Citation:
X Dai, M Jolly, B Zeng. The improvement of aluminium casting process control by application of the new CRIMSON process. IOP Conference Series: Materials Science and Engineering, 2012, Volume 33, Item number 012009
Abstract:
All The traditional foundry usually not only uses batch melting where the
aluminium alloys are melted and held in a furnace for long time, but also uses
the gravity filling method in both Sand Casting Process (SCP) and Investment
Casting Process (ICP). In the gravity filling operation, the turbulent behaviour
of the liquid metal causes substantial entrainment of the surface oxide films
which are subsequently trapped into the liquid and generate micro cracks and
casting defects. In this paper a new CRIMSON process is introduced which
features instead of gravity filling method, using the single shot up-casting
method to realize the rapid melting and rapid filling mould operations which
reduce the contact time between the melt and environment thus reducing the
possibility of defect generation. Another advantage of the new process is the
drastic reduction of energy consumption due to shortened melting and filling
time. Two types of casting samples from SCP and ICP were compared with the new
process. The commercial software was used to simulate the filling and
solidification processes of the casting samples. The results show that the new
process has a more improved behaviour during filling a mould and solidification
than the two conventional casting processes.