Improving Process Reliability of Cast-in Insertion Bonding by CAE Application

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(1)Commercial flow and solidification simulation system was applied to improve the bonding states and the process reliability of cast-in insertion, and combined with the author's bonding theory, the method of determining the optimal casting and gating system was established.(2)For the two types of insertion, buried insertion and end face bonding of steel inserts in cast iron, basic ideas to optimize the gating system was clarified.(3)The ideas were verified by the experiments. Enhancing effect of Ni alloy plating on the bonding was also examined.(4)The method was successfully adopted to the actual production line of ductile iron castings for automobile use bonded with carbon steel insertions.(5)Fatigue tests were carried out on test pieces from the bonded samples. It was verified that when the test section cleared the UT inspection and boundary diffusion progressed enough, the bonded junctions have good fatigue properties. When the diffusion is not enough, possibility of low fatigue strength was pointed out because of the plated layer acting as fatigue origin.