Cast Shop Technology: Virtual Cast Shop and Specialties
Sponsored by: TMS Light Metals Division, TMS: Aluminum Committee
Program Organizers: Johannes Morscheiser, Novelis Koblenz GmbH
Thursday 8:30 AM
February 27, 2020
Room: 1B
Location: San Diego Convention Ctr
Session Chair: Arnis Pelss, Aleris
8:30 AM Introductory Comments
8:35 AM
Digital Manufacturing for Foundries 4.0: Prateek Saxena1; Michail Papanikolaou1; Emanuele Pagone1; Konstantinos Salonitis1; Mark Jolly1; 1Cranfield University
The concept of smart foundries aims at integrating and enabling smart technologies for digitalization of manufacturing operations. Foundries 4.0 refer to the inclusion of Industry 4.0 principles in traditional foundries. The casting process is known to be one of the most energy-intensive processes. Enabling sensor-based technologies, such as the Internet of Things (IoTs) for condition monitoring, can be an efficient means to bring down the energy costs. IoTs can also be implemented for real-time waste-monitoring. Embedded sensors can be utilized in determining excessive loads during the casting operation. This is very useful to identify overloading and in avoiding potential damage to the castings. Introduction of Additive Manufacturing can reduce cycle time and material consumption. This paper aims to introduce the concept of Foundries 4.0. The key focus is to highlight the integration of digital technologies in establishing foundries of the future. Challenges involved in the establishment of smart foundries are also discussed. A case-study discussing establishment of energy-efficient smart foundries is also presented in this work.
9:00 AM
Integrating Fluid Simulation with Virtual Die Casting Machine for Industry 4.0 and Operator Training: John Moreland1; John Estrada1; Edwin Mosquera1; Kyle Toth1; Armin Silaen1; Chenn Zhou1; 1Purdue University Northwest
High Pressure Die Casting is a complex manufacturing process in which molten metal is forced into a mold cavity under high pressure where it then cools and solidifies. An interactive virtual training simulator is being developed which integrates fluid flow simulations with die casting machine parameters to improve operator understanding of the process and ultimately improve casting quality. Methods for combining fluid simulation results with tools from the game industry for virtual reality and augmented reality applications in industry 4.0 are discussed.
9:25 AM
Numerical Simulation of Wire Rod Casting of AA1370 and AA6101 Alloys: Dag Lindholm1; Shahid Akhtar2; Dag Mortensen1; 1Institute for Energy Technology; 2Hydro Aluminium
Wire rod casting, where molten aluminum is continuously fed into a trapezoidal cross-section of a rotating copper wheel, addresses challenging issues with respect to the quality of the final wire rod product. Valuable insight into the crystallization of the bar emerging from the casting wheel can be provided by numerical simulations. These must account for complex thermal and mechanical processes, especially bar shrinkage inside the cavity leading to air gap formation and reduced heat transfer. Numerical simulation of this process is challenging, and limited studies have been published. A three-dimensional thermo-mechanical model has been applied for casting of EC grade 1370 alloy. Comparison to existing measurements has been done to obtain confidence in the model results and the applied boundary conditions. The model has then been used for an Al-Mg-Si alloy (AA6101) to propose a new speed for the casting wheel.
9:50 AM
Influence of Nozzle Shape on Near-surface Segregation Formation During Twin-roll Casting of Aluminum Strips: Olexandr Grydin1; Mykhailo Stolbchenko1; Mirko Schaper1; 1Materials Science, Paderborn University
The near-surface segregation is a characteristic defect of twin-roll cast strips. Intergranular intrusions and bleeds rolled into the strip surface deteriorate the mechanical properties and corrosion resistance. The following mechanisms cause these segregations: periodic damage of the melt meniscus and low-pressure zones between the rolls and the solidified aluminum shells. The aim of this study is to identify how strong the influence of the first mechanism is.To adjust the meniscus length, two different nozzles – one conventional with a butt end and one tailored with a pointed end – are utilized. The lab scale twin-roll cast trials for the production of 3 mm strips from the aluminum alloy EN AW-1050 are conducted in the vertical plane. The microsections with a total length of up to 300 mm are analysed to establish the intensity and regularity of distribution of surface bleeds along the strips. Additionally, their mechanical properties are compared.
10:15 AM
Influence of Alloying Additives on the Electrochemical Behavior of Cast Al-5Zn Alloy: Mohamed Moussa1; Hoda Hussien1; Shimaa El-Hadad1; Madiha Shoeib1; 1Cmrdi -Central Metallurgical Research In
Cast Al-5wt. % Zn alloys are well known for their cathodic protection applications as sacrificial anodes. Based on the previous studies, the electrochemical behavior of these anodes can be enhanced by addition of alloying elements. These elements can be modifiers as magnesium (Mg), barium (Ba), (Cd) and etc. or they can act as depassivators like in the case of Indium (In), tin (Sn), titanium (Ti) and thallium (Tl). In the current investigation, alloying additives includes Mg and Sn were added during melting of Al-5wt.%Zn alloy and the samples were immersed in a sodium chloride solution to investigate their behavior as sacrificial anodes. It was observed that addition of Sn or Mg can increase the corrosion rate of the base alloy if added in certain amounts, exceeding the amount of addition results in adverse effects.