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Effect of Coating Thickness on the Molten Metal Filling Rate of Cast Iron in the Evaporative Pattern Casting Process

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Abstract

Molten metal filling rate and polystyrene foam pattern decomposition were examined in order to clarify how to improve the metal flow length of cast iron in the evaporative pattern casting process. The molten metal filling rate and the decomposition rate of a polystyrene foam pattern were measured during a casting experiment. A copper alloy was also cast using the same method for the purpose of comparison. The molten metal filling rate of cast iron was lower than that of the copper alloy. The volume of the gas gap increased with increasing melt temperature and decreasing coating permeability. A large amount of liquefied resin was formed by thermal decomposition of the foam pattern. The molten metal filling rate increased with increasing coating permeability and increased further with increasing coating thickness in the final step of molten metal filling. Even with increasing permeability of the coating, there is an occurrence of misruns in the case of molten cast iron, while the use of a thicker coating increased the molten metal flow length.

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Acknowledgments

Funding was provided by Japan Society for the Promotion of Science (Grant No. 26420760).

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Authors and Affiliations

  1. Department of Chemistry and Materials Engineering, Kansai University, Osaka, Japan

    Toru Maruyama

  2. Aisin Takaoka Co. LTD, Aichi, Japan

    Gou Nakamura

  3. Yanmar Co. LTD, Osaka, Japan

    Mitsuyoshi Tamaki

  4. Graduate School of Science and Engineering, Kansai University, Osaka, Japan

    Keisuke Nakamura

Authors
  1. Toru Maruyama
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  2. Gou Nakamura
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  3. Mitsuyoshi Tamaki
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  4. Keisuke Nakamura
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Correspondence to Toru Maruyama.

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Maruyama, T., Nakamura, G., Tamaki, M. et al. Effect of Coating Thickness on the Molten Metal Filling Rate of Cast Iron in the Evaporative Pattern Casting Process. Inter Metalcast 11, 77–83 (2017). https://doi.org/10.1007/s40962-016-0108-5

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  • DOI: https://doi.org/10.1007/s40962-016-0108-5

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