A thermomechanical study of the effects of mold topography on the solidification of Aluminum alloys at early times is provided. The various coupling mechanisms between the solid-shell and mold deformation and heat transfer at the mold/solid-shell interface during the early stages of Aluminum solidification on molds with uneven topographies are investigated. The air-gap nucleation time, the stre...

Additive manufacturing is expected to transform and upgrade the traditional foundry industry realize integrated rapid low-cost development of high-performance components with complex shapes. The additive technology commonly applied in casting mold preparation (fusible molds, sand molds/cores ceramic cores) mainly includes selective laser sintering (SLS) binder injection three-dimensional printi...

The Selective Laser Sintering Process of thermoplastics (SLS) enables the manufacturing of components with complex shape in a short time period without the manufacturing of a specific mold. However, this manufacturing process is limited by the restricted range of materials. In contrast to this primary shaping process, vacuum casting allows a quick, inexpensive and highly accurate process but it...

This paper describes activities relating to mold level control in continuous casting process as case examples of our process control solution business, in which we clarify and evaluate the process phenomena and design the control system. Initially, a mold level control model has been formulated by fluid flow analysis technique that evaluates molten steel flow in the mold quantitatively. The mod...

This study commences by performing an experimental investigation to measure the temperature distribution within a casting system comprising a cylindrical aluminum casting and a green-sand mold. The experimental temperature measurements are then used to compute the effective heat transfer coefficient at the mold/metal interface using four different formulae. In the temperature measurement, a sym...

This paper presents a new system to control secondary cooling water sprays in continuous casting of thin steel slabs, CONONLINE. It uses real-time numerical simulation of heat transfer and solidification within the strand as a software sensor, in place of unreliable temperature measurements. The one-dimensional finite-difference model, CON1D is adapted to create the real-time predictor of the s...

The ultimate goal of Patternless Casting Manufacturing (referred to as PCM) is how to obtain the casts by casting the sand mold directly. In the previous PCM, the resin content of sand mold is much higher than that required by traditional resin sand, so the casts obtained are difficult to be sound and qualified products, which limits the application of this technique greatly. In this paper, the...