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Effects of process related variations on defect formation in investment cast components
School of Innovation, Design and Engineering, Mälardalen University, Eskilstuna, Sweden.
TPC Components AB, Hallstahammar, Sweden.
TPC Components AB, Hallstahammar, Sweden.
School of Innovation, Design and Engineering, Mälardalen University, Eskilstuna, Sweden.
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2018 (English)In: Archives of Foundry Engineering, ISSN 1897-3310, E-ISSN 2299-2944, Vol. 18, no 1, p. 103-108Article in journal (Refereed) Published
Abstract [en]

Castability of thin-walled castings is sensitive to variation in casting parameters. The variation in casting parameters can lead to undesired casting conditions which result in defect formation. Variation in rejection rate due to casting defect from one batch to other is common problem in foundries and the cause of this variation usually remain unknown due to complexity of the process. In this work, variation in casting parameters resulting from human involvement in the process is investigated. Casting practices of different groups of casting operators were evaluated and resulting variations in casting parameters were discussed. The effect of these variations was evaluated by comparing the rejection statistics for each group. In order to minimize process variation, optimized casting practices were implemented by developing specific process instructions for the operators. The significance of variation in casting parameters in terms of their impact on foundry rejections was evaluated by comparing the number of rejected components before and after implementation of optimized casting practices. It was concluded that variation in casting parameters due to variation in casting practices of different groups has significant impact on casting quality. Variation in mould temperature, melt temperature and pouring rate due to variation in handling time and practice resulted in varying quality of component from one batch to other. By implementing the optimized casting instruction, both quality and process reliability were improved significantly. 

Place, publisher, year, edition, pages
De Gruyter Open, 2018. Vol. 18, no 1, p. 103-108
Keywords [en]
Casting defects, Foundry practices, Investment casting, Process variations, Foundries, Foundry practice, Thin walled structures, Casting conditions, Casting defect, Casting parameters, Melt temperature, Mould temperature, Process reliability, Process Variation, Thin-walled castings, Defects
National Category
Materials Engineering
Identifiers
URN: urn:nbn:se:hj:diva-41091DOI: 10.24425/118820ISI: 000435927100019Scopus ID: 2-s2.0-85046717206Local ID: JTHMaterialISOAI: oai:DiVA.org:hj-41091DiVA, id: diva2:1236529
Available from: 2018-08-02 Created: 2018-08-02 Last updated: 2019-02-14Bibliographically approved

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Jarfors, Anders E.W.

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