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A great number of castings were poured by the Low Pressure Permanent Mold process for a wide range of filling times and pouring temperatures. One casting was a 2mm-wall (0.080 in.) cover weighing 0.13kg (0.27lb) and the other was a 7kg (15.4lbs) bell housing with walls varying in thickness from 6 to 25mm (0. To 1 in.
A great number of castings were poured by the Low Pressure Permanent Mold process for a wide range of filling times and pouring temperatures. One casting was a 2mm-wall (0.080 in.) cover weighing 0.13kg (0.27lb) and the other was a 7kg (15.4lbs) bell housing with walls varying in thickness from 6 to 25mm (0. To 1 in.
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A great number of castings were poured by the Low Pressure Permanent Mold process for a wide range of filling times and pouring temperatures. One casting was a 2mm-wall (0.080 in.) cover weighing 0.13kg (0.27lb) and the other was a 7kg (15.4lbs) bell housing with walls varying in thickness from 6 to 25mm (0. To 1 in.
Авторское право:
Attribution Non-Commercial (BY-NC)
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Скачайте в формате PDF, TXT или читайте онлайн в Scribd
Measuring Mold Cavity Filling Time in Low Pressure Permanent Mold
Casting of Aluminum A356 Parts
F. Chiesa , and N. Gigure
Centre de Mtallurgie du Qubec, Trois-Rivires, Qubec
B. Duchesne Collge de Trois-Rivires, Trois-Rivires, Qubec
J. Baril
Technologie de lAluminium et du Magnsium, Trois-Rivires, Qubec
Copyright 2011 American Foundry Society
ABSTRACT In the present work, a great number of castings were poured by the Low Pressure Permanent Mold process for a wide range of filling times and pouring temperatures. One casting was a 2mm-wall (0.080 in.) cover weighing 0.13kg (0.27lb) and the other was a 7kg (15.4lbs) bell housing with walls varying in thickness from 6 to 25mm (0.25 to 1 in.).
Type K thermocouple wires (0.12mm diameter [0.0045 in.], with a response time of 0.1s) were connected to a data logger (20 readings per second) to detect the passage of the liquid metal front, allowing an accurate measurement of the filling time (0.05s). As the filling time is obtained by subtracting the passage times recorded by two identical thermocouples, the time lags cancels out with no detrimental effect on the accuracy.
This allowed to determine a slowing factor (SF) defined as the ratio of the actual measured filling time to the filling time calculated based on the static equilibrium level. Slowing factor was found to vary from 1, for very slow rates of filling, to values greater than 2 for extremely steep pressure ramps. For typical industrial production conditions, SF is in the range 1.3 to 1.6 and appears to be closer to 1.0 for thin castings. It was found that the pouring temperature had little effect on SF except for extremely low pouring temperatures (below 700C or 1292F).
INTRODUCTION The Low Pressure Permanent Mold casting (LPPM) process is used for producing aluminum and magnesium parts. It is a novel process for pouring magnesium alloys, 1,2 but a mature one as far as aluminum alloys are concerned. 3 The principle of the LPPM process is shown in Figure 1. The liquid metal, located under the mold, is pushed up a transfer tube by applying a gas pressure on the surface of the melt. This process presents a host of advantages over gravity casting, including: a) Tranquil and perfectly controlled bottom filling of the mold cavity as illustrated in Figure 1; b) Superior feeding without risers. In LPPM, the typical feeding pressure is 900mB versus 100- 200mB for riser fed gravity castings; c) Thinner walls may be obtained as compared to gravity filling (as thin as 2mm); d) The yield is typically 85%, versus 60% in gravity casting, leading to less returns in the melt, hence a cleaner metal with consequent energy savings and reduced melting furnace capacity (tons/h); e) The liquid metal is cleaner because it is extracted from underneath the melt surface; and f) No metal handling by the operator results in better ergonomics and a perfectly repeated filling at each cycle.
Among these advantages, the control of the filling is the most spectacular: by varying the rate of increase of the pressure applied on the melt, the filling may be sped up or slowed down at will with great ease.
Filling in the LPPM process has been previously studied. 4,5 However, the actual time necessary to fill the mold cavity is not known because the pressure applied on the melt cannot be strictly related to the level of the melt in the mold as discussed in the following section. Paper 11-003.pdf, Page 1 of 8 AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA
Fig. 1. Principle of LPPM casting.
RELATING PRESSURE AND MELT LEVEL The LPPM casting process allows the production of high integrity light metal parts with a high productivity. LPPM permits very close control of the filling process. However, the mold cavity being closed, it is difficult to accurately know the filling time of the mold cavity, as easily as it is in the case of an open cavity typical of the gravity poured permanent molds. The known pressure rise applied on the surface of the melt allows a calculation of theoretical filling time, which is always substantially less than the actual filling time, particularly at high rates. The knowledge of this actual filling time is necessary to the modeling of the process, and more importantly, for the comprehension of phenomena such as superheat losses, air entrapment and turbulence, leading to casting defects such as misruns, cold-shuts and sagging of the cope surface. The equilibrium level of the metal (i.e. when the liquid metal is at rest) in the transfer tube and the mold cavity depends only on the pressure applied on the surface of the melt inside the pressure tight crucible: This level will be called the theoretical level. Each increase in pressure of 1 mB will result in the liquid aluminum level rising by 4mm. Consequently, the equilibrium altitude, or theoretical level can be mathematically derived using the simple law stating that the difference in pressure p between two points with a difference in altitude of h (in m) is equal to p (in Pa) =.g.h, where is the density of the fluid (2600 kg.m -3 for liquid aluminum) and g the acceleration of gravity (9.81 m.s -2 ) However, this will not be the case in real life because of the following reasons: a) Part of the pressure force is used to accelerate the liquid metal at the entrance of the transfer tube and to counter viscous forces, so that the actual metal level will be lower than the theoretical level. b) Depending on the filling rate with respect to the venting of the mold, the difficulty in expelling the air from the mold cavity will result in a pressure build up which will prevent the liquid metal level to rise as fast as it should.
For instance, let us assume that the pressure ramp shown in Figure 2 is applied on the melt surface (0- 500mB in 10s, or 50mB/s), while the top of the mold is 1500mm above the melt surface. This means that the theoretical level will rise at a rate of 200 mm/s as indicated by the blue line in Figure 3. The top of the mold (at altitude 1500mm) will thus be reached after 7.5s, when the pressure is 375mB as shown by the white arrow in Figure 2.
Fig. 2. Typical pressure curve in LPPM casting.
Fig. 3. Melt level progression corresponding to the pressure curve of Fig.2 as a function of venting. 0 20 40 60 80 100 120 140 160 0 2 4 6 8 10 12 14 16 18 time, s m e t a l
h e i g h t
a b o v e
p o t
l e v e l ,
c m theoretical (4mm/mB) well vented mold poorly vented mold Paper 11-003.pdf, Page 2 of 8 AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA
However, in a normally vented mold, this relatively steep pressure rise will result in a lag mainly due to an air pressure build up in the mold cavity. The actual melt level progression in the mold will follow the red curve in Figure 3 while a poorly vented mold will result in the very slow filling depicted by the yellow curve in the same figure.
Figure 4 shows typical curves of the pressure build up in the mold cavity recorded by a manometer during four consecutive fillings of the LPPM cast bell housing referred to in the next chapter; in this particular case, the rate in pressure rise over the surface of the liquid metal was 15mB/s. The curves in Figure 4 recorded during these four consecutive cycles indicate that the backpressure varied between 25 and 40mB under identical pouring conditions; this scatter is probably due to variations in mold tightness at each mold closing.
0 10 20 30 40 50 0 1 2 3 4 5 6 7 8 9 10 11 time, s p r e s s u r e ,
m B
Fig. 4. Pressure build-up in cavity during filling.
FILLING A 7kg (15.4lbs) A356 BELL HOUSING
The filling times of a 7kg finished casting were measured for different pressure ramps and the SF obtained by dividing the measured filling time by the theoretical filling time corresponding to metallostatic equilibrium.
The filling times were measured by detecting the arrival of the flow via two quick response thermocouples encapsulated in thin copper sheaths; they were located as indicated in Figure 5 and the recording rate was 20 readings per second.
The LPPM press used in our filling experiments is shown in Figure 6 and schematized in Figure 7 where the correspondence between the pressure applied on the melt and the altitude is indicated.
Fig. 5. Location of the two thermocouple tips allowed measuring of the filling times (red dots).
Fig. 6. LPPM press with close-up on mold (at right).
Figure 7 states that when the crucible is full, assuming a very slow rise in pressure over the melt, the mold cavity will start filling when the pressure reaches 88mB, and will finish filling when the pressure reaches 143mB. Paper 11-003.pdf, Page 3 of 8 AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA
Fig. 7. Relationship between pressure and level.
However, as explained above, the actual pressures will be greater than 88 and 143mB, all the more since the filling is fast and the venting of the mold is poor.
The measurement of the filling times was done in the course of a campaign where the 40 bell housings shown in Figure 8 were produced. Nine initial pours were necessary to run in the mold and reach a dynamic thermal equilibrium.
Figure 9 shows the recorded temperature cycling in the mold during the whole campaign (49 pours); the positions of the thermocouples inserted in the mold are represented by a red dot on the models shown at two different view angles in Figure 9.
Fig. 8. Production of the casting campaign when filling times were measured (40 castings).
Fig. 9. Recorded mold temperature cycling at locations indicated by the two red dots on the casting models. Paper 11-003.pdf, Page 4 of 8 AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA
300 320 340 360 380 400 420 440 10 12 14 16 18 20 22 24 time (s) t e m p e r a t u r e
( C )
EXPERIMENTAL RESULTS (BELL HOUSING)
A typical response from the two thermocouples used to measure the filling time is shown in Figure 10. It pertains to pour #34 with a melt temperature of 745C (1373F), a pressure ramp of 0-300mB in 25s (12mB/s) corresponding to a theoretical filling time of 4.7s. The detailed analysis of the curve shows that the filling time is 21.3-14.9= 6.4s. The slowing factor is thus equal to SF=6.4s/4.7s=1.36 in this particular instance.
Slowing factor was calculated in a similar fashion for 19 normal pours, i.e. pours at a temperature between 745C and 755C(1373F and 1391F) and pressure ramps of 15mB/s and 12mB/s, or 0-300mB pressure rise in 20s and 25s respectively. The results are shown in Figure 11 for 12 pours at 15mB/s and 7 pours at 12mB/s.
It shows that under normal conditions, the SF is about 1.5 with a higher dispersion when the filling is faster. This would entail that a more reproducible filling is achieved when the filling is slower.
Fig. 10. Typical response from the thermocouples measuring the filling time. (pour#34)(See Fig.5)
Fig.11.Slowing factor for normal filling times (Bell housings).
The SF was also calculated for extreme values of filling time, namely for pressure ramps of 0-300mB in 5, 10, 15, 35, 60, 75 and 90s and pouring temperatures of 720C, 695C, 685C, 681C and 664C(1328F, 1283F, 1265F, 1258F, and 1227F respectively). This is shown in Figures 12 and 13.
Fig. 12. Slowing factor over a wide range of filling times (1:18 ratio.)(Bell housings)
The leftmost bar in the graph of Figure 12 indicates that for 0-300mB pressure ramp duration of 5s, the theoretical filling time is 0.9s and the slowing factor is equal to 2.27; hence the measured filling time has been 2.1s.
Likewise, the rightmost bar in the same graph corresponds to a 0-300mB pressure ramp duration of 90s, i.e. a very slow rate of filling; in this case, the theoretical filling time is 16.5s, the SF is 1.10, calculated from the measured filling time of 18.1s. The graph shows, quite expectedly, that SF is close to 1 for very slow filling times; it increases up to 2.3 for extremely steep pressure ramps; this results from the growing difficulty in expelling the air entrapped in the mold cavity. For normal ramp durations of 5 to 10s, the value of SF lies around 1.5. The graph on Figure 13 lumps the results obtained for normal 0-300mB pressure ramp durations of 15s, 20s, and 25s and for a range of pouring temperatures comprised between 300 350 400 450 500 550 0 10 20 30 40 50 time (s) t e m p e r a t u r e
( C ) Paper 11-003.pdf, Page 5 of 8 AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA
664C and 750C (1227F and 1382F). It shows that the SF increases slightly as the pouring temperature drops, probably due to the increased viscosity of the melt.
0 0.5 1 1.5 2 660 680 700 720 740 760 pouring temperature (C) s l o w i n g
f a c t o r ,
S F
Fig. 13. Slowing factor over a wide range of pouring temperatures for a normal range of filling times.(Bell housings)
EXPERIMENTAL RESULTS (THIN CASTING)
Similar filling times were measured when pouring thin wall castings, one of which is shown in place in the mold and after ejection in Figure 14. The cluster comprises two mirror-copy covers used to encase an airplane seat adjustment device. The massive feeding and gating system represents 70% of the total weight of the cluster.
Fig. 14. Cover castings (1kg two-part cluster).
Figure 15 shows the 72 clusters which were poured in one campaign for a range of 0-300mB pressure ramp durations of 2s (150mB/s), 4s, 6s, 8s, 12s, 16s, and 20s (15mB/s).
Fig. 15. Clusters poured in the present study. Three thermocouples represented in red in Figure 16 were inserted in the mold to record the thermal history; their responses are shown in Figure 18. The filling time was measured by fast response thermocouples in green on the same figure separated by a vertical distance of 211mm or 8.3 in. (Figure 17). In the same manner as was done for the bell housings, dividing the actual measured filling times by the theoretical filling times allowed to determine the SF for pouring temperatures of 720C, 740C and 760C(1328F, 1364F, and 1400F) . The results are plotted in Figure 19 for these 3 pouring temperatures. Looking at the three leftmost bars indicates that, for a very steep pressure ramp of 0-300mB lasting 2s, the theoretical filling time is 0.45s and the slowing factors are 4.7, 2.8 and 2.3 for pouring temperatures of 720, 740 and 760C. This translates to actual filling time of 2.1, 1.2 and 1.0s respectively. However, for slower (and more reasonable) filling rates, SF is always less than 1.5 and did not depend much on the pouring temperature between 720C and 760C(1328F and 1400F). Similarly to what was observed in the bell housing experiments, and for the same reason, SF decreases as the filling is slower. The actual filling time is generally closer to the theoretical filling time than for the bell housing experiments; this may be explained by the fact that a much lesser amount of air must be expelled from the cavity, especially in the final stage of the filling process.
Fig. 16. Thermocouples inserted in mold.
Fig. 17. Vertical distance separating the two thermocouples measuring the fill time. Paper 11-003.pdf, Page 6 of 8 AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA
Temperature at 3 locations in the mold during the casting campaign 300 350 400 450 500 550 600 10:20 10:50 11:20 11:50 12:20 12:51 13:21 13:51 14:21 14:52 time (hrs:min) t e m p e r a t u r e
( C )
Fig. 18. Response of the thermocouples represented in red on Figure 16.
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 s l o w i n g
f a c t o r ,
S F 2/0.45 4/0.9 6/1.3 8/1.75 12/2.6 16/3.5 20/4.5 time to reach 300mB (s) / theoretical filling time ( s) 760C 740C 720C
Fig. 19. Slowing factor over a wide range of filling times (1:10.)(Thin casting)
CONCLUSIONS
By measuring the filling time of a thin and a bulky casting under a range of process conditions, it was possible to determine the SF, ratio of the actual filling time to the theoretical filling time based on the static level equilibrium of the melt. SF allows a calculation of the filling time of the mold cavity after the pressure ramp of the LPPM process is selected. The knowledge of SF is very useful to input a realistic mold filling time when modeling the filling of a LPPM mold.
A SF value of 1 indicates that the actual filling time is equal to the theoretical time; this corresponds to an extremely slow mold filling, when no back pressure builds up inside the mold cavity. A value of SF of 2 means that the actual filling time is twice the time calculated based on the pressure ramp applied on the melt and the height of the casting. Paper 11-003.pdf, Page 7 of 8 AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA
It was determined that;
1) In the case of the bell housing (Casting thickness ranging from 6mm to 25mm, or 0.25 to 1), at pouring temperatures between 745C and 755C (1373C and 1391F), SF varies from 2.26 to 1.07 when the theoretical filling time is increased from 0.9 to 16.5s. For a normal theoretical filling time of 4s (corresponding to an actual filling time of about 6s), SF increases from 1.4 to 1.8 when the pouring temperature decreases from 750C to 664C (1382F to 1227F).
2) In the case of the thin casting (2mm wall cover housing), SF slowly decreases from 1.49 to 1.14 when the theoretical filling time is increased from 0.9 to 4.5s. Except for extreme pressure rises where SF can reach 4.69 for a pouring temperature of 720C (1328F), the value of SF does not depend much on the pouring temperature between 720C and 760C (1328F and 1400F). ACKNOWLEDGMENTS
The authors wish to acknowledge the contribution of Ministre du Dveloppement conomique, de lInnovation et de lExportation of Qubec and of the Canadian Foundation for Innovation to the infrastructure which made this research possible.
Part of the operating expenses for this project was covered by the Qubec government Programme dAide la Recherche Technologique. The authors are also indebted to TMA (Technologie de lAluminium et du Magnsium) for making their facilities and personnel available for the casting runs.
REFERENCES
1. Peng, L.M., Wang, Y.X., Fu P.H., Jing, W.J., Luo, A.A., Venna, R., "Numerical Simulation and Process Development for Low Pressure Die Casting of Magnesium Alloy Wheel", AFS Transactions, Vol. 118, paper 10-077 (2010) 2. Sheng, Y., Chen, S., Nath, J., Low Pressure Casting Process Simulation and Tooling Design for HIMAC's Magnesium Automotive Control Arm, AFS Transactions, Vol. 116, paper 08-148 (2008) 3. Chiesa, F., Duchesne, B., Morin. G., Baril, J., Comparing Low Pressure Permanent Mold Casting of Aluminum A356 and Magnesium AZ91E, AFS Transactions, Vol. 116, paper 08- 028 (2008) 4. Lee, J.R., Singh, D.P.K., Chen, Z.W., Improvement of the Low Pressure Permanent Mould Pressurization Sequence for Wheel Casting, AFS Transactions, Vol. 111, paper 03-016 (2003) 5. Chiesa, F., Duchesne, B., Morin, G., Influence of Artificial Cooling and pressure application on the metallurgical quality in the LPPM Casting of Aluminium Al Si7 Mg03, Conference of Metallurgists, Proceedings of the symposium Light Metals in Transport Applications, pp.27-42., Toronto (August 25-30, 2007)
Paper 11-003.pdf, Page 8 of 8 AFS Proceedings 2011 American Foundry Society, Schaumburg, IL USA