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Abstract <p>Ductile cast iron is a widely utilized alloy for its high strength, high wear resistance and good processability. Meanwhile, it possesses some disadvantages such as low resilience, high density and high scrap rate during the manufacturing of complex castings. Additionally, controlling the filling rate and solidification sequence of such castings is challenging, resulting in the formation of casting defects. In order to improve the quality of a lost foam cast EN-GJS-400-18 ductile iron semi-truck fifth wheel coupling shells, a study using a commercial simulation software, ProCAST 2021, was conducted looking at the casting process and the influence of pouring speed, pouring temperature and ferro-static head pressure influence on the total shrinkage porosity using Box-Behnken response surface methodology. Regression equations were developed and solved to determine the optimal combination of process parameters, and the optimization scheme was subsequently verified. The results indicate that shrinkage porosity is primarily concentrated at the edges of the fifth wheel coupling shell, far from the pouring system. The sequence of process parameters that most significantly affects total shrinkage porosity is ferro-static head pressure, pouring speed, and pouring temperature. The optimal process parameters were found to be a pouring temperature of 1386&#xa0;°C, a pouring speed of 6.4 kg/s and a ferro-static head pressure of 109751&#xa0;Pa. Simulation software was used to predict potential casting defects under these optimized parameters, and the quality of the test fifth wheel coupling shell was verified. The casting met the production and performance requirements, with no significant defects detected.</p> Graphical Abstract <p></p>

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Optimization of Defects in the Lost Foam Casting Process for Fifth Wheel Coupling Shell

  • 期刊论文

  • 发表日期：

    2025年6月3日

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  • Haonan Li,
  • Hongchao Ji,
  • Bing Chen,
  • Xiaomin Huang,
  • Menglong Xing,
  • Guofa Cui,
  • Changming Qiu

摘要

Abstract

Ductile cast iron is a widely utilized alloy for its high strength, high wear resistance and good processability. Meanwhile, it possesses some disadvantages such as low resilience, high density and high scrap rate during the manufacturing of complex castings. Additionally, controlling the filling rate and solidification sequence of such castings is challenging, resulting in the formation of casting defects. In order to improve the quality of a lost foam cast EN-GJS-400-18 ductile iron semi-truck fifth wheel coupling shells, a study using a commercial simulation software, ProCAST 2021, was conducted looking at the casting process and the influence of pouring speed, pouring temperature and ferro-static head pressure influence on the total shrinkage porosity using Box-Behnken response surface methodology. Regression equations were developed and solved to determine the optimal combination of process parameters, and the optimization scheme was subsequently verified. The results indicate that shrinkage porosity is primarily concentrated at the edges of the fifth wheel coupling shell, far from the pouring system. The sequence of process parameters that most significantly affects total shrinkage porosity is ferro-static head pressure, pouring speed, and pouring temperature. The optimal process parameters were found to be a pouring temperature of 1386 °C, a pouring speed of 6.4 kg/s and a ferro-static head pressure of 109751 Pa. Simulation software was used to predict potential casting defects under these optimized parameters, and the quality of the test fifth wheel coupling shell was verified. The casting met the production and performance requirements, with no significant defects detected.

Graphical Abstract