Optimization of casting conditions for heat and abrasion resistant large grey iron castings

Numerical simulation technology was applied for optimizing the casting design and conditions in large cast iron castings for marine engine. By the simulation of mold filling and solidification sequences the problems of the previous casting conditions were analyzed and marked improvements for large cylinder liner parts were derived from these results. Especially the amount and positions of chills were optimized to increase the mechanical properties and to minimize the shrinkage and microporosity in the castings. Ultrasonic testing, penetration testing and mechanical property testing were carried out for the parts with the modified casting conditions. It showed that nodefects in the castings were found and the productivity could be distinctly increased. The mechanical properties satisfied also the specification demanded.