The master thesis deals with design for casting mould of an impeller wheel for investment casting lost wax and machining technology with utilization CAD software SolidWorks 2008 and CAM software PowerMill 9. Subsequent verification of machining on vertical machining center MCV 1210. At the end, techno-economic evaluation is done.

This diploma thesis deals with the possibilities of optimization of ceramic shell molds in the method of investment casting. In the first part is mentioned a complete technological process of the method with focusing on production and quality control of the ceramic shell and components, from which it is produced. The experimental part is divided into two parts, in the first are results of laboratory tests, which were tested both the current ceramic shell and shells which have been considered as a possible replacement. In the second section were verified conclusions of the experimental findings and recommendations of the laboratory results in pilot plant conditions.

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This work deals with the issue of defects generation during the separation of the castings from a nickel-based superalloy, Inconel 738LC. The technology of investment casting is presented, followed by a description of metallurgy of superalloys, their physical and mechanical properties, as well as their technical applications. The machinability of superalloys and method of castings separation were also described as well as some of the casting defects that were reported to have impact on the generation of the defects after cutting. In the experimental part, the material microstructure and casting defects were analyzed. The experimental machining part consisted first of a comparative study of the friction sawing and plasma arc cutting technology at the standard operating conditions actually used in production. Second, an optimization study for the friction sawing was carried out, with a special focus on the suitability of an alternative cutoff wheel for the chosen application. Application of this wheel allows reducing the security distance between the cut and the part, thus reducing the production cost of the part.

Orientadores: Rubens Caram Junior, Adelino Aguiar Coelho / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-08T17:54:45Z (GMT). No. of bitstreams: 1 Andrade_ProtasioNery_M.pdf: 9178937 bytes, checksum: f63ed0f47d8aa70b2d3a755e537fbe8f (MD5) Previous issue date: 2006 / Resumo: Em função de características como alta razão resistência/peso, ótima biocompatibilidade, elevada resistência à corrosão e módulo de elasticidade que pode ser controlado pela adição de elementos de liga, o uso de ligas de titânio pela indústria médica e odontológica está em franco crescimento. No presente estudo, ligas do sistema Ti-Cu com teores entre 5 e 15 % em peso de cobre foram fundidas através do processo de fundição por centrifugação em moldes de cobre. A alta taxa de resfriamento imposta pelo molde empregado levou à formação de microestruturas totalmente martensítica. Em seguida, tais microestruturas foram modificadas através tratamentos térmicos, levando a estruturas mais estáveis. A caracterização das amostras obtidas envolveu análise microestrutural através de microscopia óptica e eletrônica de varredura, difração de raios-X, ensaios mecânicos. Os resultados obtidos indicam que as altas taxas de resfriamento envolvidas promoveram a formação da estrutura metaestável _'. O aumento da concentração de cobre levou ao aumento na dureza promovida pela formação do intermetálico Ti2Cu. O Ti2Cu apresentou módulo de elasticidade menor do que a fase _. A fratura dos corpos de prova teve caráter dúctil e é intensamente afetada pela presença de porosidade / Abstract: Due to characteristics like high strength-to-weight ratio, high biocompatibility, enhanced corrosion resistance and the possibility of controlling elastic behavior by proper addition of alloying elements, the use of titanium by medical and dental industries is continuously growing. In this work, Ti-Cu alloys with a Cu content varying from 5% to 15 wt% were prepared by arc melting and cast in copper molds. The high cooling rate imposed by copper mold led to the formation of a completely martensitic structure. Following, the microstructure of these samples were modified by applying proper heat treatments, leading to more stable microstructures. The samples characterization includes microstructure analyzes through optical and scanning electron microscopy, X-ray diffraction method and mechanical tests. The results obtained suggest that application of high cooling rates resulted in the formation of a'metastable phase. As Cu content was increased, hardness also increased due to Ti2Cu intermetallic compound precipitation. The Ti2Cu compound was found to present lower elastic modulus than the modulus of a phase. Finally, it was found that the heat treated samples presented high ductility and their mechanical behavior is affected by porosities / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

The purpose of this thesis is to assess the current state of production of ceramic shells in MESIT Foundry, a.s. and optimize it. The shells are evaluated in terms of their bending strength, gas permeability and microstructure. Subsequently, castings produced using the shells are evaluated with regard to number of non-conforming products and presence of defects. The final part seeks to compare different shells and outlines a possible new approach to the development of ceramic shells.

This master's thesis deals with the effects of the cooling rate on the grain size of magnesium alloys based on Mg–Al (AZ91E) and Mg–Zr–RE (WE43B and Elektron21). The effects of the cooling rate are analyzed on samples of varying thickness for different cooling methods (forced–air–cooling, cooling into polymer, natural air cooling). We also evaluated the final microstructure, porosity, hardness, and mechanical properties for investment castings. Based on the evaluated grain sizes, we demonstrated a significant difference in the cooling rate influence on the grain size for the alloy AZ91E. Compared to Zirconium-based alloys (WE43B and Elektron21), for which the zirconium content influences grain size the most. For the alloys based on Mg–Zr–RE, it is possible to prefer casting conditions, without negative enlarging of the grain size.

An overview of the development of the Investment Casting market and Rapid Prototyping equipment is given in the introductory part of this diploma thesis. Basic methods of rapid prototyping and the FDM method are futher described in detail. The FDM method is consequently used in the practical part of this work for the preparation of the silicon mould. The largest part deals with the issue of the simulation of pouring process of wax into the silicon mould. A characteristics of the casting wax is made; the parametres, which are inserted into the simulation software ProCAST and the possibilities of their measurement are described. The process of the simulation of the mould filling and its validation with the real filling process are described in detail.

Intermetallic alloys gama TiAl are prospective materials of future thanks its excellent machanical qualities and low density. However this alloy clash with for wider expansion to the practice on burdensomeness production and processing. Among disavantages belongs to also her bad fluidity. The diploma work is angaged in possibilities imporing fluidity alloys TiAl by the help of centrifuge casting. Casting healthy casts was achieved in experimental part.

This diploma thesis is focusing on possibilities of influencing casting’s structure of nickel superalloy Inconel 713LC by force effects caused by vibration and rotation during crystallization. In this research were cast three test castings of turbine wheels with different solidification conditions that have affected the size and distribution of the grains. The aim was to compare the different microstructure and macrostructure of castings and then compare the dependence of grain refinement on mechanical properties. Changes in the structure were analyzed by means of light and electron microscopy methods after the fracture of test bars.