., and Reinikainen T. Optimal parameter selection for electronic packaging using sequential computer simulations. J. Manuf. Sci. E-Trans. ASME 128 (2006) 705-715
12. Hallam C., and Griffiths W. A model of the interfacial heat-transfer coefficient for the aluminum gravity die casting process. Metall. Mater. Trans. B 35 (2004) 721-733
13. Hamasaiid A., Dargusch M.S., Davidson C.J., Tovar S., Loulou T., Rezai-Aria F., and Dour G. Effect of mold coating materials and thickness on heat transfer in permanent mold casting of aluminum alloys. Metall. Mater. Trans. A 38A (2007) 1303-1316
14. Hunter J.S. Design and Analysis of Experiments. In: Godfrey A.B., and Juran J.M. (Eds). Juran's Quality Handbook (1999), McGraw-Hill, New York 47.1-47.77
15. Nguyen T.T., de Looze G.R., Murray M.T., and Esdaile R.J. Research developments in the low pressure die casting of automotive components. AFS Trans. 105 (1997) 833-841
16. Ponsot A., Poitrault I., David C., Richy P.E., and Vidal V. Application of experiments designs methodology to the sensitivity study of solidification simulation results to the input data uncertainties. In: Gandin C.A., and Bellet M. (Eds). Proceedings of Modeling of Casting, Welding, and Advanced Solidification XI. Opio, France (2006) 1163-1170