Defect Analysis of Cooler Cover and Numerical Simulation of Casting Process

Wang Anshu; Qu Yingdong; Li Rongde; You Junhua; Jiang Ke

doi:10.15980/j.tzzz.2015.12.022

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Defect Analysis of Cooler Cover and Numerical Simulation of Casting Process
Vol. 35, Issue 12, Pages: 1304-1307(2015)
Published： 2015 ，
DOI： 10.15980/j.tzzz.2015.12.022

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[1]王安舒,曲迎东,李荣德,尤俊华,姜珂.铜合金冷却器盖缺陷分析及工艺数值模拟[J].特种铸造及有色合金,2015,35(12):1304-1307.

Wang Anshu, Qu Yingdong, Li Rongde, et al. Defect Analysis of Cooler Cover and Numerical Simulation of Casting Process. [J]. Special Casting & Nonferrous Alloys 35(12):1304-1307(2015)
[1]王安舒,曲迎东,李荣德,尤俊华,姜珂.铜合金冷却器盖缺陷分析及工艺数值模拟[J].特种铸造及有色合金,2015,35(12):1304-1307. DOI： 10.15980/j.tzzz.2015.12.022.

Wang Anshu, Qu Yingdong, Li Rongde, et al. Defect Analysis of Cooler Cover and Numerical Simulation of Casting Process. [J]. Special Casting & Nonferrous Alloys 35(12):1304-1307(2015) DOI： 10.15980/j.tzzz.2015.12.022.

摘要

在铜合金冷却器盖生产过程中

主要问题是铸造缺陷导致铸件出现渗漏现象

无法满足质量要求。通过扫描电镜观察冷却器盖铸件铸造缺陷的宏观及微观形貌

检测其化学成分

探讨其产生缺陷的原因。结果表明

金属液产生少数氧化夹渣

以及铸件不能完全补缩而产生的缩孔是导致铸造缺陷的主要原因。通过加快熔炼速度、控制浇注温度、优化浇注工艺

可避免缩孔缺陷产生

提高铸件的质量。采用ProCAST模拟软件对新工艺进行了数值模拟

试验结果与模拟结果一致

铸件渗漏缺陷问题得到解决。

Abstract

In production process of copper alloy cooler cover

leakage can be observed in the cooling cover due to casting defects in the water testing

which can’t meet the quality requirement.The macrostructure and microstructure of casting defects in the cooler cover were observed by SEM（scanning electron microscopy）

and the chemical composition was analyzed to understand origination of casting defects.The results reveal that the casting defects are attributed to formation of oxide inclusion and shrinkage cavity caused by incomplete feeding.The casting defects can be eliminated by controlling the smelting rate and casting temperature as well as optimizing gating system.The numerical simulation of the casting process was carried out with the help of the ProCAST software.The results of the trial production are well in agreement with the numerical ones

and leakage can be solved.