The Temperature Range in the Simulation of Residual Stress and Hot Tearing During Investment Casting
Hot tear cracking and residual stress are two different consequences of thermal stress both of which can be considered as casting problem. The purpose of the present study is simulation of the effect of casting shape characteristic on hot tearing and residual stress. This study shows that the temperature range for simulation of hot tearing and residual stress are different. In this study, in order to study the development of thermal stress and to predict the hot tearing and residual stress of shaped casting, MAGMASOFT simulation program was used. The strategy of this research was the prediction of hot tear location using pinpointing hot spot and thermal stress concentration zones. The results shows that existing of stress concentration zone increases the hot tearing probability and consequently reduces the amount of remaining residual stress in casting parts.
[1] Jason Mitchell, "Determination of strain during hot tearing by image
correlation," Materials Engineering Research Colloquium, December
2, 2005.
[2] D.G. Eskin, Suyitno, and L. Katgerman, "Mechanical properties in the semi-solid state and hot tearing of aluminium alloys," Progress in
Materials Science, vol. 49, pp. 629-711, 2004.
[3] J. Zhang and R.F. Singer, "Hot tearing of nickel-based superalloys during directional solidification," Acta Materialia, vol. 50, pp. 1869-1879, 2002.
[4] A.B. Phillion,a S.L. Cockcroft, and P.D. Lee, "X-ray microtomographic
observations of hot tear damage in an Al-Mg
commercial alloy," Scripta Materialia, vol. 55, pp. 489-492, 2006.
[5] M. Rappaz, J.-M. Drezet, and M. Gremaud, "A New Hot-Tearing Criterion," Met. and Mat Trans. A, vol. 30A, pp. 449, February 1999.
[6] Y. Wang , Q. Wang, G. Wu, Y. Zhu, and W. Ding, "Hot-tearing susceptibility of Mg-9Al-xZn alloy," Materials Letters, vol.57, pp.
929- 934, 2002.
[7] M. Easton, H. Wang, J. Grandfield, D. St. John, and E. Sweet, "An Analysis of the Effect of Grain Refinement on the Hot Tearing of
Aluminum Alloys," Materials forum, vol. 28, Institute of Materials Engineering Australasia Ltd, Published 2004.
[8] M. Blair, R. Monroe, C. Beckermann, R. Hardin, K. Carlson, and C.
Monroe, "Predicting the Occurrence and Effects of Defects in Castings," JOM, pp.29-34, May 2005.
[9] Suyitno, D.G. Eskin, and L. Katgerman, "Structure observations related to hot tearing of Al-Cu billets produced by direct-chill
casting," Materials Science and Engineering A, vol.420, pp. 1-7,2006.
[10] B. C. Liu, J. W. Kang, and S. M. Xiong, "A study on the numerical simulation of thermal stress during the solidification of shaped castings," Science and Technology of Advanced materials, vol. 2,
157-164, 2001.
[11] C. Monroe and C. Beckermann, "Development of a hot tear indicator
for steel castings," Materials Science and Engineering A, vol. 413-
414, pp. 30-36, 2005.
[12] H. Farhangi, S. Norouzi, and M. Nili-Ahmadabadi, "Effects of casting process variables on the residual stress in Ni-base
superalloys," Journal of Materials Processing Technology, vol. 153-
154, pp. 209-212, 2004.
[13] J. Withers and H.K.D.H. Bhadeshia, "Residual stress. Part 2. Nature
and origins," Mater. Sci. Technol., vol.17, pp.366-375, 2001.
[14] E. Macherauch, "Introduction to residual stress," Exp. Mech., vol. 25,
pp. 1-35, 1984.
[15] C.H. Reese and K.B. Rundman, "Residual stress in gray cast iron
brake rotors," AFS Trans., vol. 115, pp. 175-181, 1997.
[16] Y. Wang, B. Sun, Q. Wang, Y. Zhu, and W. Ding, "An understanding
of the hot tearing mechanism in AZ91 magnesium alloy," Materials Letters, vol. 53, pp. 35-39, 2002.
[17] Z. Yubo, C. Jianzhong, Z. Zhihao, Z. Haitao, and Q. Ke, "Effect of
low frequency electromagnetic field on casting crack during DC
casting super-high strength aluminum alloy ingots," Materials Science and Engineering A, vol. 406, pp. 286-292, 2005.
[18] A.B. Phillion,a S.L. Cockcroft, and P.D. Lee, "X-ray microtomographic
observations of hot tear damage in an Al-Mg
commercial alloy," Scripta Materialia, pp. 55, pp. 489-492, 2006.
[19] D. Fabre`gue, A. Deschamps, M. Suery, and J.M. Drezet, "Nonisothermal
tensile tests during solidification of Al-Mg-Si-Cu alloys: Mechanical properties in relation to the phenomenon of hot tearing,"
Acta Materialia, vol. 54, pp. 5209-5220, 2006.
[1] Jason Mitchell, "Determination of strain during hot tearing by image
correlation," Materials Engineering Research Colloquium, December
2, 2005.
[2] D.G. Eskin, Suyitno, and L. Katgerman, "Mechanical properties in the semi-solid state and hot tearing of aluminium alloys," Progress in
Materials Science, vol. 49, pp. 629-711, 2004.
[3] J. Zhang and R.F. Singer, "Hot tearing of nickel-based superalloys during directional solidification," Acta Materialia, vol. 50, pp. 1869-1879, 2002.
[4] A.B. Phillion,a S.L. Cockcroft, and P.D. Lee, "X-ray microtomographic
observations of hot tear damage in an Al-Mg
commercial alloy," Scripta Materialia, vol. 55, pp. 489-492, 2006.
[5] M. Rappaz, J.-M. Drezet, and M. Gremaud, "A New Hot-Tearing Criterion," Met. and Mat Trans. A, vol. 30A, pp. 449, February 1999.
[6] Y. Wang , Q. Wang, G. Wu, Y. Zhu, and W. Ding, "Hot-tearing susceptibility of Mg-9Al-xZn alloy," Materials Letters, vol.57, pp.
929- 934, 2002.
[7] M. Easton, H. Wang, J. Grandfield, D. St. John, and E. Sweet, "An Analysis of the Effect of Grain Refinement on the Hot Tearing of
Aluminum Alloys," Materials forum, vol. 28, Institute of Materials Engineering Australasia Ltd, Published 2004.
[8] M. Blair, R. Monroe, C. Beckermann, R. Hardin, K. Carlson, and C.
Monroe, "Predicting the Occurrence and Effects of Defects in Castings," JOM, pp.29-34, May 2005.
[9] Suyitno, D.G. Eskin, and L. Katgerman, "Structure observations related to hot tearing of Al-Cu billets produced by direct-chill
casting," Materials Science and Engineering A, vol.420, pp. 1-7,2006.
[10] B. C. Liu, J. W. Kang, and S. M. Xiong, "A study on the numerical simulation of thermal stress during the solidification of shaped castings," Science and Technology of Advanced materials, vol. 2,
157-164, 2001.
[11] C. Monroe and C. Beckermann, "Development of a hot tear indicator
for steel castings," Materials Science and Engineering A, vol. 413-
414, pp. 30-36, 2005.
[12] H. Farhangi, S. Norouzi, and M. Nili-Ahmadabadi, "Effects of casting process variables on the residual stress in Ni-base
superalloys," Journal of Materials Processing Technology, vol. 153-
154, pp. 209-212, 2004.
[13] J. Withers and H.K.D.H. Bhadeshia, "Residual stress. Part 2. Nature
and origins," Mater. Sci. Technol., vol.17, pp.366-375, 2001.
[14] E. Macherauch, "Introduction to residual stress," Exp. Mech., vol. 25,
pp. 1-35, 1984.
[15] C.H. Reese and K.B. Rundman, "Residual stress in gray cast iron
brake rotors," AFS Trans., vol. 115, pp. 175-181, 1997.
[16] Y. Wang, B. Sun, Q. Wang, Y. Zhu, and W. Ding, "An understanding
of the hot tearing mechanism in AZ91 magnesium alloy," Materials Letters, vol. 53, pp. 35-39, 2002.
[17] Z. Yubo, C. Jianzhong, Z. Zhihao, Z. Haitao, and Q. Ke, "Effect of
low frequency electromagnetic field on casting crack during DC
casting super-high strength aluminum alloy ingots," Materials Science and Engineering A, vol. 406, pp. 286-292, 2005.
[18] A.B. Phillion,a S.L. Cockcroft, and P.D. Lee, "X-ray microtomographic
observations of hot tear damage in an Al-Mg
commercial alloy," Scripta Materialia, pp. 55, pp. 489-492, 2006.
[19] D. Fabre`gue, A. Deschamps, M. Suery, and J.M. Drezet, "Nonisothermal
tensile tests during solidification of Al-Mg-Si-Cu alloys: Mechanical properties in relation to the phenomenon of hot tearing,"
Acta Materialia, vol. 54, pp. 5209-5220, 2006.
@article{"International Journal of Chemical, Materials and Biomolecular Sciences:50880", author = "Saeid Norouzi and Ali Shams and Hassan Farhangi and Alireza Darvish", title = "The Temperature Range in the Simulation of Residual Stress and Hot Tearing During Investment Casting", abstract = "Hot tear cracking and residual stress are two different consequences of thermal stress both of which can be considered as casting problem. The purpose of the present study is simulation of the effect of casting shape characteristic on hot tearing and residual stress. This study shows that the temperature range for simulation of hot tearing and residual stress are different. In this study, in order to study the development of thermal stress and to predict the hot tearing and residual stress of shaped casting, MAGMASOFT simulation program was used. The strategy of this research was the prediction of hot tear location using pinpointing hot spot and thermal stress concentration zones. The results shows that existing of stress concentration zone increases the hot tearing probability and consequently reduces the amount of remaining residual stress in casting parts.
", keywords = "Hot tearing, residual stress, simulation, investment casting.", volume = "3", number = "10", pages = "556-7", }
