Title: Experimental study on the filling process of the lost foam casting process of a cast iron plate

Authors: Jinwu Kang; Xiaokun Hao; Gang Nie; Haimin Long; Tianjiao Wang; Yongyi Hu; Tianyou Huang

Addresses: Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China ' Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China ' Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China ' Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China ' Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China ' Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China ' Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China

Abstract: Lost foam casting owns a series of advantages, however, EPS pattern burns while the liquid metal fills, which makes the filling process complicated and directly leads to defects in castings. A measurement system of the liquid metal filling based on a modified contact time method (MCTM) was established. The filling of measured points is illustrated by a LED pattern, and the filling time of all the points is obtained by the analysis of the recorded movie. This method is free of limitation of signal acquisition channels. The system was applied into the experimental study of the filling of a vertical plate-shaped specimen of cast iron. The filling of one hundred positions was measured, and the filling profiles and filling velocity during filling process were obtained, which reflected the features of its filling process. The influence of some parameters including the metastatic head, the density of the EPS pattern, the thickness of coating and the permeability of sand mould on the filling process were investigated.

Keywords: lost foam casting; LFC; mould filling; modified contact time method; MCTM; LED pattern; experimental study; cast iron plate; liquid metal filling; filling measurement; filling profiles; filling velocity; metastatic head; EPS pattern density; coating thickness; sand mould permeability.

DOI: 10.1504/IJMPT.2013.058958

International Journal of Materials and Product Technology, 2013 Vol.47 No.1/2/3/4, pp.188 - 199

Received: 18 Jan 2013
Accepted: 23 Aug 2013
Published online: 28 Jun 2014 *

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