Effects of sand and gating architecture on the performance of foot valve lever casting components used in pump industries

Journal of Materials Research and Technology

Suchart Siengchin¹  Faruq Mohammad¹  Zuheir A. Issa²  Ahmed M. Tawfeek²  Hamad A. Al-Lohedan³  Sikiru Oluwarotimi Ismail⁴  I. Rajkumar⁵  N. Rajini⁵ 

[1] Corresponding author.;Department of Chemistry, College of Science, King Saud University, Riyadh, 11451, Saudi Arabia;Department of Engineering, School of Physics, Engineering and Computer Science, University of Hertfordshire, Hatfield, AL10 9AB, Hertfordshire, England, United Kingdom;Department of Materials and Production Engineering, The Sirindhorn International Thai-German Graduate School of Engineering (TGGS), King Mongkut's University of Technology North Bangkok, 1518 Wongsawang Road, Bangsue, Bangkok, 10800, Thailand;International Research Center, Kalasalingam Academy of Research and Education, Krishnankoil, 626126, India;

关键词: Sand types;    Gating designs;    Surface roughness;    Porosity;    Simulation;    Experiment;   

DOI  :  

来源: DOAJ

【 摘 要 】

This work addresses manufacture, testing and simulation of foot valve lever (FVL) for monoblock pump industry, using a cost-effective casting design process. The impact of different types of sands, such as air-set, dry and sodium silicate as well as gating designs, namely H-, U- and O-type, were studied with respect to surface roughness and porosity. The mold pattern was produced using additive manufacturing (AM) technology. Both experimental and numerical investigations were performed on the temperature distribution of molten metal at random locations for the different gating configurations or designs, considering mold filling and solidification. It was evident from the experimental investigation that contribution of air-set sand and O-type gating architecture showed limited consistency effects. Importantly, gating architecture was the most influential parameter to determine all specified quality outcomes, independent of sand mold. An order of O < H < U-type was obtained from the gating designs for minimal surface roughness and percentage of porosity. Furthermore, the microstructure analysis depicted only an irregular defect with minimum quantity at both surface and cross-section of O-type at two different locations. Optimum pouring temperatures of 740, 750 and 790 °C were obtained for mold filling of all 24 components of H-, O- and U-type of gating designs, respectively. The varying solidification temperature was observed from real time thermocouple reading, which was in close agreement with the numerical simulation. Evidently, O-type of gating design exhibited best performance for large-scale development of the FVL in terms of surface roughness, porosity and cooling effects.

【 授权许可】

Unknown