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Numerical and Experimental Verification of Investment Casting Process / VICTORIA THOMAS

Swansea University Author: VICTORIA THOMAS

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DOI (Published version): 10.23889/SUthesis.63706

Abstract

Vacuum induction melting investment casting is a process used to produce metal components.The procedure comprises of induction melting of a billet under vacuum conditions, followed bydirect pouring into a casting mould. Castings made by this method are prone to defects suchas misrun, inclusions and...

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Published: Swansea, Wales, UK 2023
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Lavery, Nicholas P. and Brown, Stephen G. R.
URI: https://cronfa.swan.ac.uk/Record/cronfa63706
first_indexed 2023-06-26T12:00:38Z
last_indexed 2024-11-25T14:12:46Z
id cronfa63706
recordtype RisThesis
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spelling 2024-07-03T09:43:46.3018237 v2 63706 2023-06-26 Numerical and Experimental Verification of Investment Casting Process bf49c6d7ca435b32cb8dc9766c417d70 VICTORIA THOMAS VICTORIA THOMAS true false 2023-06-26 Vacuum induction melting investment casting is a process used to produce metal components.The procedure comprises of induction melting of a billet under vacuum conditions, followed bydirect pouring into a casting mould. Castings made by this method are prone to defects suchas misrun, inclusions and porosity. In this work, the impact of piping defects within IN713Cbillets is examined, specifically their size and location on flow characteristics during pouring anddefect occurrence in finished castings. Manufactured holes were introduced in concast billets asa controlled method of exploring the effect of piping on alloy pouring flow characteristics. Usinga Design of Experiments approach, an L9 array of two-piece billets was used to investigate theimpact of disc height, hole diameter and hole position. A bespoke vacuum induction meltingchamber was designed and fabricated with viewing ports which enable non-contact temperaturemeasurements and high-speed images to be recorded during the heating and pouring processes,respectively. The L9 array was reproduced in numerical models of electromagnetic inductionheating, and thermal fluid flow during alloy pouring, created using the in-development EMAGmodule for ESI ProCAST. Thermal results from electromagnetics models were used as initialconditions for alloy pouring, and additional mould filling and solidification simulations.The experimental data served as validation for numerical models and demonstrates that themodelling approach delivers representative results, while minimising computational demand.Knowledge of the temperature distribution within the billet from electromagnetic simulations isfound to be key for accurate defect prediction. By interrogating defect criteria in post-processing,the impact of piping on defect occurrence is understood. Using a 15 mm disc, or ‘penny’,resulted in a reduction of defect instances, consistent with anecdotally reported improvementsobserved in the casting industry. Through this modelling, this is explained by reductions inthe maximum alloy pouring temperature. E-Thesis Swansea, Wales, UK Vacuum Induction Melting, Investment Casting, Numerical Modelling, Experimental Verification, Casting, Design of Experiments, Industrial Experiments 14 6 2023 2023-06-14 10.23889/SUthesis.63706 COLLEGE NANME COLLEGE CODE Swansea University Lavery, Nicholas P. and Brown, Stephen G. R. Doctoral EngD M2A (via European Social Fund via the Welsh Government (c80816) and Uni-Pol Group) 2024-07-03T09:43:46.3018237 2023-06-26T12:58:20.9859568 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering VICTORIA THOMAS 1 63706__27962__81acb8bac861421089573543237a36f7.pdf 2023_Thomas_VU.final.63706.pdf 2023-06-26T13:02:31.6518431 Output 44406477 application/pdf E-Thesis true 2024-06-14T00:00:00.0000000 Copyright: The Author, Victoria U. Thomas, 2023 Distributed under the terms of a Creative Commons Attribution 4.0 License (CC BY 4.0). true eng https://creativecommons.org/licenses/by/4.0/
title Numerical and Experimental Verification of Investment Casting Process
spellingShingle Numerical and Experimental Verification of Investment Casting Process
VICTORIA THOMAS
title_short Numerical and Experimental Verification of Investment Casting Process
title_full Numerical and Experimental Verification of Investment Casting Process
title_fullStr Numerical and Experimental Verification of Investment Casting Process
title_full_unstemmed Numerical and Experimental Verification of Investment Casting Process
title_sort Numerical and Experimental Verification of Investment Casting Process
author_id_str_mv bf49c6d7ca435b32cb8dc9766c417d70
author_id_fullname_str_mv bf49c6d7ca435b32cb8dc9766c417d70_***_VICTORIA THOMAS
author VICTORIA THOMAS
author2 VICTORIA THOMAS
format E-Thesis
publishDate 2023
institution Swansea University
doi_str_mv 10.23889/SUthesis.63706
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 1
active_str 0
description Vacuum induction melting investment casting is a process used to produce metal components.The procedure comprises of induction melting of a billet under vacuum conditions, followed bydirect pouring into a casting mould. Castings made by this method are prone to defects suchas misrun, inclusions and porosity. In this work, the impact of piping defects within IN713Cbillets is examined, specifically their size and location on flow characteristics during pouring anddefect occurrence in finished castings. Manufactured holes were introduced in concast billets asa controlled method of exploring the effect of piping on alloy pouring flow characteristics. Usinga Design of Experiments approach, an L9 array of two-piece billets was used to investigate theimpact of disc height, hole diameter and hole position. A bespoke vacuum induction meltingchamber was designed and fabricated with viewing ports which enable non-contact temperaturemeasurements and high-speed images to be recorded during the heating and pouring processes,respectively. The L9 array was reproduced in numerical models of electromagnetic inductionheating, and thermal fluid flow during alloy pouring, created using the in-development EMAGmodule for ESI ProCAST. Thermal results from electromagnetics models were used as initialconditions for alloy pouring, and additional mould filling and solidification simulations.The experimental data served as validation for numerical models and demonstrates that themodelling approach delivers representative results, while minimising computational demand.Knowledge of the temperature distribution within the billet from electromagnetic simulations isfound to be key for accurate defect prediction. By interrogating defect criteria in post-processing,the impact of piping on defect occurrence is understood. Using a 15 mm disc, or ‘penny’,resulted in a reduction of defect instances, consistent with anecdotally reported improvementsobserved in the casting industry. Through this modelling, this is explained by reductions inthe maximum alloy pouring temperature.
published_date 2023-06-14T06:32:40Z
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score 11.090362

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