Foundries represent an important sector of the manufacturing industry and these foundry industries in developing countries suffer from poor quality and productivity due to number of process parameters involved in the casting process. Even in a completely controlled process, defects in casting are observed and hence casting process is also known as process of uncertainty which challenges explana...

Increasingly, Solid Freeform Fabrication (SFF) processes are being considered for creating functional parts. In such applications, SFF can either be used for creating tooling (i.e., patterns for casting, low volume molds, etc.) or directly creating the functional part itself. In order to create defect free functional parts, it is extremely important to fabricate the parts within allowable dimen...

1 ABSTRACT The continuous casting process is a widely used technique in modern steel plants. However, it is a complicated process that is not well understood. The objective of this research is to model the porosity and macrosegregation due to shrinkage related effects and solid deformation in the continuous casting of steel. Solid phase movements due to bulging and variable roll gap are modeled...

Components for engineering systems, such as gas turbines and jet engines operating at high temperature are usually produced in superalloys. The investment casting process is most widely used for manufacturing these components due to the ability of the process to produce parts with complex geometries to close dimensional tolerances. Other processing routes are less advantageous due to high mecha...

There are about 33 processes commercially available for the production of aluminium castings. About 70% of the castings are produced using conventional high-pressure die-casting process. It’s main drawbacks are 1) Air and gas blow holes 2) Unable to weld 3) unable to heat treat to enhance mechanical properties. To overcome these, many modern processes have been invented. A few of them are 1) Hi...

Casting has many process variations depending upon the material, the type of pattern, mould and the pouring technique like sand casting, investment casting, die casting, squeeze casting and lost foam casting. Sand casting is the most widely used process which can be used to produce intricate parts in almost every metal that can be melted. Casting defects analysis is process of finding the root ...

Water-cooling plays a major role in extracting heat from both the mold and solidifying metal during the continuous casting of steel and aluminum alloys and is characterized by complex boiling phenomena. Heat extraction rates during water-cooling, which have strong dependence on the metal surface temperature, can rapidly change with time as the strand cools down. Consequently, uncontrolled cooli...

Surface quality of the steel slabs in a Continuous Casting (C.C.) process is mainly determined by the stability of the Mold Level Control (MLC). Excessive mold level fluctuations lead to an additional machine scarfing process which is applied to the slabs to avoid surface defects. A conventional Proportional-Integral-Derivative (PID) controller is not robust enough to deal with the disturbances...