Defect Reduction in Castings, a paradigm shifts to defects elimination: A Hybrid Casting Approach by MAM method

Casting technology continues to be one of the most fundamental manufacturing methods over the centuries and decades, with high production capacity and the ability to produce complex geometries. However, this manufacturing method is prone to numerous metallurgical defects, such as shrinkage porosity, inclusions, hot tear, and distortion, which pose a serious challenge to researchers in the field of manufacturing based on high standards to achieve the lowest possible part defects. The Metal Additive Manufacturing method (MAM) cannot be a reliable manufacturing method in the industry due to the speed and cost of mass production. This does not make the technology a substitute for casting, but rather provides a basis for its integration and the use of techniques that can be used for hybrid casting. This strategic integration of the hybrid casting by MAM method to produce optimized molds such as: cooling channels and optimized topology feeders that are the direct and root causes of defects, provides a transformative integrated manufacturing option and method to achieve minimal defect parts that ultimately overcome the fundamental weaknesses of casting. Parts that require precision, quality, minimal defects, and high efficiency in the Formula ۱ automotive industry and engineering cannot be met by conventional casting methods, which undoubtedly fail to meet this need. Hybrid casting, in conjunction with the MAM method, can produce highly sensitive parts in the Formula ۱ automotive industry and engineering by minimizing the cost of critical defects and waste, and providing a product that meets high standards. This study shows that the hybrid casting production method with the MAM method provides the possibility to achieve defect reduction and ultimately eliminate defects. For example, topology-optimized feeders to eliminate shrinkage cavities, laminar flow gating to remove inclusions, and adaptive cooling in the controlled solidification process to prevent hot spots and gas porosity can reduce and eliminate limitations and defects common even in advanced casting, resulting in dimensional accuracy and minimal defects that can make a big difference in the quality of industrial and engineering parts for Formula ۱ automotive industry and engineering.

کلیدواژه ها:

Hybrid Casting ، MAM method ، Additive Manufacturing ، Defect Reduction