Figure 4. Thermal data recorded during a Fe-Mn-Al-C pour at Missouri S&T and used for thermodynamic modeling.
Figure 5. Shell mold thermal conductivity used for thermodynamic modeling.
(a)
(b)
Figure 6. Horizontally cast bonded sand molds without venting give the worst simulated filling results. (a) At a superheat of 100°C the whole P900 plate is between the liquidus and solidus temperature which leads to the incomplete filling. (b) At a superheat of 300°C the middle-back of the mold experiences temperatures near the liquidus temperature, which leads to cold shut defects in this area.
(a)
(b)
Figure 7. 15° tilted, bonded olivine sand simulations are shown with vents along the back, y-axis. The drag side is shown because this is where most of the cold shut defects are located. The 100°C superheat simulation (a) shows areas in light blue which are 100% solid at 14 seconds. These areas correspond with cold shut defects found in castings poured under the same conditions. The 300°C superheat simulation (b) exhibits temperatures between the solidus and liquidus that could form cold shut defects.
International Journal of Metalcasting/Winter 10 61
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