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Abstract

The solubility of Fe in aluminium alloys is known to be a problem in the casting of aluminium alloys. Due to the formation of various intermetallic phases, the mechanical properties decrease. Therefore, it is important to determine the formation mechanisms of such intermetallic. In this work, A360 alloy was used, and Fe additions were made. The alloy was cast into the sand and die moulds that consisted of three different thicknesses. In this way, the effect of the cooling rate was investigated. The holding time was selected to be 5 hours and every hour, a sample was collected from the melt for microstructural analysis. Additionally, the melt quality change was also examined by means of using a reduced pressure test where the bifilm index was measured. It was found that the iron content was increased after 2 hours of holding and the melt quality was decreased. There was a correlation between the duration and bifilm index. The size of Al-Si-Mn-Fe phases was increased in parallel with the bifilm content regardless of the iron content.
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Bibliography

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[2] Ferraro, S. & Timelli, G. (2015). Influence of sludge particles on the tensile properties of die-cast secondary aluminum alloys. Metallurgical and Materials Transactions B. 46(2), 1022-1034. DOI:10.1007/s11663-014-0260-3
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[5] Tunçay, T., Özyürek, D., Dişpinar, D. & Tekeli, S. (2020). The effects of Cr and Zr additives on the microstructure and mechanical properties of A356 alloy. Transactions of the Indian Institute of Metals. 73(5), 1273-1285. DOI: 10.1007/s12666-020-01970-4
[6] Gao, T., Hu, K., Wang, L., Zhang, B. & Liu, X. (2017). Morphological evolution and strengthening behavior of α-Al (Fe, Mn) Si in Al–6Si–2Fe–xMn alloys. Results in physics. 7, 1051-1054. https://doi.org/10.1016/j.rinp.2017.02.040
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[9] Khalifa, W., Samuel, F. & Gruzleski, J. (2003). Iron intermetallic phases in the Al corner of the Al-Si-Fe system. Metallurgical and Materials Transactions A. 34(13), 807-825. DOI:10.1007/s11661-003-1009-9
[10] Liu, L., Mohamed, A., Samuel, A., Samuel, F., Doty, H. & Valtierra, S. (2009). Precipitation of β-Al5FeSi phase platelets in Al-Si based casting alloys. Metallurgical and Materials Transactions A. 40(10), 2457-2469. DOI:10.1007/s11661-009-9944-8
[11] Tupaj, M., Orłowicz, A., Mróz, M., Trytek, M. & Markowska, O. (2016). Usable properties of AlSi7Mg alloy after sodium or strontium modification. Archives of Foundry Engineering. 16(3), 129-132. DOI:10.1515/afe-2016-0064
[12] Dinnis, C.M., Taylor, J.A. & Dahle, A. (2006). Iron-related porosity in Al–Si–(Cu) foundry alloys. Materials Science and Engineering: A. 425(1-2), 286-296. DOI: 10.1016/j.msea.2006.03.045
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[14] Tunçay, T., Tekeli, S., Özyürek, D. & Dişpinar, D. (2017). Microstructure–bifilm interaction and its relation with mechanical properties in A356. International Journal of Cast Metals Research. 30(1), 20-29. https://doi.org/10.1080/13640461.2016.1192826
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Authors and Affiliations

E.N. Bas
1
S. Alper
1
T. Tuncay
2
ORCID: ORCID
D. Dispinar
3
ORCID: ORCID
S. Kirtay
1
ORCID: ORCID

  1. Istanbul University-Cerrahpasa, Turkey
  2. Karabuk University, Turkey
  3. Foseco, Netherlands
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Abstract

Hot deformation of metals is a widely used process to produce end products with the desired geometry and required mechanical properties. To properly design the hot forming process, it is necessary to examine how the tested material behaves during hot deformation. Model studies carried out to characterize the behaviour of materials in the hot deformation process can be roughly divided into physical and mathematical simulation techniques.
The methodology proposed in this study highlights the possibility of creating rheological models for selected materials using methods of artificial intelligence, such as neuro-fuzzy systems. The main goal of the study is to examine the selected method of artificial intelligence to know how far it is possible to use this method in the development of a predictive model describing the flow of metals in the process of hot deformation.
The test material was Inconel 718 alloy, which belongs to the family of austenitic nickel-based superalloys characterized by exceptionally high mechanical properties, physicochemical properties and creep resistance. This alloy is hardly deformable and requires proper understanding of the constitutive behaviour of the material under process conditions to directly enable the optimization of deformability and, indirectly, the development of effective shaping technologies that can guarantee obtaining products with the required microstructure and desired final mechanical properties.
To be able to predict the behaviour of the material under non-experimentally tested conditions, a rheological model was developed using the selected method of artificial intelligence, i.e. the Adaptive Neuro-Fuzzy Inference System (ANFIS).
The source data used in these studies comes from a material experiment involving compression of the tested alloy on a Gleeble 3800 thermo-mechanical simulator at temperatures of 900, 1000, 1050, 1100, 1150oC with the strain rates of 0.01 - 100 s-1 to a constant true strain value of 0.9.
To assess the ability of the developed model to describe the behaviour of the examined alloy during hot deformation, the values of yield stress determined by the developed model (ANFIS) were compared with the results obtained experimentally. The obtained results may also support the numerical modelling of stress-strain curves.

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Authors and Affiliations

Barbara Mrzygłód
ORCID: ORCID
A. Łukaszek-Sołek
1
ORCID: ORCID
Izabela Olejarczyk-Wożeńska
ORCID: ORCID
K. Pasierbiewicz
1
ORCID: ORCID

  1. AGH University of Science and Technology, Faculty of Metals Engineering and Industrial Computer Science, Cracow, Poland
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Abstract

Smoothed Particle Hydrodynamics (SPH) is a Lagrangian formula-based non-grid computational method for simulating fluid flows, solid deformation, and fluid structured systems. SPH is a method widely applied in many fields of science and engineering, especially in the field of materials science. It solves complex physical deformation and flow problems. This paper provides a basic overview of the application of the SPH method in metal processing. This is a very useful simulation method for reconstructing flow patterns, solidification, and predicting defects, limitations, or material destruction that occur during deformation. The main purpose of this review article is to give readers better understanding of the SPH method and show its strengths and weaknesses. Studying and promoting the advantages and overcoming the shortcomings of the SPH method will help making great strides in simulation modeling techniques. It can be effectively applied in training as well as for industrial purposes.
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Authors and Affiliations

Trang T.T. Nguyen
1
ORCID: ORCID
Marcin Hojny

  1. AGH University of Science and Technology, Faculty of Metals Engineering and Industrial Computer Science, Department of Applied Computer Science and Modeling, al. Mickiewicza 30, 30-059 Kraków, Poland
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Abstract

The article describes the influence of optimization parameters on the efficiency of aluminium melt refining by using physical modelling. The blowing of refining gas, through a rotating impeller into the ladle is a widely used operating technology to reduce the content of impurities in molten aluminium, e.g. hydrogen. The efficiency of this refining process depends on the creation of fine bubbles with a high interphase surface, wide-spread distribution, the residence time of its effect in the melt, and mostly on the wide-spread dispersion of bubbles in the whole volume of the refining ladle and with the long period of their effect in the melt. For physical modelling, a plexiglass model on a scale of 1:1 is used for the operating ladle. Part of the physical model is a hollow shaft used for gas supply equipped with an impeller and also two baffles. The basis of physical modelling consists in the targeted utilization of the similarities of the processes that take place within the actual device and its model. The degassing process of aluminium melt by blowing inert gas is simulated in physical modelling by a decrease of dissolved oxygen in the model liquid (water).
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Bibliography

[1] Michalek, K., Tkadlečková, M., Socha, L., Gryc, K., Saternus, M., Pieprzyca, J. & Merder, T. (2018). Physical modelling of degassing process by blowing of inert gas. Archives of Metallurgy and Materials. 63(2), 987-992. DOI: 10.24425/122432.
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[5] Saternus, M., Merder, T. & Pieprzyca, J. (2015). The influence of impeller geometry on the gas bubbles dispersion in URO-200 reactor – RTD curves. Archives of Metallurgy and Materials. 60(4), 2887-2893. DOI: 10.1515/amm-2015-0461.
[6] Yamamoto, T., Suzuki, A., Komarov, S.V. & Ishiwata, Y. (2018). Investigation of impeller design and flow structures in mechanical stirring of molten aluminium. Journal of Materials Processing Technology. 261, 164-172. DOI: 10.1016/j.jmatprotec.2018.06.012.
[7] Gao, G., Wang, M., Shi, D. & Kang, Y. (2019). Simulation of bubble behavior in a water physical model of an aluminium degassing ladle unit employing compound technique of rotary blowing and ultrasonic. Metallurgical and Materials Transactions B. 50(4), 1997-2005. DOI: 10.1017/j.s11663-019-01607-y. [8] Yu, S., Zou, Z.-S., Shao, L. & Louhenkilpi, S. (2017). A theoretical scaling equation for designing physical modelling of gas-liquid flow in metallurgical ladles. Steel Research International. 88(1), 1600156. DOI: 10.1002/srin.201600156.
[9] Abreu-López, D., Dutta, A., Camacho-Martínez, J.L., Trápaga-Martínez, G. & Ramírez-Argáez, M. A. (2018). Mass transfer study of a batch aluminium degassing ladle with multiple designs of rotating impellers. JOM. 70, 2958-2967. DOI: 10.1007/s11837-018-3147-y.
[10] Walek, J., Michalek, K., Tkadlečková, M. & Saternus, M. (2021). Modelling of technological parameters of aluminium melt refining in the ladle by blowing of inert gas through the rotating impeller. Metals. 11(2), 284. DOI: 10.3390/met11020284.
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[13] Lichý, P., Kroupová, I., Radkovský, F. & Nguyenová, I. (2016). Possibilities of the controlled gasification of aluminium alloys for eliminating the casting defects. 25th Anniversary International Conference on Metallurgy and Materials, May 25th - 27th 2016 (1474-1479). Hotel Voroněž I, Brno, Czech Republic, EU: Lichý, P.

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Authors and Affiliations

J. Walek
1
ORCID: ORCID
K. Michalek
1
ORCID: ORCID
M. Tkadlečková
1
ORCID: ORCID

  1. VŠB - Technical University of Ostrava, Faculty of Materials Science and Technology, Department of Metallurgical Technologies

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