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E. Riedel
Otto-von-Guericke-University Magdeburg, Institute of Manufacturing Technology and Quality Management, Universitaetsplatz 2, 39106 Magdeburg, Germany

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Journal article
Published: 10 March 2021 in Procedia CIRP
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Aluminium casting alloys are important for numerous industrial applications. Due to the high affinity of aluminium melts for the absorption of hydrogen, hydrogen-related porosity is regarded as one of the main defects affecting the quality of castings. The use of rotor degassing and/or chemical degassing tablets prior to casting are state of the art to reduce the hydrogen content of the melt but require the use of additional substances and are often difficult to digitize. Due to its purely physical operating principle ultrasonic degassing (USD) is considered an environmentally friendly alternative to the established procedures and allows digital process monitoring. However, its small primary treatment zone, the cavitation zone, is the reason why the USD has so far been denied widespread industrial use. The approach presented here aims at an USD of aluminium casting alloy A356 in the basin prior to tilt casting. Here the melting volumes are sufficiently small. By using Particle Image Velocimetry (PIV) analyses, CFD simulation and casting tests, this case of application was systematically investigated. It could be shown that the approach followed contributes to a significant reduction of the hydrogen dissolved in the melt by more than 50 % resulting in an increase of mechanical properties, especially elongation.

ACS Style

E. Riedel; P. Köhler; M. Ahmed; B. Hellmann; I. Horn; S. Scharf. Industrial suitable and digitally recordable application of ultrasound for the enviromentally friendly degassing of aluminium melts before tilt casting. Procedia CIRP 2021, 98, 589 -594.

AMA Style

E. Riedel, P. Köhler, M. Ahmed, B. Hellmann, I. Horn, S. Scharf. Industrial suitable and digitally recordable application of ultrasound for the enviromentally friendly degassing of aluminium melts before tilt casting. Procedia CIRP. 2021; 98 ():589-594.

Chicago/Turabian Style

E. Riedel; P. Köhler; M. Ahmed; B. Hellmann; I. Horn; S. Scharf. 2021. "Industrial suitable and digitally recordable application of ultrasound for the enviromentally friendly degassing of aluminium melts before tilt casting." Procedia CIRP 98, no. : 589-594.

Journal article
Published: 18 November 2020 in Metals
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Ultrasonic treatment (UST) and its effects, primarily cavitation and acoustic streaming, are useful for a high range of industrial applications, e.g., welding, filtering, cleaning or emulsification. In the metallurgy and foundry industry, UST can be used to modify a material’s microstructure by treating metal in the liquid or semi-solid state. Cavitation (formation, pulsating growth and implosion of tiny bubbles) and its shock waves, released during the implosion of the cavitation bubbles, are able to break forming structures and thus refine them. In this context, especially aluminium alloys are in the focus of the investigations. Aluminium alloys, e.g., A356, have a significantly wide range of industrial applications in automotive, aerospace and machine engineering, and UST is an effective and comparatively clean technology for its treatment. In recent years, the efforts for simulating the complex mechanisms of UST are increasing, and approaches for computing the complex cavitation dynamics below the radiator during high intensity ultrasonic treatment have come up. In this study, the capabilities of the established CFD simulation tool FLOW-3D to simulate the formation and dynamics of acoustic cavitation in aluminium A356 are investigated. The achieved results demonstrate the basic capability of the software to calculate the above-mentioned effects. Thus, the investigated software provides a solid basis for further development and integration of numerical models into an established software environment and could promote the integration of the simulation of UST in industry.

ACS Style

Eric Riedel; Niklas Bergedieck; Stefan Scharf. CFD Simulation Based Investigation of Cavitation Dynamics during High Intensity Ultrasonic Treatment of A356. Metals 2020, 10, 1529 .

AMA Style

Eric Riedel, Niklas Bergedieck, Stefan Scharf. CFD Simulation Based Investigation of Cavitation Dynamics during High Intensity Ultrasonic Treatment of A356. Metals. 2020; 10 (11):1529.

Chicago/Turabian Style

Eric Riedel; Niklas Bergedieck; Stefan Scharf. 2020. "CFD Simulation Based Investigation of Cavitation Dynamics during High Intensity Ultrasonic Treatment of A356." Metals 10, no. 11: 1529.

Journal article
Published: 11 August 2020 in Sustainability
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Energy consumption, greenhouse gas emissions, environmental impact levels, and the availability of materials as well as their sustainable usage are all topics of high current interest. The energy intensive processes of casting production such as heat treatment are particularly affected by the pursuit of sustainability. It has been estimated that up to 20% of the total energy demand in a non-ferrous foundry is required to provide the heat energy necessary during heat treatment processes. This paper addresses the application-oriented development of a sustainable configuration of the heat treatment process at the example of the aluminium-casting alloy A356 (AlSi7Mg0.3). Based on calculations of the physically necessary operating modes and under investigation of previous parameter recommendations, experimental studies were carried out to investigate the effects of various heat treatment parameters on the ultimate mechanical properties of the alloy. Since the achievable mechanical properties of the finished casting are decisive, the static and dynamic casting properties resulting from the heat treatment with optimized process parameters were compared with those of conventional process control. Significant optimization potential is shown for reducing the treatment time and thus lowering the energy consumption.

ACS Style

Stefan Scharf; Niklas Bergedieck; Eric Riedel; Hans Richter; Norbert Stein. Unlocking Sustainability Potentials in Heat Treatment Processes. Sustainability 2020, 12, 6457 .

AMA Style

Stefan Scharf, Niklas Bergedieck, Eric Riedel, Hans Richter, Norbert Stein. Unlocking Sustainability Potentials in Heat Treatment Processes. Sustainability. 2020; 12 (16):6457.

Chicago/Turabian Style

Stefan Scharf; Niklas Bergedieck; Eric Riedel; Hans Richter; Norbert Stein. 2020. "Unlocking Sustainability Potentials in Heat Treatment Processes." Sustainability 12, no. 16: 6457.

Journal article
Published: 04 April 2020 in Metals
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Ultrasonic treatment (UST), more precisely, cavitation and acoustic streaming, of liquid light metal alloys is a very promising technology for achieving grain and structure refinement, and therefore, better mechanical properties. The possibility of predicting these process phenomena is an important requirement for understanding, implementing, and scaling this technology in the foundry industry. Using an established (casting) computational fluid dynamics (CFD)-simulation tool, we studied the ability of this software to calculate the onset and expansion of cavitation and acoustic streaming for the aluminum alloy A356, partly depending on different radiator geometries. A key aspect was a holistic approach toward pressure distribution, cavitation, and acoustic streaming prediction, and the possibility of two- and (more importantly) three-dimensional result outputs. Our feasibility analysis showed that the simulation tool is able to predict the mentioned effects and that the results obtained are in good agreement with the results and descriptions of previous investigations. Finally, capabilities and limitations as well as future challenges for further developments are discussed.

ACS Style

Eric Riedel; Martin Liepe; Stefan Scharf. Simulation of Ultrasonic Induced Cavitation and Acoustic Streaming in Liquid and Solidifying Aluminum. Metals 2020, 10, 476 .

AMA Style

Eric Riedel, Martin Liepe, Stefan Scharf. Simulation of Ultrasonic Induced Cavitation and Acoustic Streaming in Liquid and Solidifying Aluminum. Metals. 2020; 10 (4):476.

Chicago/Turabian Style

Eric Riedel; Martin Liepe; Stefan Scharf. 2020. "Simulation of Ultrasonic Induced Cavitation and Acoustic Streaming in Liquid and Solidifying Aluminum." Metals 10, no. 4: 476.

Journal article
Published: 04 May 2019 in Procedia CIRP
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The casting process is one of the most important steps in the production and supply chain of metallic components. Certain aspects, such as a clean melt, a finely clustered microstructure, and homogeneous solidification, are the basic requirements for making high-quality components and therefore influence all subsequent production stages. Current procedures to fulfill these requirements are the use of additional chemical substrates and stirring units, as well as energy-intensive technologies for cooling and tempering the molds. The goals of this work can be summarized as the development and investigation of a new ultrasonic treatment (UST) applied during the solidification of the aluminum casting alloy A356. The main idea is to expand the well-known physical effects of UST by exploiting the possibility of influencing microstructure formation during solidification. From the viewpoint of industrial applicability, the contribution of this work is the presentation of a new simulation tool that allows for making comprehensive predictions of UST processes. The presented results confirm the huge potential of the proposed treatment for increasing strength, reducing wall thicknesses, and saving valuable resources, such as materials and energy.

ACS Style

E. Riedel; I. Horn; N. Stein; H. Stein; R. Bähr; S. Scharf. Ultrasonic treatment: a clean technology that supports sustainability in casting processes. Procedia CIRP 2019, 80, 101 -107.

AMA Style

E. Riedel, I. Horn, N. Stein, H. Stein, R. Bähr, S. Scharf. Ultrasonic treatment: a clean technology that supports sustainability in casting processes. Procedia CIRP. 2019; 80 ():101-107.

Chicago/Turabian Style

E. Riedel; I. Horn; N. Stein; H. Stein; R. Bähr; S. Scharf. 2019. "Ultrasonic treatment: a clean technology that supports sustainability in casting processes." Procedia CIRP 80, no. : 101-107.