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Quality improvment of casting with the replacment of feeders systems in the gravity doe casting

In bachelor`s thesis is presents research work on »Quality Improvement of casting with the replacement of feeders systems in the gravity die casting process«. With research work we want to show a comparison in the same conditions for all process parameters in the gravitational casting phase by using of alloy AlSi10Mg between the metal feeder systems of the type steel H13 with the use insulating casting painting in comparison between the ceramic type Insural C140. For the feeders system. As the same procedural conditions it understood the following: the quality of the melt , the temperature (melt and tools / of die), the preparation of the foundry tools with foundry coating, cycle time of crystallization – the solidification of the cast, the transition of the melt from the liquid state into a solid state.

The primary purpose of the research is to know the exact comparisons between the replacement metal feeder with the ceramic feeder systems, and ensure high standards of conformity and quality cast.

The ProCAST software performs accurate compositions of the simulation casting between the metal and ceramic feeders systems, under same conditions of process parameters and cast geometry. The difference, which is reflected in the simulation of the casting is in the conductivity of heat (ceramic – metal), this is reflected in the simulation through the contact with the casting and through conductivity heated Foundry tool. The Foundry tools are cooled on external surfaces due to air temperature or working space.

Design structural change is performed on the Foundry tool in the upper half tool by inserting special protective metal bushings, which preventing mechanical damage of ceramic Insural C140. In phase of opening of the Foundry tool or. separating the castings in a solidified state from the upper half of the Foundry tool. In the upper half of the Foundry tool, it is necessary to ensure adequate fixation of proactive metal bushing with an efficient ventilating gas system accumulated in the supply system during the solidification phase or transition of the liquid alloy into a solid state

To confirm the quality requirements used in the research work methods of testing, control and analysis (X- ray, Spectro analysis – chemical composition of alloys, Ideco – density index melt, thermos analysis – alloys AlSi10Mg with curve cooling, recording of process parameters of temperature melt and tool, time, preparation of foundry tools – coating with foundry coats. 

AUTHOR

Tomaž Štumberger

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