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Cold Shut and Misrun Defect in Al Casting

Misruns are defects that occur when molten metal fails to fully fill the mold cavity, resulting in an incomplete or missing part. They are caused by factors like poor pouring practices, improper gating design, low mold or metal temperatures, non-uniform part dimensions, and low metal fluidity. Suggested cures include increasing temperatures, improving flow through gating design and alloy composition modification, and ensuring uniform part dimensions. Numerical simulations can be used to analyze filling sequences and predict fluid flow to minimize misruns.

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Rudi Yansah
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2K views

Cold Shut and Misrun Defect in Al Casting

Misruns are defects that occur when molten metal fails to fully fill the mold cavity, resulting in an incomplete or missing part. They are caused by factors like poor pouring practices, improper gating design, low mold or metal temperatures, non-uniform part dimensions, and low metal fluidity. Suggested cures include increasing temperatures, improving flow through gating design and alloy composition modification, and ensuring uniform part dimensions. Numerical simulations can be used to analyze filling sequences and predict fluid flow to minimize misruns.

Uploaded by

Rudi Yansah
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Cold Shut / Misrun defect in Alumunium Casting

Rudiyansah edit Master subtitle style Click to 0806331973 Teknik Metalurgi dan Material Universitas Indonesia

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Misrun/ Cold Shut


v

Misruns merupakan suatu cacat yang terjadi karena logam cair tidak mengisi seluruh rongga cetakan sehingga benda cor menjadi tidak lengkap atau ada bagian yang hilang

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Misrun defect

Example of misrun defect


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Cold Shut and Misrun

Probable Cause a. Poor poring practice b. Improper gating c. Low shell permeability d. Low metal fluidity e. Low metal or mold temperature

f. Ketidakseragaman dimensi benda cor, mengganggu aliran dari logam cair


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Cold Shut and Misrun

Suggested Cure a. Increas metal and/or mold temperature

b. Increase head pressure and/or rate of pour; avoid splashing c. improve gating to enhance mold fill d. Modify alloy composition to enhance fluidity e. Increase permeability by using coarse refractory flour (200 mesh for primary, 120 mesh 4/29/12

Comparison of filling sequences, with and without misrun, in Alumunium Motor Rotor in Die casting

Numerical analysis result without misrun (Core length 700mm, slot width 9mm, slot length 25.5mm) 4/29/12

Comparison of filling sequences, with and without misrun, in Alumunium Motor Rotor in Die casting

Numerical analysis result with misrun (Core length 700mm, slot width 7.6mm, slot length 18.8mm)
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Misrun defect in Alumunium motor rotor (Hyundai Heavy Industries)

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Misrun defect in Alumunium motor rotor (Hyundai Heavy Industries)

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Surface defect of semi-solid die casting of ADC 12 Alumunium alloy

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Misrun defect in intercooler of radiator assembly, which is used in buses and trucks

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Continued (Prevention)

To minimize the misrun defect in intercooler assembly, several parameter process must be kept in controlled. Such as :

Fluid flow behaviour, gating and feeding design, flows breaks between riser and casting, hot spot area

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Continued (prevention)

Actualization of intercoolar assembly condition with gating system and risers 4/29/12

Continued (prevention)

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Simulation with ProCAST, to predict fluid flow behaviour in casting process

Continued (prevention)

Problems that occurred and must be evaluate to minimize the misrun

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Continued (prevention)

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Continued (prevention)

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Continued (prevention)

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Continued (prevention)

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Safe band for operating DIE, in intercooler assembly process

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References
Bambang Suharno.Diktat kuliah Pembentukan Logam.FTUI http://www.foundryinfo-india.org/tech_section/pdf/15_OP.pdf http://www.me.gatech.edu/jonathan.colton/me4210/castdefect.pdf http://www.foseco.com.tr/tr/downloads/FoundryPractice/23503_Using_the_SEM_for_defect_analysis.pdf http://www.indianfoundry.org/docs/paper_4_jan11.pdf http://www.springerlink.com/content/pmc0lej1fw6xc9wl/ http://www.ysxbcn.com/upfile/soft/201099/33-p1756-4163.pdf http://www.wpi.edu/Pubs/ETD/Available/etd-1223102102625/unrestricted/ziolkowski.pdf http://www.ifme.eu/scopi/group/foundry/foundry.nsf/pagesref/SBDD7MDMSB?Opendocument&lang=en
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