Design of casting systems for stainless steel exhaust manifold based on defective prediction model and experimental verification

Jenn Kun Kuo, Pei Hsing Huang, Steven Hsin-Yi Lai, Wei Jen Wu

Research output: Contribution to journalArticle

3 Citations (Scopus)

Abstract

High-performance exhaust manifolds are expected to operate in high-temperature and corrosive environments. Any cavitation or surface corrosion induced by casting defects can cause air leakage, reduce exhaust efficiency, and shorten the lifespan of the device. In this study, we sought to eliminate casting defects by optimizing the gating system used in the production of an SUS316 stainless steel exhaust manifold, based on the probability and distribution of porosity defects, as determined using the retained melt modulus (RMM) model. Mold flow analysis and experiments were conducted to configure gating systems to operate under a variety of processing parameters. Our predictions pertaining to defect formation were in good agreement with experiment results. Simulations revealed that side gating systems improved flow stability and reduced the encapsulation of gas in the cavity of the top gating section. The resulting scheme increased the casting yield from 24% (using the original casting scheme) to 28%. Experimental verification using non-destructive testing methods revealed that the proposed scheme succeeded in eliminating all of the porosity defects from the cast exhaust manifold.

Original languageEnglish
Pages (from-to)529-540
Number of pages12
JournalInternational Journal of Advanced Manufacturing Technology
Volume100
Issue number1-4
DOIs
Publication statusPublished - 2019 Jan 16

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Exhaust manifolds
Casting
Stainless steel
Defects
Porosity
Leakage (fluid)
Nondestructive examination
Encapsulation
Cavitation
Experiments
Corrosion
Processing
Air
Gases

All Science Journal Classification (ASJC) codes

  • Control and Systems Engineering
  • Software
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

Cite this

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abstract = "High-performance exhaust manifolds are expected to operate in high-temperature and corrosive environments. Any cavitation or surface corrosion induced by casting defects can cause air leakage, reduce exhaust efficiency, and shorten the lifespan of the device. In this study, we sought to eliminate casting defects by optimizing the gating system used in the production of an SUS316 stainless steel exhaust manifold, based on the probability and distribution of porosity defects, as determined using the retained melt modulus (RMM) model. Mold flow analysis and experiments were conducted to configure gating systems to operate under a variety of processing parameters. Our predictions pertaining to defect formation were in good agreement with experiment results. Simulations revealed that side gating systems improved flow stability and reduced the encapsulation of gas in the cavity of the top gating section. The resulting scheme increased the casting yield from 24{\%} (using the original casting scheme) to 28{\%}. Experimental verification using non-destructive testing methods revealed that the proposed scheme succeeded in eliminating all of the porosity defects from the cast exhaust manifold.",
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Design of casting systems for stainless steel exhaust manifold based on defective prediction model and experimental verification. / Kuo, Jenn Kun; Huang, Pei Hsing; Lai, Steven Hsin-Yi; Wu, Wei Jen.

In: International Journal of Advanced Manufacturing Technology, Vol. 100, No. 1-4, 16.01.2019, p. 529-540.

Research output: Contribution to journalArticle

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