International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

The use of mathematical models of control processes in foundry such as: K-test and Chemical spectral analysis is a good set of mathematics (thermal conductivity theory) and theoretical physics (first-order phase transition) are important elements for ensuring high quality castings in micro-foundries.
The idea of estimating the overheating of a liquid metal alloy based on the appearance of a curing process upon filling has been developed. These control processes combined with zone refining are an important opportunity to create a waste-free foundry in a circular economy in Industry 4.0.

Based on the finite element method, the Stefan-Schwartz problem in micron size is solved in the estimation of contact heat exchange in the foundry. The dimensions of the contact spots are minimal, but using a good computing network it has proved possible to consider contact heat transfer processes. A temperature field in the area of complex geometry of the contact surface was obtained. A casting / mold temperature jump with perfect contact was also obtained.

Two tasks are enumerated: a task of hardening spheres with a radius of 50 nm and a task of crystallization – the underlying kinetic equation of formation of new phases. These tasks are rational bridges for multi-scale approach.
There is an opportunity to create additive production with traditional machines and technologies in the field of anti-pressure casting

This paper proposes the idea of a “small volume” in which to consider complicated processes to create structures in phase transitions of first and second order in the foundry. The small volume is chosen based on the classical theory of crystallization and its use for quantum mechanics. A numerical solution of Stefan-Schwarz’s task was presented by obtaining the temperature field of solidification of a composite cast in a squeeze casting. This little volume we proposed for a good possibility in the direction for a theoretical possibility of hybridization of production and technology.

The base process was obtained: 3D hardening temperature field for the K-test under heat transfer at conditions with maximum intensity. A methodology for determining macro-level defects in aluminum alloys. It is definitely the placement of the K-test method in the process of creating the first order phase transition in a casting technology. The idea of interaction between the classical theory of crystallization and quantum mechanics for the processes of structure formation at casting was introduced by Stefan’s task in volume with nano-size.

An integral representation of technological parameters of low pressure casting for the production of a car wheel is made. An algorithm and methodology for communication between micro-foundry and material science induced by the change Industry 4.0.

The identification of the heat exchange intensity at the work surface of the mold is defined by the base information of the type and movement of the solidification front. Parameters and their influence are shown on the type and movement of the solidification front: initial melt temperature; initial temperature of the mold; the ceramic coating on the work surface of the mold; distribution of the mass of the mold. The methodological link of these parameters is shown in the creation of each casting technology.