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Influence of ferritic nitrocarburizing on the high ...

1. Introduction. The harsh working environment in the exhaust manifolds of heavy-duty engines puts high requirements on the applied materials. Generally speaking, high-temperature mechanical properties, oxidation resistance, and thermophysical properties are the most fundamental properties to consider when evaluating a candidate material, to ensure long lifetime of the manifolds.

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Design of casting systems for stainless steel exhaust ...

Sep 25, 2018· High-performance exhaust manifolds are expected to operate in high-temperature and corrosive environments. Any cavitation or surface corrosion induced by casting defects can cause air leakage, reduce exhaust efficiency, and shorten the lifespan of the device. In this study, we sought to eliminate casting defects by optimizing the gating system used in the production of an SUS316 …

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Numerical Simulation and Process Optimization of Vacuum ...

Apr 11, 2018· Be–Al alloy castings are widely used in aviation, aerospace and marine industries due to their excellent comprehensive properties. To improve the quality of products, vacuum investment casting of a bracket casting of Be–Al alloys was simulated using the finite-element method and the evolution of the flow field and temperature field as well as the formation of shrinkage porosity were simulated.

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Shivani Adulkar - Project Engineer - BEE Incorporations ...

- Project is based on Rejection Analysis of Automotive Casting in MDI Exhaust Manifold component - Identified the major casting defects of the selected casting by Pareto Analysis Chart - Analysed the sand drop and shrinkage defect using diagnostic defect study and casting simulation approach

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Cracking failure analysis of an engine exhaust manifold at ...

Apr 15, 2019· 3. Crack failure analysis simulation. Salehnejad and Mohammadi determined stress fields on this exhaust manifold under thermo-mechanical analysis in their study on the D5S exhaust manifold finite element simulation .Based on the study, the maximum normal stress occurs on the exhaust manifold confluence, where the exhaust ports join together.

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CN102527939B - Mold for gravity casting and gravity ...

A mold and method for gravity casting may integrally cast a turbine housing having a twin scroll unit and a bypass unit and an exhaust manifold having a plurality of exhaust runner units. A turbine housing-side riser may be formed based on the end portion of the twin scroll unit within a first mold and a second mold in the state where the cavity of the turbine housing is formed so that the end ...

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Gating system optimization of low pressure casting A356 ...

Figure 5 shows the simulated shrinkage porosity defects of the intake manifold casting. As can be seen, many shrinkage porosity defects can be observed through the casting, especially in some positions with heavy wall thickness. It is too difficult to obtain denser casting if shrinkage porosity defects cannot be eliminated.

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Sente Software - JMatPro linked with CAE packages

Introduction of Materials Modelling into Processing Simulation Prediction of geometric distortion and residual stresses in hot rolled and heat treated large rings through finite element modelling Modelling of Material Properties - A Viable Solution to the Lack of Material Data in Casting Simulation Simulation of Shrinkage Defect Formation in Exhaust Manifold Castings Modelling Materials ...

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Bending overload and thermal fatigue fractures in a cast ...

Dec 01, 2017· The visual inspection showed that the exhaust manifold had the common features of a sand cast component exposed to an oxidizing atmosphere: a rough and scaled surface without significant casting defects. Moreover, the measured wall thickness ranged between 4 and 8 mm at the transversal pipe, and within 6 and 8 mm on the runners.

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Simulation of Shrinkage Defect Formation in Exhaust ...

shrinkage defect formation in manifold castings. Keywords: material data, shrinkage defect, casting simulation, cast irons, exhaust manifold, castability. 1. Introduction With increasing complexity in casting geometry and continued stringent requirements for completely sound castings, understanding the shrinkage behaviour of

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EP2829337B1 - Gravity casting mold - Google Patents

238000004088 simulation Methods 0.000 description 2; ... An example of conventional gravity casting molds for integrally casting the exhaust manifold and the turbine housing into a single body is referred to Korean Patent No. 1180951 ... and this may cause shrinkage defects in a cast product that is a turbine housing. ...

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(PDF) Investigation of effect thickness gate on formation ...

This paper investigates the formation of shrinkage defects in exhaust manifold castings via CAE simulation. The JMatPro software is used to calculate the material property data required by the ...

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Simulation Comparison Between PTC/Creo and Professional ...

This paper investigates the formation of shrinkage defects in exhaust manifold castings via CAE simulation. The JMatPro software is used to calculate the material property data required by the ...

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US5271451A - Metal casting using a mold having attached ...

Apparatus and method for countergravity casting a melt employs a particulate mass disposed in a container about a mold having a mold cavity, an ingate passage communicated to the mold cavity for supplying the melt to the mold cavity, and a separate, preformed riser-forming member connected to the mold so as to communicate to an isolated and/or enlarged region of the mold cavity needing ...

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From Metallurgy to Optimized Casting Properties

The quality and profitability of iron castings are driven by the metallurgy of the melt, the design of the pattern, the productivity of the process, reproducible manufacturing conditions and the resulting properties of the cast iron material after casting and heat treatment.

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Indigenous Development and Industrial Application of Metal ...

Oct 06, 2015· Zhanli G, Young-Hoon Y, Shuya K and Mook Y J, Simulation of Shrinkage Defect Formation in EXhaust Manifold. Korea, The time and production resources. Indian foundries, especially 8th Pacific Rim International Conference on Modeling of Casting small and medium units can utilize such tools for com- and Solidification (2010). puter-aided design ...

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Numerical simulation and design of casting system for ...

Numerical simulation and design of casting system for stainless steel exhaust manifold ... we used the Niyama criterion to predict the probability and distribution of shrinkage porosity defects in the exhaust manifold and made improvements to enhance the quality of exhaust manifold castings. Keywords: exhaust manifold, mold flow analysis ...

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MAGMAproject – Metal Casting Project Engineering Service

MAGMAproject is the metal casting simulation project engineering service that we provide to our existing & non-existing clients who are seeking for a comprehensive solution on process optimization using our well proven MAGMA APPROACH methodology together with our experts who are experienced foundry engineers, metallurgical specialists and ...

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Methoding of Exhaust Manifold and Fan Hub Castings for ...

Casting, Alloy Steel Castings, S.S. Casting, Boiler Casting, S.G. Iron Castings & Alloy C.I. Castings. The problem under consideration is regarding, control of rejections related to shrinkage by improved methoding (gating & risering). The components we found for our study are, For Control of rejections 1. Exhaust Manifold - 5337 2.

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(PDF) Numerical simulation and design of casting system ...

Numerical simulation and design of casting system for stainless steel exhaust manifold ... the elimination of porosity defects from the exhaust manifold castings. ... of shrinkage defect formation ...

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Defects - Solidification Cracking - TWI

Weld repair on a cast iron exhaust manifold A crack may be defined as a local discontinuity produced by a fracture which can arise from the stresses generated on cooling or acting on the structure. It is the most serious type of imperfection found in a weld and should be removed.

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Exhaust Manifold - IJERT

2.1 For Exhaust Manifold's material The material selected for making exhaust manifold was cast iron ductile from CES based on in-service conditions. For manufacturing a part like exhaust manifold which has 3D hallow shape with cast iron ductile, mainly investment casting and sand casting comes into view. Cast iron ductile can be made into

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Design of casting systems for stainless steel exhaust ...

In this study, we sought to eliminate casting defects by optimizing the gating system used in the production of an SUS316 stainless steel exhaust manifold, based on the probability and ...

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EP2829337A1 - Gravity casting mold - Google Patents

A gravity casting mold including a first mold, a second mold and an exhaust runner mold, which are combined with each other and form a turbine housing cavity having a twin scroll part, a first riser, a sprue, a runner, a second riser, an exhaust manifold cavity, third risers and gates. A heating sleeve is provided in the first riser so as to prevent shrinkage of the molten metal in the twin ...

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Numerical Simulation of Filling and Solidification in ...

Nov 28, 2015· In this study, investment casting is used as the manufacturing methodfor an exhaust manifold of modified-HF stainless steel, and the filling and solidification process is simulated by Procast software. The simulated results of the preliminary design show that the porosity defects exist in the exhaust manifold and the casting yield is only 38.8%, which is in good agreement with the actual ...

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Simulation of casting process: case study on the gating ...

Sep 24, 2018· In this paper, the sand casting process was evaluated using ProCAST simulating software and practical experience for manufacturing of the high chromium stainless steel outlet diaphragms used in iron ore ball mill. In the simulation practice, the effects of feeding and gating designs on the liquid flow, heat transfer and solidification phenomenon were evaluated to minimize the liquid …

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Manifold Pipe Ductile Iron, Green Sand Casting

junctions and is prone to internal defects. Thickness contour analysis of the cast part shows maximum thickness of 22 mm inscribed sphere diameter. Solidification simulation shows isolated hotspots (yellow colour) at the thickest sections, which match the shrinkage defect observed in the actual casting. Manifold Pipe Ductile Iron, Green Sand ...

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Optimal design of investment casting system for toothed ...

Dec 14, 2019· The toothed chain joint is a major component in heavy lifting equipment. They are usually fabricated using casting; however, residual casting defects in the joint tend to reduce mechanical strength and can lead to crack formation and creep following long-term usage. They also pose a safety hazard. In this study, numerical simulation was used to optimize the investment casting parameters …

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Home - DRO

Home - DRO

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Reducing Porosity in Aluminum Lost Castings Through ...

Simulation results shown in Figure 7b showed that there were large regions of porosity between the exhaust manifold and cylinder bores. After slicing the casting in these regions, macroporosity was discovered where simulations indicated it would be located.

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A Literature Survey Of Methods To Study And Analyze The ...

Jan 01, 2018· JianWenming et. al(2014) used numerical simulation of filling & solidification process for optimizing the gating system to eliminate the shrinkage porosity of an aluminum alloy intake manifold casting with the initial design, the filling of molten metal was not stable & the casting does not follow sequential solidification causing shrinkage ...