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Emission standards getting harder and tougher day by day, therefore this challenge causes a decrease in diesel engine and increase in hybrid systems usage. But, for heavy duty industries; diesel engines are still very economic and feasible because of today’s technological developments and market competitions. In this direction, research and development process of heavy duty diesel engines continues on process optimisation and weight reductions. In this study, weight reduction and design development is applied for a tractor diesel engine block which manufactured for prototype to gain an industrial advantage. New light weight design is optimized according to manufacturing parameters and moulding requirements via casting simulation software. In additional, a commercial finite element-based analysing program is used to simulate the mechanical properties of the new design, and to predict possible deviations by comparing the first and final design.

International Iron & Steel Symposium
UDCS

Ümit Kirenci Ali Serdar Vanlı Anıl Akdoğan

As the known lightest structural metal, Magnesium (Mg) has attracted interests for automotive, electronics and aircraft industries. There is a common usage at industrial applications of Mg alloys because of their distinguishing performance characteristics. However, there almost isn’t an integrated mass production line at the industrial scale in Turkey which can supply high density and strong mechanical property Mg products due to the lack of experience and knowledge in this subject. Unfortunately, Turkey deliberately avoid to manufacture Mg alloy parts thus can only use them by importing. Honestly, there is an integrated mass production system including a dosing furnace, a molten metal transfer system, a gas mixing unit, a die heating-cooling device, and a cold chamber die casting machine for Mg alloys mass production in Yildiz Technical University, Mechanical Engineering Department, Die Casting Laboratory. Today, it is possible to get acceptable mechanical and metallurgical propertied, high density parts by considering the three basic production steps i.e. melting, dosing, and casting precisely.

International Iron & Steel Symposium
UDCS

Ali Serdar Vanlı Anıl Akdoğan

Casting, one of the oldest manufacturing techniques, is based on the basis of phase changing. Even if there are different types, sand casting is most preferred one. Casting processes have many parameters and due to that for obtaining the products which have the best quality, those parameters should be adjusted as optimal. Simulation is a useful way for determining the optimum values, estimating the risks and avoiding the defect possibilities before the production. Each part is unique and gating systems have to be designed according to part geometry to get better results. In this study, unpressurized gating system design is investigated for ductile iron. Dimensions of the critical areas as the cross-section of the runner and gates which are very important for determining pouring time and liquid metal velocity, are calculated precisely.

International Iron & Steel Symposium
UDCS

Atahan Erbul Ali Serdar Vanlı

In this paper, SiC particle reinforced magnesium (Mg) matrix composite material fabrication was realized by using high pressure die casting (HPDC) method. The production of the composite materials was carried out by injecting of AZ91 magnesium alloy into the die casting mold thorough the preheated SiC preform reinforcing element having a porous structure. The abrasion strengths, which are important in terms of the application area of the produced composite materials, are measured by wear test using ball-on-disk method. In addition, the microstructures, characteristic features and wear marks of the composites were examined by scanning electron microscopy.

International Conference of Advanced Materials and Manufacturing Technologies
ICAMT

Ali Serdar Vanlı Bedri Onur Kucukyildirim Anıl Akdoğan