12/15/2020 Analysis on the defects of loose and under cast thin wall castings – ZHY Casting

Analysis on the defects of loose and under

cast thin wall castings
When the wall thickness of high-temperature alloy castings such as adjusting
piece and sealing piece is changed from 1.1mm to 0.8mm, the solidification
speed of castings will be accelerated. The original casting processcan not
effectively fill and supplement the edges of castings, resulting in under casting
and loose defects. Therefore, on the basis of the original process plan, the
method of wrapping asbestos in the thin-walled area is adopted to slow down the
temperature of the die shell, prolong the solidification time in the thin-walled area,
effectively fill the mold with alloy liquid and supplement the edge of the casting,
so as to eliminate the under cast and loose defects.

The wall thickness of over 90% of the high-temperature alloy castings, such as
adjusting and sealing pieces, is required to be 0.8mm. The wall thickness of the
castings is cast according to the upper deviation (+ 0.3). The casting molding
effect and metallurgical quality are good. The process plan is basically mature,
but the weight exceeds the design requirements. After the wall thickness is
changed to 0.8mm, the castings are still produced according to the original
process plan. Almost 100% of the castings are cast In addition, more than 40%
of the castings are under cast, and slag inclusions are also increased.

The sectional view of the edge on both sides of the bottom plate of the casting is
shown in Figure 3. There is a stiffener plate on the edge. The design
requirements for the wall thickness of the stiffener plate and the wall thickness of
the bottom plate are shown in Figure 3. In the initial design of the mold, the wall
thickness of the rib plate and the wall thickness of the base plate are all 1.1mm,
that is, the equal wall thickness. The joint between the rib plate and the bottom
plate wall forms the hot joint of casting. Compared with the bottom plate, the
modulus of the hot joint has little difference. In addition, the hot joint is on the
edge of the casting, and the cooling and solidification are relatively fast. The alloy
liquid can supplement the hot joint through the bottom plate without loose
defects.

When the thickness of the bottom plate is changed to 0.8 mm, the modulus of the
bottom plate is reduced by nearly 1/3, and the cooling and solidification speed of
the bottom plate is accelerated; while the thickness of the reinforced plate is not
changed, the modulus of the hot node is basically unchanged, and the cooling
and solidification speed is basically unchanged, which leads to the failure of the
alloy liquid to effectively shrink the hot node through the bottom plate, resulting in
porosity.

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12/15/2020 Analysis on the defects of loose and under cast thin wall castings – ZHY Casting
The whole casting is of plate structure, with thin wall and large area. In order to
ensure casting forming, the shell needs to be packed with sand for preheating. In
the preheating process, the shell is softened by heat and the strength is reduced.
Under the sand extrusion, there will be a certain amount of deformation, resulting
in narrower inner cavity, slightly smaller wall thickness of the casting. After the
wall thickness of the bottom plate is changed to 0.8mm, the actual wall thickness
will be smaller. In addition The cooling and solidification speed is accelerated,
and the alloy liquid has solidified before it flows to some places, so the under
casting defects appear.

When the wall thickness of the bottom plate is changed to 0.8 mm, the cooling
and solidification speed will be accelerated. Before the slag inclusions in the alloy
liquid float or sink, the alloy liquid will be solidified, thus remaining in the casting,
forming slag inclusion defects.

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