Numerical Simulation and Experimental Validation of Melt Flow in the Naturally Pressurized Gating System

The main problem during the production of castings from aluminium alloys is the presence of the reoxidation, which negatively affects the final casting quality. Liquid metal surface reacts with the surrounding atmosphere and oxide layer of Al<sub>2</sub>O<sub>3</sub> is forme...

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Autores principales:	Marek Brůna, Iveta Vasková, Marek Galčík
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	foam filter vortex element melt velocity double oxide layer reoxidation process Chemical technology TP1-1185 Chemistry QD1-999
Acceso en línea:	https://doaj.org/article/4e93362fe94f4b548518b8466c571c55
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spelling	oai:doaj.org-article:4e93362fe94f4b548518b8466c571c552021-11-25T18:50:32ZNumerical Simulation and Experimental Validation of Melt Flow in the Naturally Pressurized Gating System10.3390/pr91119312227-9717https://doaj.org/article/4e93362fe94f4b548518b8466c571c552021-10-01T00:00:00Zhttps://www.mdpi.com/2227-9717/9/11/1931https://doaj.org/toc/2227-9717The main problem during the production of castings from aluminium alloys is the presence of the reoxidation, which negatively affects the final casting quality. Liquid metal surface reacts with the surrounding atmosphere and oxide layer of Al<sub>2</sub>O<sub>3</sub> is formed on its surface. The problem occurs when the oxide layer is entrained to the internal volume of the melt by turbulence and double oxide layers are formed, also known as “bifilms”. Its formation is related to the melt velocity and gating system design. In paper, naturally pressurized gating system was calculated and designed. Effect of the filter media and vortex element on the melt velocity, amount of oxides, mechanical properties, and porosity were observed. Designs with 10 ppi and 20 ppi foam filters and vortex element were compared with design without filters to prove the positive (or negative) effect of filter media on melt velocity and thus on final casting quality. The melt velocity and amount of oxides were observed with the aid of simulation software. Mechanical properties, quantity of pores, bifilm index and EDX analysis were evaluated after experimental casts. It was proven that by using 20 ppi foam filter in combination with vortex element, the best results were achieved.Marek BrůnaIveta VaskováMarek GalčíkMDPI AGarticlefoam filtervortex elementmelt velocitydouble oxide layerreoxidation processChemical technologyTP1-1185ChemistryQD1-999ENProcesses, Vol 9, Iss 1931, p 1931 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	foam filter vortex element melt velocity double oxide layer reoxidation process Chemical technology TP1-1185 Chemistry QD1-999
spellingShingle	foam filter vortex element melt velocity double oxide layer reoxidation process Chemical technology TP1-1185 Chemistry QD1-999 Marek Brůna Iveta Vasková Marek Galčík Numerical Simulation and Experimental Validation of Melt Flow in the Naturally Pressurized Gating System
description	The main problem during the production of castings from aluminium alloys is the presence of the reoxidation, which negatively affects the final casting quality. Liquid metal surface reacts with the surrounding atmosphere and oxide layer of Al<sub>2</sub>O<sub>3</sub> is formed on its surface. The problem occurs when the oxide layer is entrained to the internal volume of the melt by turbulence and double oxide layers are formed, also known as “bifilms”. Its formation is related to the melt velocity and gating system design. In paper, naturally pressurized gating system was calculated and designed. Effect of the filter media and vortex element on the melt velocity, amount of oxides, mechanical properties, and porosity were observed. Designs with 10 ppi and 20 ppi foam filters and vortex element were compared with design without filters to prove the positive (or negative) effect of filter media on melt velocity and thus on final casting quality. The melt velocity and amount of oxides were observed with the aid of simulation software. Mechanical properties, quantity of pores, bifilm index and EDX analysis were evaluated after experimental casts. It was proven that by using 20 ppi foam filter in combination with vortex element, the best results were achieved.
format	article
author	Marek Brůna Iveta Vasková Marek Galčík
author_facet	Marek Brůna Iveta Vasková Marek Galčík
author_sort	Marek Brůna
title	Numerical Simulation and Experimental Validation of Melt Flow in the Naturally Pressurized Gating System
title_short	Numerical Simulation and Experimental Validation of Melt Flow in the Naturally Pressurized Gating System
title_full	Numerical Simulation and Experimental Validation of Melt Flow in the Naturally Pressurized Gating System
title_fullStr	Numerical Simulation and Experimental Validation of Melt Flow in the Naturally Pressurized Gating System
title_full_unstemmed	Numerical Simulation and Experimental Validation of Melt Flow in the Naturally Pressurized Gating System
title_sort	numerical simulation and experimental validation of melt flow in the naturally pressurized gating system
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/4e93362fe94f4b548518b8466c571c55
work_keys_str_mv	AT marekbruna numericalsimulationandexperimentalvalidationofmeltflowinthenaturallypressurizedgatingsystem AT ivetavaskova numericalsimulationandexperimentalvalidationofmeltflowinthenaturallypressurizedgatingsystem AT marekgalcik numericalsimulationandexperimentalvalidationofmeltflowinthenaturallypressurizedgatingsystem
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Numerical Simulation and Experimental Validation of Melt Flow in the Naturally Pressurized Gating System

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