Obtención de una aleación Cu – Zn libre de plomo mediante simulación y validación experimental.

Abstract

Casting is a fundamental process in the manufacturing industry due to its capability to produce a wide variety of components through various procedures. In this study, the feasibility of using specialized software to simulate gravity casting in sand molds for the production of Cu-Zn alloys with the addition of ferro-silicon in different proportions (0.5 %, 1 %, 1.5 %, and 2 % by weight) was evaluated. Furthermore, the orientation of the test samples (horizontal and vertical) was varied to prevent and mitigate potential defects in the process, comparing the experimental results with those obtained through computer simulation using Altair Inspire Cast software. The inclusion of ferro-silicon in the composition was motivated by the need to find an alternative to lead in alloys (C38500) used in plumbing products, due to the health and environmental risks associated with lead. Therefore, the research aims not only to optimize the casting process but also to contribute to the replacement of harmful materials. The experimental process began with the preparation of specimens under controlled conditions, varying the amount of ferro-silicon, as well as the orientation of the specimens. The operating parameters determined in the experimental process were used as a reference point to validate and adjust the simulation performed with Altair Inspire Cast software. The simulation results indicated that the vertically positioned specimens exhibited optimal performance compared to horizontally positioned specimens. This was attributed to the configuration of the feeding system used in the casting. To achieve this, parameters such as temperature, liquid metal velocity, filling time, and the presence of trapped air, among others, were evaluated. Additionally, a characterization analysis of the vertically cast samples was conducted, considering the ferro-silicon content in their composition, through hardness tests, microhardness, metallography, and scanning electron microscopy (SEM). Based on the qualitative and quantitative analysis of these tests, it was concluded that the material's hardness is directly related to the amount of silicon in the composition and the percentage of the β' phase.