Dissertations and Theses @ UNI

Availability

Open Access Thesis

Keywords

Metal castings; Molding (Founding);

Abstract

This research work was conducted to develop a proposed transparent fluid model to mimic dross formation and dispersion in metal castings during the mold filling process. The major cause for dross formation includes the air entrainment, surface turbulence, and bubbles, which create oxide films inside the molten metal. The oxide films are trapped inside the casting after solidification causing detrimental effects on the mechanical properties of the casting.

The objective of the investigation was to explore the feasibility using phenolic urethane as a transparent fluid material to investigate air entrainment mechanism. The experimentation consists of the following materials: the phenolic urethane cold box binder system which two types of resins called part 1 and part 2, biodiesel solvent, and amine in gas phase. The two part liquid resins were diluted with biodiesel solvent to develop viscosity properties lower than 15cP, so the physics can be applied without too much variation in results. The thin film formed by the exposure of the solution to the amine gas, showed excellent properties to mimic dross formation caused by air entrainment and oxidation. To be able to manipulate those properties a deeper investigation was performed on the film including various observational and experimental tests.

The observational and experimental tests demonstrated that the solution has the ability to create a thin film when exposed to the amine. Besides, the tests showed that the effects on the film ́s mechanical and physical properties could be manipulated by altering the resins and dilution ratios. The physical property tests helped to measure the actual effects of altering the recipe of the solution on the strength and flexibility of the film.

The solution then was poured into a simple acrylic mold prototype demonstrating the ability of the solution to form thin films, which proved the reactive liquid concept. The experiments proved the solution was able to demonstrate air entrainment, surface turbulence, and bubble formation and dispersion inside the mold. It has the potential for researchers to study and customize the solution to emulate different metal and oxide films.

Year of Submission

2021

Degree Name

Master of Science

Department

Department of Technology

First Advisor

Scott Giese, Chair, Thesis Committee

Date Original

2021

Object Description

1 PDF file (viii, 53 pages)

Language

en

File Format

application/pdf

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