Critical parameters influencing the quality of metal castings: a systematic literature review

Abstract

PurposeCasting is one of the well-known manufacturing processes to make durable parts of goods and machinery. However, the quality of the casting parts depends on the proper choice of process variables related to properties of the materials used in making a mold and the product itself; hence, variables related to product/process designs are taken into consideration. Understanding casting techniques considering significant process variables is critical to achieving better quality castings and helps to improve the productivity of the casting processes. This study aims to understand the computational models developed for achieving better quality castings using various casting techniques.Design/methodology/approachA systematic literature review is conducted in the field of casting considering the period 2000–2020. The keyword co-occurrence network and word cloud from the bibliometric analysis and text mining of the articles reveal that optimization and simulation models are extensively developed for various casting techniques, including sand casting, investment casting, die casting and squeeze casting, to improve quality aspects of the casting's product. This study further investigates the optimization and simulation models and has identified various process variables involved in each casting technique that are significantly affecting the outcomes of the processes in terms of defects, mechanical properties, yield, dimensional accuracy and emissions.FindingsThis study has drawn out the need for developing smart casting environments with data-driven modeling that will enable dynamic fine-tuning of the casting processes and help in achieving desired outcomes in today's competitive markets. This study highlights the possible technology interventions across the metal casting processes, which can further enhance the quality of the metal casting products and productivity of the casting processes, which show the future scope of this field.Research limitations/implicationsThis paper investigates the body of literature on the contributions of various researchers in producing high-quality casting parts and performs bibliometric analysis on the articles. However, research articles from high-quality journals are considered for the literature analysis in identifying the critical parameters influencing quality of metal castings.Originality/valueThe systematic literature review reveals the analytical models developed using simulation and optimization techniques and the important quality characteristics of the casting products. Further, the study also explores critical influencing parameters involved in every casting process that significantly affects the quality characteristics of the metal castings.

Study the effects of machining parameters on the surface characteristics of aluminum-magnesium alloy with different nose radiuses

“…The comparison was made to obtain the optimal parameters graphically using the data in table (2) which represents the experimental design, new parameters arise and are obtained and these parameters do not exist in table (2), to predict the mean for the treatment condition average of result for the trail is set at this particular level is calculated. The comparison of the optimal set of parameters is represented graphically by using the data in table (3) which represents the experimental design, new parameters arise and are obtained and these parameters do not exist in table (3), to predict the mean for the treatment condition average of result for the trail is set at this particular level is calculated. The comparison of the optimal set of parameters is represented graphically by using the data in table (4) which represents the experimental design, new parameters arise and are obtained, and these parameters do not exist in table (4), to predict the mean for the treatment condition average of result for the trail is set at this particular level is calculated.…”

“…Cutting parameters such as speed feed depth of cut strongly influence the surface roughness of the machined product [2]. Producing a desired surface roughness, which is one of the most important factors in measuring the quality of machined products, presents mechanical and economic issues in manufacturing environments [3]. Not only does producing the appropriate surface roughness affect the functional attributes of products also affects manufacturing costs [4].…”

Investigating the causes and remedies for porosity defects in the casting process: A review

“…For example, another study investigated the use of a 3D-printed ceramic core in the investment casting of titanium alloys and found that this approach led to improved surface quality and reduced defects such as surface cracks. This can lead to improved product quality, lower production costs, and increased competitiveness in the market (33). To fully realize the potential of these cutting-edge materials and technologies, however, and to guarantee their scalability and affordability for industrial-scale production, more research and development is required.…”

Aluminium Casting Technology Management Analysis

“…The effectiveness of these studies is influenced by the identification of resource constraints (bottlenecks) and the consideration of organisationspecific critical resources [7].Due to the increase in demand for aluminium alloy parts and components and the increase in demands placed on these components in the metallurgical industry, analyses are being carried out on the progress and achievements in the shaping of aluminium alloys [8], on the improvement of manufacturing technology [9] or on the improvement of casting quality -the microstructure and properties of castings [10]. The literature on the subject also identifies critical parameters affecting each casting process and which significantly determine the quality characteristics of metal castings [11]. Comparative analyses of casting techniques [12] and reviews of new process technologies [13] developed to identify the most favourable solution to help foundry men make the optimum decision on the choice of technique taking into account the assurance of a high level of quality, environmental friendliness, favourable cost implications and taking into account occupational safety are being carried out.…”