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Sample records for semi-solid die casting

  1. Semi-solid Twin-roll Casting Process of Magnesium Alloy Sheets

    NASA Astrophysics Data System (ADS)

    Watari, H.; Davey, K.; Rasgado, M. T. Alonso; Haga, T.; Koga, N.

    2004-06-01

    An experimental approach has been performed to ascertain the effectiveness of semi-solid strip casting using a horizontal twin roll caster. The demand for light-weight products with high strength has grown recently due to the rapid development of automobile and aircraft technology. One key to such development has been utilization of magnesium alloys, which can potentially reduce the total product weight. However, the problems of utilizing magnesium alloys are still mainly related to high manufacturing cost. One of the solutions to this problem is to develop magnesium casting-rolling technology in order to produce magnesium sheet products at competitive cost for commercial applications. In this experiment, magnesium alloy AZ31B was used to ascertain the effectiveness of semi-solid roll strip casting for producing magnesium alloy sheets. The temperature of the molten magnesium, and the roll speeds of the upper and lower rolls, (which could be changed independently), were varied to find an appropriate manufacturing condition. Rolling and heat treatment conditions were changed to examine which condition would be appropriate for producing wrought magnesium alloys with good formability. Microscopic observation of the crystals of the manufactured wrought magnesium alloys was performed. It has been found that a limiting drawing ratio of 2.7 was possible in a warm deep drawing test of the cast magnesium alloy sheets after being hot rolled.

  2. Fatigue Characteristics and Quality Index of A357 Type Semi-Solid Aluminum Castings Used for Automotive Application

    NASA Astrophysics Data System (ADS)

    Bouazara, M.; Bouaicha, A.; Ragab, Kh. A.

    2015-08-01

    The present work aims to investigate the fatigue characteristics of automotive lower suspension arm made of semi-solid A357 aluminum castings using metallurgical and analytical approaches. The fatigue life calculations of analytical model are used to identify and introduce the model parameters based on the suspension arm material followed by analyzing the load-number of cycles fatigue curve. The critical stress areas capable of initiating cracks during fatigue tests are detected using ABAQUS software followed by the installation of strain gages on the suspension arm to calculate maximum stress. The fatigue experiments are carried out to compare the results of the analytical method with the experimental endurance curves traced by lower suspension arm samples. Microstructure characteristics of the semi-solid A357 under T6 heat treatment conditions are examined using scanning electron microscope. The results show that the fatigue life and the quality index of alloys investigated are affected by casting technique, castings design, microstructural characterization, and heat treatment condition.

  3. Sputtered protective coatings for die casting dies

    NASA Technical Reports Server (NTRS)

    Mirtich, M. J.; Nieh, C. Y.; Wallace, J. F.

    1981-01-01

    This investigation determined whether selected ion beam sputtered coatings on H-13 die steel would have the potential of improving the thermal fatigue behavior of the steel used as a die in aluminum die casting. The coatings were selected to test candidate insulators and metals capable of providing protection of the die surface. The studies indicate that 1 micrometer thick W and Pt coatings reduced the thermal fatigue more than any other coating tested and are candidates to be used on a die surface to increase die life.

  4. Casting Characteristics of Aluminum Die Casting Alloys

    SciTech Connect

    Makhlouf M. Makhlouf; Diran Apelian

    2002-02-05

    The research program investigates the casting characteristics of selected aluminum die casting alloys. Specifically, the alloys' tendencies towards die soldering and sludge formation, and the alloys' fluidity and machinability are evaluated. It was found that: When the Fe and Mn contents of the alloy are low; caution has to be taken against possible die soldering. When the alloy has a high sludge factor, particularly a high level of Fe, measures must be taken to prevent the formation of large hardspots. For this kind of alloy, the Fe content should be kept at its lowest allowable level and the Mn content should be at its highest possible level. If there are problems in die filling, measures other than changing the alloy chemistry need to be considered first. In terms of alloy chemistry, the elements that form high temperature compounds must be kept at their lowest allowable levels. The alloys should not have machining problems when appropriate machining techniques and machining parameters are used.

  5. Die Soldering in Aluminium Die Casting

    SciTech Connect

    Han, Q.; Kenik, E.A.; Viswanathan, S.

    2000-03-15

    Two types of tests, dipping tests and dip-coating tests were carried out on small steel cylinders using pure aluminum and 380 alloy to investigate the mechanism of die soldering during aluminum die casting. Optical and scanning electron microscopy were used to study the morphology and composition of the phases formed during soldering. A soldering mechanism is postulated based on experimental observations. A soldering critical temperature is postulated at which iron begins to react with aluminum to form an aluminum-rich liquid phase and solid intermetallic compounds. When the temperature at the die surface is higher than this critical temperature, the aluminum-rich phase is liquid and joins the die with the casting during the subsequent solidification. The paper discusses the mechanism of soldering for the case of pure aluminum and 380 alloy casting in a steel mold, the factors that promote soldering, and the strength of the bond formed when soldering occurs. conditions, an aluminum-rich soldering layer may also form over the intermetallic layer. Although a significant amount of research has been conducted on the nature of these intermetallics, little is known about the conditions under which soldering occurs.

  6. Energy Consumption of Die Casting Operations

    SciTech Connect

    Jerald Brevick; clark Mount-Campbell; Carroll Mobley

    2004-03-15

    Molten metal processing is inherently energy intensive and roughly 25% of the cost of die-cast products can be traced to some form of energy consumption [1]. The obvious major energy requirements are for melting and holding molten alloy in preparation for casting. The proper selection and maintenance of melting and holding equipment are clearly important factors in minimizing energy consumption in die-casting operations [2]. In addition to energy consumption, furnace selection also influences metal loss due to oxidation, metal quality, and maintenance requirements. Other important factors influencing energy consumption in a die-casting facility include geographic location, alloy(s) cast, starting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting machine, related equipment (robots, trim presses), and downstream processing (machining, plating, assembly, etc.). Each of these factors also may influence the casting quality and productivity of a die-casting enterprise. In a die-casting enterprise, decisions regarding these issues are made frequently and are based on a large number of factors. Therefore, it is not surprising that energy consumption can vary significantly from one die-casting enterprise to the next, and within a single enterprise as function of time.

  7. Prediction of Part Distortion in Die Casting

    SciTech Connect

    R. Allen Miller

    2005-03-30

    The die casting process is one of the net shape manufacturing techniques and is widely used to produce high production castings with tight tolerances for many industries. An understanding of the stress distribution and the deformation pattern of parts produced by die casting will result in less deviation from the part design specification, a better die design and eventually more productivity and cost savings. This report presents methods that can be used to simulate the die casting process in order to predict the deformation and stresses in the produced part and assesses the degree to which distortion modeling is practical for die casting at the current time. A coupled thermal-mechanical finite elements model was used to simulate the die casting process. The simulation models the effect of thermal and mechanical interaction between the casting and the die. It also includes the temperature dependant material properties of the casting. Based on a designed experiment, a sensitivity analysis was conducted on the model to investigate the effect of key factors. These factors include the casting material model, material properties and thermal interaction between casting and dies. To verify the casting distortion predictions, it was compared against the measured dimensions of produced parts. The comparison included dimensions along and across the parting plane and the flatness of one surface.

  8. Modeling the Mechanical Performance of Die Casting Dies

    SciTech Connect

    R. Allen Miller

    2004-02-27

    The following report covers work performed at Ohio State on modeling the mechanical performance of dies. The focus of the project was development and particularly verification of finite element techniques used to model and predict displacements and stresses in die casting dies. The work entails a major case study performed with and industrial partner on a production die and laboratory experiments performed at Ohio State.

  9. Sputtered protective coatings for die casting dies

    NASA Technical Reports Server (NTRS)

    Mirtich, M. J.; Nieh, C.-Y.; Wallace, J. F.

    1981-01-01

    Three experimental research designs investigating candidate materials and processes involved in protective die surface coating procedures by sputter deposition, using ion beam technologies, are discussed. Various pre-test results show that none of the coatings remained completely intact for 15,000 test cycles. The longest lifetime was observed for coatings such as tungsten, platinum, and molybdenum which reduced thermal fatigue, but exhibited oxidation and suppressed crack initiation only as long as the coating did not fracture. Final test results confirmed earlier findings and coatings with Pt and W proved to be the candidate materials to be used on a die surface to increase die life. In the W-coated specimens, which remained intact on the surface after thermal fatigue testing, no oxidation was found under the coating, although a few cracks formed on the surface where the coating broke down. Further research is planned.

  10. Solvent casting flow from slot die

    NASA Astrophysics Data System (ADS)

    Lee, Semi; Nam, Jaewook

    2015-11-01

    A continuous solvent casting method using a slot die can precisely control the film thickness by adjusting the operating conditions, such as the belt speed and pumping rate, not the liquid property. Therefore, it is a suitable method for high precision continuous film production. In this particular method, the dope, or casting solution, is pumped through the feed slot to form a short curtain between the die and the moving belt. Although this method is widely used in producing films for various applications, it is difficult to find indepth analyses of such flow. In this study, we developed a finite element computational model for the steady-state two-dimensional sovent casting flow from the slot die. The effect of die configurations, rheological properties and operating conditions on the behavior and shape of the gas/liquid interfaces and the location of the dynamic contact line, which is the place where the dope meets the moving belt, were investigated.

  11. Compared production behavior of borax and unborax premixed SiC reinforcement Al7Si-Mg-TiB alloys composites with semi-solid stir casting method

    NASA Astrophysics Data System (ADS)

    Haryono, M. B.; Sulardjaka, Nugroho, Sri

    2016-04-01

    The present study was aimed to investigate the effect of borax additive on physical and mechanical properties of Al7Si-Mg-TiB with the reinforcement of silicon carbide. In this case, the different weight percentage from the reinforcement of SiC (10, 15, and 20% wt), and the borax additive (ratio 1:4) were homogenously added into the matrix by employing the semi-solid stir casting method at the temperature of 590°C. Al7Si-Mg-TiB melted in an electric resistance furnace at 800°C for 25 minutes and the holding time of 5 minutes; SiC was stirred with borax inside the chamber and heated at the temperature of 250°C for 25 minutes. Then, it melted by lowing the temperature into 590°C. The SiC-borax mixture was added into the electric resistance furnace, and automatically stirred by the stirrer at a constant speed (500 rpm for 3 minutes) in the composite A17Si-Mg-TiB. It melted when heated at 750°C for 17minutes,then, casting was performed on the prepared mould. The characterizations of Al7Si-Mg-TiB-SiC/borax were porosity, hardness, and microstructure on the Al7Si-Mg-TiB-SiC/ borax. The porosity of AMC tended to increase along with the increaseof the wt% SiC (1.4%-3.6%); however, borax additive underwent a decrease in porosity (0.14%-1.3%). Further, hardness tended to improve along with the increase of wt% SiC. The unboraxmixture had 79,6 HRB up to 94 HRB. Whereas, the borax additive mixture had 105,8 HRB up to 121 HRB.

  12. Fatigue of die cast zinc alloys

    SciTech Connect

    Schrems, K.K.; Dogan, O.N.; Goodwin, F.E.

    2006-04-01

    The rotating bending fatigue limit of die cast zinc alloy 2, alloy 3, alloy 5, AcuZinc 5, and ZA-8 were determined as a part of an on-going program by ILZRO into the mechanical properties of die cast zinc. The stress-life (S-N) curves of alloys 3, 5, AcuZinc 5, and ZA-8 were determined previously. This presentation reports the results of the S-N curve for Alloy 2 and the calculated fatigue limits for all five alloys. During the previous stress-life testing, the samples were stopped at 10 million cycles and the fatigue limit for alloy 3, alloy 5, and AcuZinc 5 appeared to be higher and the fatigue limit for ZA-8 appeared to be lower than the values reported in the literature. This was further investigated in alloy 5 and ZA-8 by testing continuous cast bulk alloy 5 and ZA-8.

  13. National Metal Casting Research Institute final report. Volume 2, Die casting research

    SciTech Connect

    Jensen, D.

    1994-06-01

    Four subprojects were completed: development and evaluation of die coatings, accelerated die life characterization of die materials, evaluation of fluid flow and solidification modeling programs, selection and characterization of Al-based die casting alloys, and influence of die materials and coatings on die casting quality.

  14. Use of RSP Tooling to Manufacture Die Casting Dies

    SciTech Connect

    Kevin McHugh

    2004-07-01

    The technology and art used to construct die casting dies has seen many improvements over the years. However, the time lag from when a design is finalized to the time a tool is in production has remained essentially the same. The two main causes for the bottleneck are the need to qualify a part design by making prototypes (usually from an alternative process), and the production tooling lead time after the prototypes are approved. Production tooling costs are high due to the labor and equipment costs associated with transforming a forged block of tool steel into a finished tool. CNC machining, sink EDM, benching, engraving and heat treatment unit operations are typically involved. As a result, there is increasing interest in rapid tooling (RT) technologies that shorten the design-to-part cycle and reduce the cost of dies. There are currently more than 20 RT methods being developed and refined around the world (1). The "rapid" in rapid tooling suggests time compression for tool delivery, but does not address robustness as nearly all RT approaches are intended for low-volume prototype work, primarily for molding plastics. Few options exist for die casting. An RT technology suitable for production-quality tooling in the time it normally takes for prototype tooling is highly desirable. In fact, there would be no need for a distinction between prototype and production tooling. True prototype parts could be made using the same processing conditions and materials intended for production. Qualification of the prototype part would allow the manufacturer to go directly into production with the same tool. A relatively new RT technology, Rapid Solidification Process (RSP) Tooling, is capable of making production-quality tooling in an RT timeframe for die casting applications. RSP Tooling, was developed at the Idaho National Engineering and Environmental Laboratory (INEEL), and commercialized with the formation of RSP Tooling, LLC (2). This paper describes the process, and

  15. Enhancements in Magnesium Die Casting Impact Properties

    SciTech Connect

    David Schwam; John F. Wallace; Yulong Zhu; Srinath Viswanathan; Shafik Iskander

    2000-06-30

    % in AM50 to over 9% in AZ91, more of the intermetallic Mg17Al12 is formed in the microstructure. For instance, for 15 increase in the aluminum content from AM50 to AM60, the volume fraction of eutectic present in the microstructure increases by 35%! Eventually, the brittle Mg17Al12 compound forms an interconnected network that reduces ductility and impact resistance. The lower aluminum in AM50 and AM60 are therefore a desirable feature in applications that call for higher impact resistance. Further improvement in impact resistance depends on the processing condition of the casting. Sound castings without porosity and impurities will have better mechanical properties. Since magnesium oxidizes readily, good melting and metal transfer practices are essential. The liquid metal has to be protected from oxidation at all times and entrainment of oxide films in the casting needs to be prevented. In this regard, there is evidence that us of vacuum to evacuate air from the die casting cavity can improve the quality of the castings. Fast cooling rates, leading to smaller grain size are beneficial and promote superior mechanical properties. Micro-segregation and banding are two additional defect types often encountered in magnesium alloys, in particular in AZ91D. While difficult to eliminate, segregation can be minimized by careful thermal management of the dies and the shot sleeve. A major source of segregation is the premature solidification in the shot sleeve. The primary solid dendrites are carried into the casting and form a heterogeneous structure. Furthermore, during the shot, segregation banding can occur. The remedies for this kind of defects include a hotter shot sleeve, use of insulating coatings on the shot sleeve and a short lag time between pouring into the shot sleeve and the shot.

  16. Die Casting Part Distortion: Prediction and Attenuation

    SciTech Connect

    Dr, R. Allen Miller

    2002-02-12

    The goal of this research was to predict the part deformation and residual stresses after ejection from the die and cooling to room temperature. A finite element model was built to achieve this goal and several modeling techniques were investigated throughout this research. Die-casting is a very complex process and the researchers are faced with a large number of hard to solve physical problems when modeling the process. Several assumptions are made in our simulation model. The first significant assumption is the instantaneous cavity filling. This means that the cavity filling stage is not considered in our model. Considering the cavity filling stage increases the modeling complexity as a result of different flow patterns. expected in the shot sleeve, gate, runner and different cavity features. The flow of gas from the cavity through the vents is another problem that is ignored in our model as a result of this assumption. Our second assumption is that the cast metal has uniform temperature distribution inside the cavity, at the starting point of simulation. This temperature is assumed to be over liquidus limit, i.e. the solid fraction is 0.0% of the cast metal. The third assumption is due to ABAQUS (commercial software used in this research) limitations. ABAQUS cannot deal with multi-phase models; therefore we use solid elements to define the casting instead of multi-phase (liquid/solid) elements. Liquid elements can carry the hydrostatic pressure from the shot sleeve and apply it on the cavity surfaces, while the solid elements do not have this capability. To compensate for this assumption we add the cavity pressure as a boundary condition and apply it on the cavity surface separately from the part. Another issue with this assumption is that, liquid casting can follow the cavity shape when it distorts. With the use of solid elements to represent the casting during its liquid state, it loses this capability to follow the cavity. Several techniques were tested to

  17. Effect composition of SiCp and TiB to the mechanical properties of composite Al7Si-Mg-SiCp by the method of semi solid stir casting

    NASA Astrophysics Data System (ADS)

    Bhiftime, E. I.; Sulardjaka, Nugroho, Sri

    2016-04-01

    Recently, studies on Aluminum Matrix Composite (AMC) were growing rapidly. AMC reinforced with SiCp particles in the semi solid stir casting method was the most simple way. In particular, the purpose of the present study was to investigate the effect composition of SiCp and TiB to the mechanical properties of the composites Al7Si-Mg-SiCp and Al7Si-Mg-TiB-SiCp. The composites used were Al7Si as the matrix and SiCp as the reinforcement (10, 15, 20 wt%). The casting method used on the study was the semi solid stir casting. The matrix was melted at the temperature of 800 °C. Then, the stirring process started at 590 °C with the speed of 500 rpm for 180 seconds. The composites was heated again until the pouring temperature was at 750 °C. The results of the present study indicated to be successful in which SiCp particles dispersed uniformly in the matrix composites. Further, the hardness value and porosity of the composites Al7Si-Mg-SiCp and Al7Si-Mg-TiB-SiCp increased along with the addition of TiB. Besides, the hardness value increased in the average of 10.5% at the variation of 20% SiCp. Whereas, the porosity value increased in the average of 54.3% at the variation of 20% SiCp.

  18. Effect of Some Parameters on the Cast Component Properties in Hot Chamber Die Casting

    NASA Astrophysics Data System (ADS)

    Singh, Rupinder; Singh, Harvir

    2016-04-01

    Hot chamber die casting process is designed to achieve high dimensional accuracy for small products by forcing molten metal under high pressure into reusable moulds, called dies. The present research work is aimed at study of some parameters (as a case study of spring adjuster) on cast component properties in hot chamber die casting process. Three controllable factors of the hot chamber die casting process (namely: pressure at second phase, metal pouring temperature and die opening time) were studied at three levels each by Taguchi's parametric approach and single-response optimization was conducted to identify the main factors controlling surface hardness, dimensional accuracy and weight of the casting. Castings were produced using aluminium alloy, at recommended parameters through hot chamber die casting process. Analysis shows that in hot chamber die casting process the percentage contribution of second phase pressure, die opening time, metal pouring temperature for surface hardness is 82.48, 9.24 and 6.78 % respectively. While in the case of weight of cast component the contribution of second phase pressure is 94.03 %, followed by metal pouring temperature and die opening time (4.58 and 0.35 % respectively). Further for dimensional accuracy contribution of die opening time is 76.97 %, metal pouring temperature is 20.05 % and second phase pressure is 1.56 %. Confirmation experiments were conducted at an optimal condition showed that the surface hardness, dimensional accuracy and weight of the castings were improved significantly.

  19. Method and apparatus for semi-solid material processing

    DOEpatents

    Han, Qingyou; Jian, Xiaogang; Xu, Hanbing; Meek, Thomas T.

    2007-05-15

    A method of forming a material includes the steps of: vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein; forming the semi-solid material into a desired shape; and cooling the material to a solid state. The method makes semi-solid castings directly from molten materials (usually a metal), produces grain size usually in the range of smaller than 50 .mu.m, and can be easily retrofitted into existing conventional forming machine.

  20. Method and apparatus for semi-solid material processing

    DOEpatents

    Han, Qingyou [Knoxville, TN; Jian, Xiaogang [Knoxville, TN; Xu, Hanbing [Knoxville, TN; Meek, Thomas T [Knoxville, TN

    2009-02-24

    A method of forming a material includes the steps of: vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein; forming the semi-solid material into a desired shape; and cooling the material to a solid state. The method makes semi-solid castings directly from molten materials (usually a metal), produces grain size usually in the range of smaller than 50 .mu.m, and can be easily retrofitted into existing conventional forming machine.

  1. Method and apparatus for semi-solid material processing

    DOEpatents

    Han, Qingyou [Knoxville, TN; Jian, Xiaogang [Knoxville, TN; Xu, Hanbing [Knoxville, TN; Meek, Thomas T [Knoxville, TN

    2009-11-24

    A method of forming a material includes the steps of: vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein; forming the semi-solid material into a desired shape; and cooling the material to a solid state. The method makes semi-solid castings directly from molten materials (usually a metal), produces grain size usually in the range of smaller than 50 .mu.m, and can be easily retrofitted into existing conventional forming maching.

  2. Microstructures and properties of aluminum die casting alloys

    SciTech Connect

    M. M. Makhlouf; D. Apelian; L. Wang

    1998-10-01

    This document provides descriptions of the microstructure of different aluminum die casting alloys and to relate the various microstructures to the alloy chemistry. It relates the microstructures of the alloys to their main engineering properties such as ultimate tensile strength, yield strength, elongation, fatigue life, impact resistance, wear resistance, hardness, thermal conductivity and electrical conductivity. Finally, it serves as a reference source for aluminum die casting alloys.

  3. Casting defects in low-pressure die-cast aluminum alloy wheels

    NASA Astrophysics Data System (ADS)

    Zhang, B.; Cockcroft, S. L.; Maijer, D. M.; Zhu, J. D.; Phillion, A. B.

    2005-11-01

    Defects in automotive aluminum alloy casting continue to challenge metallurgists and production engineers as greater emphasis is placed on product quality and production cost. A range of casting-related defects found in low-pressure die-cast aluminum wheels were examined metallographically in samples taken from several industrial wheel-casting facilities. The defects examined include macro- and micro- porosity, entrained oxide films, and exogenous oxide inclusions. Particular emphasis is placed on the impact of these defects with respect to the three main casting-related criteria by which automotive wheel quality are judged: wheel cosmetics, air-tightness, and wheel mechanical performance.

  4. The thermal fatigue resistance of H-13 Die Steel for aluminum die casting dies

    NASA Technical Reports Server (NTRS)

    1982-01-01

    The effects of welding, five selected surface coatings, and stress relieving on the thermal fatigue resistance of H-13 Die Steel for aluminum die casting dies were studied using eleven thermal fatigue specimens. Stress relieving was conducted after each 5,000 cycle interval at 1050 F for three hours. Four thermal fatigue specimens were welded with H-13 or maraging steel welding rods at ambient and elevated temperatures and subsequently, subjected to different post-weld heat treatments. Crack patterns were examined at 5,000, 10,000, and 15,000 cycles. The thermal fatigue resistance is expressed by two crack parameters which are the average maximum crack and the average cracked area. The results indicate that a significant improvement in thermal fatigue resistance over the control was obtained from the stress-relieving treatment. Small improvements were obtained from the H-13 welded specimens and from a salt bath nitrogen and carbon-surface treatment. The other surface treatments and welded specimens either did not affect or had a detrimental influence on the thermal fatigue properties of the H-13 die steel.

  5. Characterization of Spray Lubricants for the Die Casting Process

    SciTech Connect

    Sabau, Adrian S

    2008-01-01

    During the die casting process, lubricants are sprayed in order to cool the dies and facilitate the ejection of the casting. The cooling effects of the die lubricant were investigated using Thermogravimetric analysis (TGA), heat flux sensors (HFS), and infrared imaging. The evolution of the heat flux and pictures taken using a high speed infrared camera revealed that lubricant application was a transient process. The short time response of the HFS allows the monitoring and data acquisition of the surface temperature and heat flux without additional data processing. A similar set of experiments was performed with deionized water in order to assess the lubricant effect. The high heat flux obtained at 300 C was attributed to the wetting and absorbant properties of the lubricant. Pictures of the spray cone and lubricant flow on the die were also used to explain the heat flux evolution.

  6. An indicator for fitting castings to a die.

    PubMed

    Troendle, G R; Troendle, K B

    1992-10-01

    This article describes a procedure for making an indicator to be used in fitting a casting to a die. It also describes how to use the indicator in the laboratory. The materials for making the indicator are inexpensive, present no health hazard, and are readily available at any arts and crafts store. PMID:1403953

  7. Evaluation of permanent die coatings to improve the wear resistance of die casting dies. Final project report, January 1, 1995--April 30, 1997

    SciTech Connect

    Shivpuri, R.

    1997-09-18

    Die Casting dies are subject to severe service conditions during the die casting operation. While these severe conditions are necessary to achieve high production rates, they cause the dies which are commonly made of H13 die steel, to suffer frequent failures. The major die failure mechanisms are erosion or washout, Heat checking, soldering and corrosion. Due to their geometrical complexity, die casting dies are very expensive (some dies cost over a million dollars), and thus a large number of parts have to be produced by a die, to justify this cost and leverage the advantages of the die casting process (high production rates, low manpower costs). A potential increase in the die service life, thus has a significant impact on the economics of the die; casting operation. There are many ways to extend die life: developing new wear resistant die materials, developing new surface treatments including coatings, improving heat treatment of existing H13 dies, using better lubricants that can protect the die material, or modifying the die geometry and process parameters to reduce the intensity of wear. Of these the use of coatings to improve the wear resistance of the die surface has shown a lot of promise. Consequently, use of coatings in the die casting industry and their wide use to decrease die wear can improve significantly the productivity of shop operations resulting in large savings in material and energy usage.

  8. Die casting die deflections: Prediction and attenuation. Final report, July 1, 1995--September 30, 1997

    SciTech Connect

    Miller, R.A.; Ahuett-Garza, H.; Choudhury, A.K.; Dedhia, S.

    1998-05-01

    This report summarizes two years of research intended to develop methods to model and predict the deflection patterns in die casting dies. No comprehensive analysis of this type had previously been completed. The die casting process is complex and involves numerous mechanical and thermal phenomena that effect the mechanical behavior of the die. A critical activity in this work was sorting out and evaluating the relative contributions of the various mechanisms to die deflections. This evaluation was accomplished through a series of simple engineering analyses based primarily on the order of magnitude of the influence of each load considered on die deflections. A modeling approach incorporating commercially available finite element analysis software was developed and tested. The model evolved by testing simple models against more comprehensive models and against the limited experimental data that is available. The development of the modeling approach lead to consideration of the die casting machine in more detail than was originally anticipated. The machine is critical and cannot be ignored. A simplified model described as a spring/platen model was developed to account for the machine platens, tie bars, and toggles. The characteristics of this model are described and predictions based on this model are compared against full machine models and measured deflections of machine platens. Details of the modeling approach and the various case studies are provided in the report and in several publications that have resulted from the work.

  9. A study of erosion in die casting dies by a multiple pin accelerated erosion test

    NASA Astrophysics Data System (ADS)

    Shivpuri, R.; Yu, M.; Venkatesan, K.; Chu, Y.-L.

    1995-04-01

    An accelerated erosion test was developed to evaluate the erosion resistance of die materials and coatings for die casting application. An acceleration in wear was achieved by selecting pyramid-shaped core pins, hypereutectic aluminum silicon casting alloy, high melt temperatures and high gate velocities. Multiple pin design was selected to enable multiple test sites for comparative evaluation. Apilot run was conducted on a 300 ton commercial die casting machine at various sites (pins) to verify the thermal and flow similarities. Subsequently, campaigns were run on two different 300 ton commercial die casting machines to evaluate H13 die material and different coatings for erosive resistance. Coatings and surface treatments evaluated included surface micropeening, titanium nitride, boron carbide, vanadium carbide, and metallic coatings—tungsten, molybdenum, and platinum. Recent campaigns with different melt temperatures have indicated a possible link between soldering phenomena and erosive wear. This paper presents the details of the test set up and the results of the pilot and evaluation tests.

  10. Manufacture of die casting dies by hot isostatic pressing. CRADA final report

    SciTech Connect

    Viswanathan, S.; Ren, W.; Luk, K.; Brucher, H.G.

    1998-09-01

    The reason for this Cooperative Research and Development Agreement (CRADA) between the Oak Ridge National Laboratory (ORNL) and Doehler-Jarvis was to investigate the manufacture die-casting dies with internal water-cooling lines by hot-isostatic pressing (HIPing) of H13 tool steel powder. The use of HIPing will allow the near-net-shape manufacture of dies and the strategic placement of water-cooling lines during manufacture. The production of near-net-shape dies by HIPing involves the generation of HIPing diagrams, the design of the can that can be used for HIPing a die with complex details, strategic placement of water-cooling lines in the die, computer modeling to predict movement of the water lines during HIPing, and the development of strategies for placing water lines in the appropriate locations. The results presented include a literature review, particle analysis and characterization of H13 tool steel powder, and modeling of the HIPing process.

  11. Energy Saving Melting and Revert Reduction Technology: Innovative Semi-Solid Metal (SSM) Processing

    SciTech Connect

    Diran Apelian

    2012-08-15

    Semi-solid metal (SSM) processing has emerged as an attractive method for near-net-shape manufacturing due to the distinct advantages it holds over conventional near-net-shape forming technologies. These advantages include lower cycle time, increased die life, reduced porosity, reduced solidification shrinkage, improved mechanical properties, etc. SSM processing techniques can not only produce the complex dimensional details (e.g. thin-walled sections) associated with conventional high-pressure die castings, but also can produce high integrity castings currently attainable only with squeeze and low-pressure permanent mold casting processes. There are two primary semi-solid processing routes, (a) thixocasting and (b) rheocasting. In the thixocasting route, one starts from a non-dendritic solid precursor material that is specially prepared by a primary aluminum manufacturer, using continuous casting methods. Upon reheating this material into the mushy (a.k.a. "two-phase") zone, a thixotropic slurry is formed, which becomes the feed for the casting operation. In the rheocasting route (a.k.a. "slurry-on-demand" or "SoD"), one starts from the liquid state, and the thixotropic slurry is formed directly from the melt via careful thermal management of the system; the slurry is subsequently fed into the die cavity. Of these two routes, rheocasting is favored in that there is no premium added to the billet cost, and the scrap recycling issues are alleviated. The CRP (Trade Marked) is a process where the molten metal flows through a reactor prior to casting. The role of the reactor is to ensure that copious nucleation takes place and that the nuclei are well distributed throughout the system prior to entering the casting cavity. The CRP (Trade Marked) has been successfully applied in hyper-eutectic Al-Si alloys (i.e., 390 alloy) where two liquids of equal or different compositions and temperatures are mixed in the reactor and creating a SSM slurry. The process has been mostly

  12. Deburring die-castings by wet vibratory plant

    NASA Astrophysics Data System (ADS)

    Loeschbart, H. M.

    1980-02-01

    A wet vibratory procedure for the removal of burrs from die castings is described. In this process synthetic abrasive chips and detergent solutions are agitated with the work in such a way as to produce a spiral circulatory movement. Details of various forms of vibrator basin and shapes of abrasive are illustrated. The automation of deburring is illustrated through the application of vibrators of spiral design in combination with transport and drying devices.

  13. Deburring die-castings by wet vibratory plant

    NASA Technical Reports Server (NTRS)

    Loeschbart, H. M.

    1980-01-01

    A wet vibratory procedure for the removal of burrs from die castings is described. In this process synthetic abrasive chips and detergent solutions are agitated with the work in such a way as to produce a spiral circulatory movement. Details of various forms of vibrator basin and shapes of abrasive are illustrated. The automation of deburring is illustrated through the application of vibrators of spiral design in combination with transport and drying devices.

  14. Determination of the metal/die interfacial heat transfer coefficient of high pressure die cast B390 alloy

    NASA Astrophysics Data System (ADS)

    Cao, Yongyou; Guo, Zhipeng; Xiong, Shoumei

    2012-07-01

    High-pressure die cast B390 alloy was prepared on a 350 ton cold chamber die casting machine. The metal/die interfacial heat transfer coefficient of the alloy was investigated. Considering the filling process, a "finger"-shaped casting was designed for the experiments. This casting consisted of five plates with different thicknesses (0.05 inch or 1.27 mm to 0.25 inch or 6.35 mm) as well as individual ingates and overflows. Experiments under various operation conditions were conducted, and temperatures were measured at various specific locations inside the die. Based on the results, the interfacial heat transfer coefficient and heat flux were determined by solving the inverse heat transfer problem. The influence of the mold-filling sequence, sensor locations, as well as processing parameters including the casting pressure, die temperature, and fast/slow shot speeds on the heat transfer coefficient were discussed.

  15. Notched bar Izod impact properties of zinc die castings

    SciTech Connect

    Schrems, K.K.; Dogan, O.N.; Goodwin, F.E.

    2007-03-01

    Notched bar Izod impact testing of zinc die cast Alloy 3, Alloy 5, ZA-8, and AcuZinc 5 was performed at five temperatures between -40\\mDC and room temperature in accordance with ASTM E23 for impact testing of metallic materials. A direct comparison between ASTM D256 for impact testing of plastics and ASTM E23 was performed using continuously cast zinc specimens of Alloy 5 and ZA-8 at -40\\mDC and room temperature. There are differences in sample sizes, impact velocity, and striker geometry between the two tests. Bulk zinc tested according to ASTM E23 resulted in higher impact energies at -40\\mDC and lower impact energies at room temperature then did the same alloys when tested according to ASTM D256.

  16. High-Pressure Die-Casting: Contradictions and Challenges

    NASA Astrophysics Data System (ADS)

    Bonollo, Franco; Gramegna, Nicola; Timelli, Giulio

    2015-05-01

    High-pressure die casting (HPDC) is particularly suitable for high production rates and it is applied in several industrial fields; actually, approximately half of the world production of light metal castings is obtained by this technology. An overview of the actual status of HPDC technology is described in the current work, where both critical aspects and potential advantages are evidenced. Specific attention is paid to the quality requirements from the end users, as well as to the achievable production rate, the process monitoring and control, and the European and worldwide scenario. This overview leads to individuate the most relevant challenges for HPDC industry: "zero-defect" production, real-time process control, understanding the role of the process variables, process optimization, introduction of research and development activities, and disseminating the knowledge about HPDC technology. Performing these actions, HPDC foundries could achieve a more mature and efficient approach to large end users and exploit their really relevant potential.

  17. Development of Thin Section Zinc Die Casting Technology

    SciTech Connect

    Goodwin, Frank

    2013-10-31

    A new high fluidity zinc high pressure die casting alloy, termed the HF alloy, was developed during laboratory trials and proven in industrial production. The HF alloy permits castings to be achieved with section thicknesses of 0.3 mm or less. Technology transfer activities were conducted to develop usage of the HF high fluidity alloy. These included production of a brochure and a one-hour webinar on the HF alloy. The brochure was then sent to 1,184 product designers in the Interzinc database. There was excellent reception to this mailing, and from this initial contact 5 technology transfer seminars were conducted for 81 participants from 30 companies across a wide range of business sectors. Many of the successful applications to date involve high quality surface finishes. Design and manufacturing assistance was given for development of selected applications.

  18. Vacuum Die Casting of Silicon Sheet for Photovoltaic Applications

    NASA Technical Reports Server (NTRS)

    1979-01-01

    The development of a vacuum die-casting process for producing silicon sheet suitable for photovoltaic cells with a terrestrial efficiency greater than 12 percent and having the potential to be scaled for large quantity production is considered. The initial approach includes: (1) obtaining mechanical design parameters by using boron nitride, which has been shown to non-wetting to silicon; (2) optimizing silicon nitride material composition and coatings by sessile drop experiments; (3) testing effectiveness of fluoride salt interfacial media with a graphite mold; and (4) testing the effect of surface finish using both boron nitride and graphite. When the material and mechanical boundary conditions are established, a finalized version of the prototype assembly will be constructed and the casting variables determined.

  19. The Effects of Externally Solidified Product on Wave Celerity and Quality of Die Cast Products

    SciTech Connect

    Carroll Mobley; Yogeshwar Sahai; Jerry Brevick

    2003-10-10

    The cold chamber die casting process is used to produce essentially all the die cast aluminum products and about 50% of the die cast magnesium products made today. Modeling of the cold chamber die casting process and metallographic observations of cold chamber die cast products indicate that typically 5 to 20% of the shot weight is solidified in the shot sleeve before or during cavity filling. The protion of the resulting die casting which is solidified in the shot sleeve is referred to as externally solidified product, or, when identified as a casting defect, as cold flakes. This project was directed to extending the understanding of the effects of externally solidified product on the cold chamber die casting process and products to enable the production of defect-free die castings and reduce the energy associated with these products. The projected energy savings from controlling the fraction of externally solidified product in die cast components is 40 x 10 Btu through the year 2025.

  20. Microstructural analysis of aluminum high pressure die castings

    NASA Astrophysics Data System (ADS)

    David, Maria Diana

    Microstructural analysis of aluminum high pressure die castings (HPDC) is challenging and time consuming. Automating the stereology method is an efficient way in obtaining quantitative data; however, validating the accuracy of this technique can also pose some challenges. In this research, a semi-automated algorithm to quantify microstructural features in aluminum HPDC was developed. Analysis was done near the casting surface where it exhibited fine microstructure. Optical and Secondary electron (SE) and backscatter electron (BSE) SEM images were taken to characterize the features in the casting. Image processing steps applied on SEM and optical micrographs included median and range filters, dilation, erosion, and a hole-closing function. Measurements were done on different image pixel resolutions that ranged from 3 to 35 pixel/μm. Pixel resolutions below 6 px/μm were too low for the algorithm to distinguish the phases from each other. At resolutions higher than 6 px/μm, the volume fraction of primary α-Al and the line intercept count curves plateaued. Within this range, comparable results were obtained validating the assumption that there is a range of image pixel resolution relative to the size of the casting features at which stereology measurements become independent of the image resolution. Volume fraction within this curve plateau was consistent with the manual measurements while the line intercept count was significantly higher using the computerized technique for all resolutions. This was attributed to the ragged edges of some primary α-Al; hence, the algorithm still needs some improvements. Further validation of the code using other castings or alloys with known phase amount and size may also be beneficial.

  1. Interfacial Heat Transfer during Die Casting of an Al-Si-Cu Alloy

    NASA Astrophysics Data System (ADS)

    Hamasaiid, A.; Wang, G.; Davidson, C.; Dour, G.; Dargusch, M. S.

    2009-12-01

    The relationship between in-cavity pressure, heat flux, and heat-transfer coefficient during high-pressure die casting of an Al-9 pct Si-3 pct Cu alloy was investigated. Detailed measurements were performed using infrared probes and thermocouple arrays that accurately determine both casting and die surface temperatures during the pressure die casting of an aluminum A380 alloy. Concurrent in-cavity pressure measurements were also performed. These measurements enabled the correlation between in-cavity pressure and accurate heat-transfer coefficients in high-pressure die-casting operations.

  2. Die casting die deflections: Prediction and attenuation. Final report, July 1, 1995--September 30, 1997

    SciTech Connect

    Miller, R.Allen; Ahuett-Garza, Horacio; Choudhury, Aswin K.; Dedhia, Sanjay

    1998-05-01

    The objective of this work was to develop and test die casting design evaluation techniques based on the visualization of geometric data that is related to potential defects or problems. Specifically, thickness information is used to provide insight into potential thermal problems in the part and die. Distance from the gate and a special type of animation of the fill pattern is used to provide an assessment of gate, vent and overflow locations. Techniques have been developed to convert part design information in the form of STL files to a volume-based representation called a voxel model. The use of STL files makes the process CAD system independent. Once in voxel form, methods that were developed in this work are used to identify thick regions in the part, thin regions in the part and/or die, distance from user specified entry locations (gates), and the qualitative depiction of the fill pattern. The methods were tested with a prototype implementation on the UNIX platform. The results of comparisons with numerical simulation and field reported defects were surprisingly good. The fill-related methods were also compared against short-shots and a water analog study using high speed video. The report contains the results of the testing plus detailed background material on the construction of voxel models, the methods used for displaying results, and the computational geometric reasoning methods used to create die casting-related information from the voxel model for display to the user.

  3. WARM WATER SCALE MODEL EXPERIMENTS FOR MAGNESIUM DIE CASTING

    SciTech Connect

    Sabau, Adrian S

    2006-01-01

    High-pressure die casting (HPDC) involves the filling of a cavity with the molten metal through a thin gate. High gate velocities yield jet break-up and atomization phenomena. In order to improve the quality of magnesium parts, the mold filling pattern, including atomization phenomena, needs to be understood. The goal of this study was to obtain experimental data on jet break-up characteristics for conditions similar to that of magnesium HPDC, and measure the droplet velocity and size distribution. A scale analysis is first presented in order to identify appropriate analogue for liquid magnesium alloys. Based on the scale analysis warm water was chosen as a suitable analogue and different nozzles were manufactured. A 2-D component phase Doppler particle analyzer (PDPA) and 2-D component particle image velocimetry (PIV) were then used to obtain fine particle diameter and velocity distributions in 2-D plane.

  4. Modeling and Analysis of The Pressure Die Casting Using Response Surface Methodology

    SciTech Connect

    Kittur, Jayant K.; Herwadkar, T. V.; Parappagoudar, M. B.

    2010-10-26

    Pressure die casting is successfully used in the manufacture of Aluminum alloys components for automobile and many other industries. Die casting is a process involving many process parameters having complex relationship with the quality of the cast product. Though various process parameters have influence on the quality of die cast component, major influence is seen by the die casting machine parameters and their proper settings. In the present work, non-linear regression models have been developed for making predictions and analyzing the effect of die casting machine parameters on the performance characteristics of die casting process. Design of Experiments (DOE) with Response Surface Methodology (RSM) has been used to analyze the effect of effect of input parameters and their interaction on the response and further used to develop nonlinear input-output relationships. Die casting machine parameters, namely, fast shot velocity, slow shot to fast shot change over point, intensification pressure and holding time have been considered as the input variables. The quality characteristics of the cast product were determined by porosity, hardness and surface rough roughness (output/responses). Design of experiments has been used to plan the experiments and analyze the impact of variables on the quality of casting. On the other-hand Response Surface Methodology (Central Composite Design) is utilized to develop non-linear input-output relationships (regression models). The developed regression models have been tested for their statistical adequacy through ANOVA test. The practical usefulness of these models has been tested with some test cases. These models can be used to make the predictions about different quality characteristics, for the known set of die casting machine parameters, without conducting the experiments.

  5. Understanding the Relationship Between Filling Pattern and Part Quality in Die Casting

    SciTech Connect

    Jerald Brevick; R. Allen Miller

    2004-03-15

    The overall objective of this research project was to investigate phenomena involved in the filling of die cavities with molten alloy in the cold chamber die-casting process. It has long been recognized that the filling pattern of molten metal entering a die cavity influences the quality of die-cast parts. Filling pattern may be described as the progression of molten metal filling the die cavity geometry as a function of time. The location, size and geometric configuration of points of metal entry (gates), as well as the geometry of the casting cavity itself, have great influence on filling patterns. Knowledge of the anticipated filling patterns in die-castings is important for designers. Locating gates to avoid undesirable flow patterns that may entrap air in the casting is critical to casting quality - as locating vents to allow air to escape from the cavity (last places to fill). Casting quality attributes that are commonly flow related are non-fills, poor surface finish, internal porosity due to trapped air, cold shuts, cold laps, flow lines, casting skin delamination (flaking), and blistering during thermal treatment.

  6. Investigation of the interface phenomena and its effect on erosion and corrosion in aluminum die casting

    NASA Astrophysics Data System (ADS)

    Chu, Yeou-Li

    When performing an aluminum die casting operation, hot molten metal is injected into the die cavity. The die locks for part solidification. After the part solidifies, the casting will eject from the die. During this operation, the die surface experiences thermal cycling, high velocity impingement, chemical attack and interface friction. Thermal cycling leads to heat checking wear, high velocity impingement to erosive wear, chemical attack to soldering, and interface friction to the part bending and/or galling during ejection. The die casting process is a very capital intensive operation. All the above problems result in down time of the die casting shop. This down time results in loss of production and ultimately loss of capital. The purpose of this study is to (a) investigate the physical and chemical phenomena active at the die-cast aluminum metal interface, and (b) understand the performance of selected die surface treatments in protecting the interface from aluminum foundry alloy. Four laboratory tests were selected to study the aluminum die casting stages: (a) molten metal injection stage (erosive test), (b) filling and solidification (dissolution and wettability tests), and (c) parts ejection stage (friction test). Both qualitative and quantitative results were generated. This research produced many interesting discussions. In erosive testing, in addition to impingement velocity, the melt superheat and alloy types also found to play an important role in the erosion of the die steel. In the past, die casters believed that the higher molten aluminum temperature would cause higher erosive wear loss. However, this study found lower melt temperatures to result in greater erosive wear. In dissolution testing, the alloy elements were found to play an important role. In the past, die casters thought that Fe (Iron) was the main element which affects the dissolution of the die steel into the molten aluminum. This was found not to be necessary true. The Mn and Si

  7. Application of High-Temperature Mold Materials to Die Cast Copper Motor Rotor for Improved Efficiency

    SciTech Connect

    John G. Cowie; Edwin F. Brush, Jr.; Dale T. Peters; Stephen P. Midson; Darryl J. Van Son

    2003-05-01

    The objective of the study, Application of High-Temperature Mold Materials to Die Cast Copper Motor Rotor for Improved Efficiency, was to support the Copper Development Association (CDA) in its effort to design, fabricate and demonstrate mold technologies designed to withstand the copper motor rotor die casting environment for an economically acceptable life. The anticipated result from the compiled data and tests were to: (1) identify materials suitable for die casting copper, (2) fabricate motor rotor molds and (3) supply copper rotor motors for testing in actual compressor systems. Compressor manufacturers can apply the results to assess the technical and economical viability of copper rotor motors.

  8. Mechanical Properties of Die-Cast Magnesium Alloy MRI 230D

    NASA Astrophysics Data System (ADS)

    Aghion, Eli; Moscovitch, Nir; Arnon, Amir

    2009-10-01

    MRI 230D was specially developed to overcome the high-temperature limitations of conventionally die-cast magnesium alloys. This innovative alloy was primarily developed for the automotive industry, mainly for power-train applications operating under high-temperature conditions. The present article aims at evaluating the die-casting characteristics of MRI 230D in comparison with conventional AZ91D Mg alloy. These characteristics are used to evaluate the applicability of this alloy for die-casting operations which are essential for mass production.

  9. A method for surface quality assessment of die-castings based on laser triangulation

    NASA Astrophysics Data System (ADS)

    Bračun, Drago; Gruden, Valter; Možina, Janez

    2008-04-01

    This paper presents a new method for the surface quality assessment of safety-critical die-castings. We have developed a measurement system that measures the surface of a die-casting and provides quantitative surface quality assessment within a die-casting cycle of 70 s. The measurement system, based on the laser triangulation principle, has an asymmetrical measuring range and is capable of high-resolution measurements of the casting surface (0.02 mm). Geometry specific parameters (flatness of the particular surface region, average deviation of the measured points and height of the surface defects) are calculated from the acquired surface data and then checked whether/how they fit within the tolerances specified in a technical documentation. The method has been tested in the laboratory by examination of a sample of castings taken randomly from the production process. A comparison of the results obtained by this method and by a qualified operator has shown good agreement.

  10. Effect of Process Parameters, Casting Thickness, and Alloys on the Interfacial Heat-Transfer Coefficient in the High-Pressure Die-Casting Process

    NASA Astrophysics Data System (ADS)

    Guo, Zhi-Peng; Xiong, Shou-Mei; Liu, Bai-Cheng; Li, Mei; Allison, John

    2008-12-01

    The heat transfer at the metal-die interface is believed to have great influence on the solidification process and cast structure of the high-pressure die-casting (HPDC) process. The present article focused on the effects of process parameters, casting thickness, and alloys on the metal-die interfacial heat-transfer coefficient (IHTC) in the HPDC process. Experiment was carried out on a cold-chamber die-casting machine with two casting alloys AM50 and ADC12. A special casting, namely, “step-shape” casting, was used and cast against a H13 steel die. The IHTC was determined using an inverse approach based on the temperature measurements inside the die. Results show that the IHTC is different at different steps and changes as the solidification of the casting proceeds. Process parameters only influence the IHTC in its peak value, and for both AM50 and ADC12 alloys, a greater fast shot velocity leads to a greater IHTC peak value at steps 1 and 2. The initial die surface temperature has a more prominent influence on the IHTC peak values at the thicker steps, especially step 5. Results also show that a closer contact between the casting and die could be achieved when the casting alloy is ADC12 instead of AM50, which consequently leads to a higher IHTC.

  11. Evaluation of a Heat Flux Sensor for Spray Cooling for the Die Casting Processes

    SciTech Connect

    Sabau, Adrian S; Wu, Zhuoxi

    2007-02-01

    During the die casting process, lubricants are sprayed in order to cool the dies and facilitate the ejection of the casting. In this paper, a new technique for measuring the heat flux during lubricant application is evaluated. Data from experiments conducted using water spray are first presented. Water spray experiments were conducted for different initial plate temperatures. Measurements were conducted for the application of two different lubricants, of dilution ratios of 1/15 and 1/50 of lubricant in water. The measurement uncertainties were documented. The results show that the surface temperature decreases initially very fast. Numerical simulation results confirmed that the abrupt temperature drop is not an artifact but illustrates the thermal shock experienced by the dies during the initial stages of lubricant application. The lubricant experiments show that the sensor can be successfully used for testing die lubricants with typical dilution ratios encountered in the die casting process.

  12. Energy Saving Melting and Revert Reduction Technology (E-SMARRT): Development of Surface Engineered Coating Systems for Aluminum Pressure Die Casting Dies: Towards a 'Smart' Die Coating

    SciTech Connect

    Dr. John J. Moore; Dr. Jianliang Lin,

    2012-07-31

    The main objective of this research program was to design and develop an optimal coating system that extends die life by minimizing premature die failure. In high-pressure aluminum die-casting, the die, core pins and inserts must withstand severe processing conditions. Many of the dies and tools in the industry are being coated to improve wear-resistance and decrease down-time for maintenance. However, thermal fatigue in metal itself can still be a major problem, especially since it often leads to catastrophic failure (i.e. die breakage) as opposed to a wear-based failure (parts begin to go out of tolerance). Tooling costs remain the largest portion of production costs for many of these parts, so the ability prevent catastrophic failures would be transformative for the manufacturing industry.The technology offers energy savings through reduced energy use in the die casting process from several factors, including increased life of the tools and dies, reuse of the dies and die components, reduction/elimination of lubricants, and reduced machine down time, and reduction of Al solder sticking on the die. The use of the optimized die coating system will also reduce environmental wastes and scrap parts. Current (2012) annual energy saving estimates, based on initial dissemination to the casting industry in 2010 and market penetration of 80% by 2020, is 3.1 trillion BTU's/year. The average annual estimate of CO2 reduction per year through 2020 is 0.63 Million Metric Tons of Carbon Equivalent (MM TCE).

  13. High Density Die Casting (HDDC): new frontiers in the manufacturing of heat sinks

    NASA Astrophysics Data System (ADS)

    Sce, Andrea; Caporale, Lorenzo

    2014-07-01

    Finding a good solution for thermal management problems is every day more complex. due to the power density and the required performances. When a solution suitable for high volumes is needed. die-casting and extrusion are the most convenient technologies. However designers have to face the well-known limitations for those processes. High Density Die Casting (HDDC) is a process under advanced development. in order to overcome the extrusion and traditional die casting limits by working with alloys having much better thermal performances than the traditional die-casting process. while keeping the advantages of a flexible 3D design and a low cost for high volumes. HDDC offers the opportunity to design combining different materials (aluminium and copper. aluminium and stainless steel) obtaining a structure with zero porosity and overcoming some of die-casting limits. as shown in this paper. A dedicated process involving embedded heat pipes is currently under development in order to offer the possibility to dramatically improve the heat spreading.

  14. Development of an Innovative Laser-Assisted Coating Process for Extending Lifetime of Metal Casting Dies. Final Report

    SciTech Connect

    Madhav Rao Gonvindaraju

    1999-10-18

    Die casting dies used in the metal casting industry fail due to thermal fatigue cracking accompanied by the presence of residual tensile stresses, corrosion, erosion and wear of die surfaces. This phase 1 SBIR Final Report summarize Karta Technologies research involving the development of an innovative laser coating technology for metal casting dies. The process involves depositing complex protective coatings of nanocrystalline powders of TiC followed by a laser shot peening. The results indicate a significant improvement in corrosion and erosion resistance in molten aluminum for H13 die casting die steels. The laser-coated samples also showed improved surface finish, a homogeneous and uniform coating mircrostructure. The technology developed in this research can have a significant impact on the casting industry by saving the material costs involved in replacing dies, reducing downtime and improving the quality.

  15. Recycling of Al-Si die casting scraps for solar Si feedstock

    NASA Astrophysics Data System (ADS)

    Seo, Kum-Hee; Jeon, Je-Beom; Youn, Ji-Won; Kim, Suk Jun; Kim, Ki-Young

    2016-05-01

    Recycling of aluminum die-casting scraps for solar-grade silicon (SOG-Si) feedstock was performed successfully. 3 N purity Si was extracted from A383 die-casting scrap by using the combined process of solvent refining and an advanced centrifugal separation technique. The efficiency of separating Si from scrap alloys depended on both impurity level of scraps and the starting temperature of centrifugation. Impurities in melt and processing temperature governed the microstructure of the primary Si. The purity of Si extracted from the scrap melt was 99.963%, which was comparable to that of Si extracted from a commercial Al-30 wt% Si alloy, 99.980%. The initial purity of the scrap was 2.2% lower than that of the commercial alloy. This result confirmed that die-casting scrap is a potential source of high-purity Si for solar cells.

  16. Semi-solid Processing of Alloys

    NASA Astrophysics Data System (ADS)

    Kirkwood, David H.; Suéry, Michel; Kapranos, Plato; Atkinson, Helen V.; Young, Kenneth P.

    The original semisolid forming process, developed at MIT in 1972, involved stirring an alloy during solidification to produce a slurry of spheroidal primary particles in a liquid matrix, which was then injected directly into a die to produce a solid component. This was termed "rheocasting." Subsequently, it was found more convenient to solidify the slurry completely during the continuous casting of an electromag netically stirred strand, which was then cut into slugs for partial remelting back into semisolid billets on demand. These could be loaded into a diecasting machine in this state for injection into the die. This alternative process route is called "thixoforming," and until recently, it was the preferred industrial process. For this reason, the microstructure developed during the reheating and melting for thixo forming will be considered first. Experimentally, it has been found that the most effective fraction solid f s for thixoforming, lies between 0.5 and 0.6. Below this range, the semisolid slug becomes too soft to support its own weight and sags during remelting; above this range, it is too stiff to flow readily and fill the die. However, the slurry technologies used in rheocasting typically operate at lower fraction solids and rely on the ability to pour the semisolid alloy much like a liquid (see Chap. 4). It has been observed in practice that the fraction solid is in fact a critical factor for effective thixoforming, and therefore, both good temperature control and lack of sensitivity of f s to small temperature variations of the alloy are essential to efficient manufacturing.

  17. The effect of process parameters on the internal quality of an aluminum die casting

    NASA Astrophysics Data System (ADS)

    Dewit, M. C. A. J.

    1986-01-01

    The influence of process parameters on the porosity of an aluminum die casting was investigated. Two types of die one of which had an interchangeable gate and two alloys, AlSi8Cu3 and AlSi7, were used. During the solidification phase of a die casting, air entrapment can occur; the air remains in the die casting under high pressure after solidification. The Rayleigh number which contains the velocity in the gate, the gate diameter, and the liquid metal surface tension, determines the air entrapment. It appears that there are two types of filling: solid front filling at low velocities, and standard spray filling at high velocities. With the former type, the castings contain no air, but the shrinkage is concentrated in big holes; with the latter type the castings contain much air, and the shrinkage is distributed over fine holes. The first phase velocity has no significant influence on the porosity; a decrease of the third phase velocity increases the porosity. Variations of the changeover point between the first and second phase have little influence.

  18. Evolution of Intermetallic Phases in Soldering of the Die Casting of Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Song, Jie; Wang, Xiaoming; DenOuden, Tony; Han, Qingyou

    2016-06-01

    Most die failures are resulted from chemical reactions of dies and molten aluminum in the die casting of aluminum. The formation of intermetallic phases between a steel die and molten aluminum is investigated by stationary immersion tests and compared to a real die casting process. Three intermetallic phases are identified in the stationary immersion tests: a composite layer and two compact layers. The composite layer is a mixture of α bcc, Al, and Si phases. The α bcc phase changes in morphology from rod-like to spherical shape, while the growth rate of the layer changes from parabolic to linear pattern with immersion time. The first compact layer forms rapidly after immersion and maintains a relatively constant thickness. The second compact layer forms after 4 hours of immersion and exhibits parabolic growth with immersion time. In comparison, only a composite layer and the first compact layer are observed in a real die casting process. The fresh molten aluminum of high growth rate washes away the second intermetallic layer easily.

  19. Simple visualization techniques for die casting part and die design. Final report, July 1, 1995--September 30, 1997

    SciTech Connect

    Miller, R.A.; Lu, S.C.; Rebello, A.B.

    1998-05-01

    The objective of this work was to develop and test die casting design evaluation techniques based on the visualization of geometric data that is related to potential defects of problems. Specifically, thickness information is used to provide insight into potential thermal problems in the part and die. Distance from the gate and a special type of animation of the fill pattern is used to provide an assessment of gate, vent and overflow locations. Techniques have been developed to convert part design information in the form of STL files to a volume-based representation called a voxel model. The use of STL files makes the process CAD system independent. Once in voxel form, methods that were developed in this work are used to identify thick regions in the part, thin regions in the part and/or die, distance from user specified entry locations (gates), and the qualitative depiction of the fill pattern. The methods were tested with a prototype implementation on the UNIX platform. The results of comparisons with numerical simulation and field reported defects were surprisingly good. The fill-related methods were also compared against short-shots and a water analog study using high speed video. The report contains the results of the testing plus detailed background material on the construction of voxel models, the methods used for displaying results, and the computational geometric reasoning methods used to create die casting-related information from the voxel model for display to the user.

  20. Simple visualization techniques for die casting part and die design. Final report, July 1, 1995--September 30, 1997

    SciTech Connect

    Miller, R.A.; Lu, S.C.; Rebello, A.B.

    1998-05-01

    The objective of this work was to develop and test die casting design evaluation techniques based on the visualization of geometric data that is related to potential defects of problems. Specifically, thickness information is used to provide insight into potential thermal problems in the part and die. Distance from the gate and a special type of animation of the fill pattern is used to provide an assessment of gate, vent and overflow locations. Techniques have been developed to convert part design information in the form of STL files to a volume-based representation called a voxel model. The use of STL files makes the process CAD system independent. Once in voxel form, methods that were developed in this work are used to identify thick regions in the part, thin regions in the part and/or die, distance from user specified entry locations (gates), and the qualitative depiction of the fill pattern. The methods were tested with a prototype implementation on the UNIX platform. The results of comparisons with numerical simulation and field reported defects were surprisingly good. The fill-related methods were also compared against short-shots and a water analog study using high speed video. The report contains the results of the testing plus detailed background material on the construction of voxel models, the methods used for displaying results, and the computational geometric reasoning methods used to create die casting-related information form the voxel model for display to the user.

  1. Metallic Reinforcement of Direct Squeeze Die Casting Aluminum Alloys for Improved Strength and Fracture Resistance

    SciTech Connect

    D. Schwam: J.F. Wallace: Y. Zhu: J.W. Ki

    2004-10-01

    The utilization of aluminum die casting as enclosures where internal equipment is rotating inside of the casting and could fracture requires a strong housing to restrain the fractured parts. A typical example would be a supercharger. In case of a failure, unless adequately contained, fractured parts could injure people operating the equipment. A number of potential reinforcement materials were investigated. The initial work was conducted in sand molds to create experimental conditions that promote prolonged contact of the reinforcing material with molten aluminum. Bonding of Aluminum bronze, Cast iron, and Ni-resist inserts with various electroplated coatings and surface treatments were analyzed. Also toughening of A354 aluminum cast alloy by steel and stainless steel wire mesh with various conditions was analyzed. A practical approach to reinforcement of die cast aluminum components is to use a reinforcing steel preform. Such performs can be fabricated from steel wire mesh or perforated metal sheet by stamping or deep drawing. A hemispherical, dome shaped casting was selected in this investigation. A deep drawing die was used to fabricate the reinforcing performs. The tendency of aluminum cast enclosures to fracture could be significantly reduced by installing a wire mesh of austenitic stainless steel or a punched austenitic stainless steel sheet within the casting. The use of reinforcements made of austenitic stainless steel wire mesh or punched austenitic stainless steel sheet provided marked improvement in reducing the fragmentation of the casting. The best strengthening was obtained with austenitic stainless steel wire and with a punched stainless steel sheet without annealing this material. Somewhat lower results were obtained with the annealed punched stainless steel sheet. When the annealed 1020 steel wire mesh was used, the results were only slightly improved because of the lower mechanical properties of this unalloyed steel. The lowest results were

  2. Influence of Sludge Particles on the Tensile Properties of Die-Cast Secondary Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Ferraro, Stefano; Timelli, Giulio

    2015-04-01

    The effects of sludge intermetallic particles on the mechanical properties of a secondary AlSi9Cu3(Fe) die-casting alloy have been studied. Different alloys have been produced by systematically varying the Fe, Mn, and Cr contents within the composition tolerance limits of the standard EN AC-46000 alloy. The microstructure shows primary α-Al x (Fe,Mn,Cr) y Si z sludge particles, with polyhedral and star-like morphologies, although the presence of primary β-Al5FeSi phase is also observed at the highest Fe:Mn ratio. The volume fraction of primary compounds increases as the Fe, Mn, and Cr contents increase and this can be accurately predicts from the Sludge Factor by a linear relationship. The sludge amount seems to not influence the size and the content of porosity in the die-cast material. Furthermore, the sludge factor is not a reliable parameter to describe the mechanical properties of the die-cast AlSi9Cu3(Fe) alloy, because this value does not consider the mutual interaction between the elements. In the analyzed range of composition, the design of experiment methodology and the analysis of variance have been used in order to develop a semi-empirical model that accurately predicts the mechanical properties of the die-cast AlSi9Cu3(Fe) alloys as function of Fe, Mn, and Cr concentrations.

  3. Modeling of microstructure evolution of magnesium alloy during the high pressure die casting process

    NASA Astrophysics Data System (ADS)

    Wu, Mengwu; Xiong, Shoumei

    2012-07-01

    Two important microstructure characteristics of high pressure die cast magnesium alloy are the externally solidified crystals (ESCs) and the fully divorced eutectic which form at the filling stage of the shot sleeve and at the last stage of solidification in the die cavity, respectively. Both of them have a significant influence on the mechanical properties and performance of magnesium alloy die castings. In the present paper, a numerical model based on the cellular automaton (CA) method was developed to simulate the microstructure evolution of magnesium alloy during cold-chamber high pressure die casting (HPDC) process. Modeling of dendritic growth of magnesium alloy with six-fold symmetry was achieved by defining a special neighbourhood configuration and calculating of the growth kinetics from complete solution of the transport equations. Special attention was paid to establish a nucleation model considering both of the nucleation of externally solidified crystals in the shot sleeve and the massive nucleation in the die cavity. Meanwhile, simulation of the formation of fully divorced eutectic was also taken into account in the present CA model. Validation was performed and the capability of the present model was addressed by comparing the simulated results with those obtained by experiments.

  4. Energy Saving Melting and Revert Reduction Technology: Melting Efficiency in Die Casting Operations

    SciTech Connect

    David Schwam

    2012-12-15

    This project addressed multiple aspects of the aluminum melting and handling in die casting operations, with the objective of increasing the energy efficiency while improving the quality of the molten metal. The efficiency of melting has always played an important role in the profitability of aluminum die casting operations. Consequently, die casters need to make careful choices in selecting and operating melting equipment and procedures. The capital cost of new melting equipment with higher efficiency can sometimes be recovered relatively fast when it replaces old melting equipment with lower efficiency. Upgrades designed to improve energy efficiency of existing equipment may be well justified. Energy efficiency is however not the only factor in optimizing melting operations. Melt losses and metal quality are also very important. Selection of melting equipment has to take into consideration the specific conditions at the die casting shop such as availability of floor space, average quantity of metal used as well as the ability to supply more metal during peaks in demand. In all these cases, it is essential to make informed decisions based on the best available data.

  5. Assessment of Computer Simulation Software and Process Data for High Pressure Die Casting of Magnesium

    SciTech Connect

    Sabau, Adrian S; Hatfield, Edward C; Dinwiddie, Ralph Barton; Kuwana, Kazunori; Viti, Valerio; Hassan, Mohamed I; Saito, Kozo

    2007-09-01

    Computer software for the numerical simulation of solidification and mold filling is an effective design tool for cast structural automotive magnesium components. A review of commercial software capabilities and their validation procedures was conducted. Aside form the software assessment, the program addressed five main areas: lubricant degradation, lubricant application, gate atomization, and heat transfer at metal mold interfaces. A test stand for lubricant application was designed. A sensor was used for the direct measurement of heat fluxes during lubricant application and casting solidification in graphite molds. Spray experiments were conducted using pure deionized water and commercial die lubricants. The results show that the sensor can be used with confidence for measuring heat fluxes under conditions specific to the die lube application. The data on heat flux was presented in forms suitable for use in HPDC simulation software. Severe jet breakup and atomization phenomena are likely to occur due to high gate velocities in HPDC. As a result of gate atomization, droplet flow affects the mold filling pattern, air entrapment, skin formation, and ensuing defects. Warm water analogue dies were designed for obtaining experimental data on mold filling phenomena. Data on break-up jet length, break-up pattern, velocities, and droplet size distribution were obtained experimentally and was used to develop correlations for jet break-up phenomena specific to die casting gate configurations.

  6. Low Cost and Energy Efficient Methods for the Manufacture of Semi-Solid (SSM) Feedstock

    SciTech Connect

    Diran Apelian; Qingyue Pan; Makhlouf Makhlouf

    2005-11-07

    The SSM Consortium (now ACRC) at WPI has been carrying out fundamental, pre-competitive research in SSM for several years. Current and past research (at WPI) has generated many results of fundamental and applied nature, which are available to the SSM community. These include materials characterization, yield stress effects, alloy development, rheological properties, process modeling/simulation, semi-solid slurry formation, etc. Alternative method to produce SSM slurries at lower processing costs and with reduced energy consumption is a critical need. The production of low cost SSM feedstock will certainly lead to a dramatic increase in the tonnage of castings produced by SSM, and will provide end users such as the transportation industry, with lighter, cheaper and high performance materials. In this program, the research team has addressed three critical issues in semi-solid processing. They are: (1) Development of low cost, reliable slurry-on-demand approaches for semi-solid processing; (2) Application of the novel permanent grain refining technology-SiBloy for the manufacture of high-quality SSM feedstock, and (3) Development of computational and modeling tools for semi-solid processing to enhance SSM process control. Salient results from these studies are summarized and detailed in our final technical report.

  7. Characterization of pores in high pressure die cast aluminum using active thermography and computed tomography

    NASA Astrophysics Data System (ADS)

    Maierhofer, Christiane; Myrach, Philipp; Röllig, Mathias; Jonietz, Florian; Illerhaus, Bernhard; Meinel, Dietmar; Richter, Uwe; Miksche, Ronald

    2016-02-01

    Larger high pressure die castings (HPDC) and decreasing wall thicknesses are raising the issue of casting defects like pores in aluminum structures. Properties of components are often strongly influenced by inner porosity. As these products are being established more and more in lightweight construction (e.g. automotive and other transport areas), non-destructive testing methods, which can be applied fast and on-site, are required for quality assurance. In this contribution, the application of active thermography for the direct detection of larger pores is demonstrated. The analysis of limits and accuracy of the method are completed by numerical simulation and the method is validated using computed tomography.

  8. Fatigue Crack Growth Mechanisms in High-Pressure Die-Cast Magnesium Alloys

    NASA Astrophysics Data System (ADS)

    El Kadiri, Haitham; Horstemeyer, M. F.; Jordon, J. B.; Xue, Yibin

    2008-01-01

    Microstructure-affected micromechanisms of fatigue crack growth operating near the limit plasticity regime were experimentally identified for the four main commercial high-pressure die-cast (HPDC) magnesium alloys: AM50, AM60, AZ91, and AE44. These fatigue micromechanisms manifested by the concomitant effects of casting pores, interdendritic Al-rich solid solution layer, β-phase particles, Mn-rich inclusions, rare earth-rich intermetallics, dendrite cell size, and surface segregation phenomena. These concomitant mechanisms clearly delineated the fatigue durability observed for the AM50, AM60, AZ91, and AE44 Mg alloys in both the low- and high-cycle fatigue regimes.

  9. Development of materials for the rapid manufacture of die cast tooling

    NASA Astrophysics Data System (ADS)

    Hardro, Peter Jason

    The focus of this research is to develop a material composition that can be processed by rapid prototyping (RP) in order to produce tooling for the die casting process. Where these rapidly produced tools will be superior to traditional tooling production methods by offering one or more of the following advantages: reduced tooling cost, shortened tooling creation time, reduced man-hours for tool creation, increased tool life, and shortened die casting cycle time. By utilizing RP's additive build process and vast material selection, there was a prospect that die cast tooling may be produced quicker and with superior material properties. To this end, the material properties that influence die life and cycle time were determined, and a list of materials that fulfill these "optimal" properties were highlighted. Physical testing was conducted in order to grade the processability of each of the material systems and to optimize the manufacturing process for the downselected material system. Sample specimens were produced and microscopy techniques were utilized to determine a number of physical properties of the material system. Additionally, a benchmark geometry was selected and die casting dies were produced from traditional tool materials (H13 steel) and techniques (machining) and from the newly developed materials and RP techniques (selective laser sintering (SLS) and laser engineered net shaping (LENS)). Once the tools were created, a die cast alloy was selected and a preset number of parts were shot into each tool. During tool creation, the manufacturing time and cost was closely monitored and an economic model was developed to compare traditional tooling to RP tooling. This model allows one to determine, in the early design stages, when it is advantageous to implement RP tooling and when traditional tooling would be best. The results of the physical testing and economic analysis has shown that RP tooling is able to achieve a number of the research objectives, namely

  10. Casting Technology.

    ERIC Educational Resources Information Center

    Wright, Michael D.; And Others

    1992-01-01

    Three articles discuss (1) casting technology as it relates to industry, with comparisons of shell casting, shell molding, and die casting; (2) evaporative pattern casting for metals; and (3) high technological casting with silicone rubber. (JOW)

  11. Prediction of Thermal Fatigue in Tooling for Die-casting Copper via Finite Element Analysis

    NASA Astrophysics Data System (ADS)

    Sakhuja, Amit; Brevick, Jerald R.

    2004-06-01

    Recent research by the Copper Development Association (CDA) has demonstrated the feasibility of die-casting electric motor rotors using copper. Electric motors using copper rotors are significantly more energy efficient relative to motors using aluminum rotors. However, one of the challenges in copper rotor die-casting is low tool life. Experiments have shown that the higher molten metal temperature of copper (1085 °C), as compared to aluminum (660 °C) accelerates the onset of thermal fatigue or heat checking in traditional H-13 tool steel. This happens primarily because the mechanical properties of H-13 tool steel decrease significantly above 650 °C. Potential approaches to mitigate the heat checking problem include: 1) identification of potential tool materials having better high temperature mechanical properties than H-13, and 2) reduction of the magnitude of cyclic thermal excursions experienced by the tooling by increasing the bulk die temperature. A preliminary assessment of alternative tool materials has led to the selection of nickel-based alloys Haynes 230 and Inconel 617 as potential candidates. These alloys were selected based on their elevated temperature physical and mechanical properties. Therefore, the overall objective of this research work was to predict the number of copper rotor die-casting cycles to the onset of heat checking (tool life) as a function of bulk die temperature (up to 650 °C) for Haynes 230 and Inconel 617 alloys. To achieve these goals, a 2D thermo-mechanical FEA was performed to evaluate strain ranges on selected die surfaces. The method of Universal Slopes (Strain Life Method) was then employed for thermal fatigue life predictions.

  12. Characterization of Flow Behavior of Semi-Solid Slurries with Low Solid Fractions

    NASA Astrophysics Data System (ADS)

    Chucheep, Thiensak; Wannasin, Jessada; Canyook, Rungsinee; Rattanochaikul, Tanate; Janudom, Somjai; Wisutmethangoon, Sirikul; Flemings, Merton C.

    2013-10-01

    Semi-solid slurry casting is a metal-forming process that involves transforming liquid metal into slurry having a low solid fraction and then forming the slurry into solid parts. To successfully apply this slurry-forming process, it is necessary to fully understand the flow behavior of semi-solid slurries. This present work applied the rapid quenching method and the modified gravity fluidity casting to investigate the flow behavior, which involves characterizations of the initial solid fraction, fluidity, and microstructure of semi-solid slurries. Three commercial aluminum alloys were used in this study: 383 (Al-Si11Cu), 356 (Al-Si7MgFe), and 7075 (Al-Zn6MgCu) alloys. The results show that the initial solid fractions can be controlled by varying the rheocasting time. The rapid quenching mold can be used to determine the initial solid fractions. In this method, it is important to apply the correcting procedure to account for growth during quenching and to include all the solid phases. Results from the fluidity study of semi-solid slurries show that the fluidity decreases as the initial solid fraction increases. The decrease is relatively rapid near the low end of the initial solid fraction curves, but is quite slow near the high end of the curves. All the three alloys follow this trend. The results also demonstrate that the slurries that contain high solid fractions of up to 30 pct can still flow well. The microstructure characterization results show that the solid particles in the slurries flow uniformly in the channel. A uniform and fine microstructure with limited phase segregation is observed in the slurry cast samples.

  13. Microstructural stability and creep properties of die casting Mg-4Al-4RE magnesium alloy

    SciTech Connect

    Rzychon, Tomasz; Kielbus, Andrzej; Cwajna, Jan; Mizera, Jaroslaw

    2009-10-15

    The AE44 (Mg-4Al-4RE) alloy was prepared by a hot-chamber die casting method. The microstructure, microstructural stability and creep properties at 175 deg. C were investigated. The microstructure was analyzed by scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD) and the Rietveld method. The results show that die cast AE44 magnesium alloy consists of {alpha}-Mg, Al{sub 11}RE{sub 3}, Al{sub 2}RE and Al{sub 2.12}RE{sub 0.88} phases. The Al{sub 11}RE{sub 3} phase is thermally stable at 175 deg. C whereas the metastable Al{sub 2.12}RE{sub 0.88} phase undergoes a transition into the equilibrium Al{sub 2}RE phase. The alloy investigated is characterized by good creep properties at temperatures of 175 deg. C and 200 {sup o}C.

  14. Fabrication of glass photonic crystal fibers with a die-cast process

    NASA Astrophysics Data System (ADS)

    Guiyao, Zhou; Zhiyun, Hou; Shuguang, Li; Lantian, Hou

    2006-06-01

    We demonstrate a novel method for the fabrication of glass photonic crystal fibers (PCFs) with a die-cast process. SF6 glass is used as the material for PCFs, and the die is made of heat-resisting alloy steel, whose inner structure matches the PCF's structure. The die is put vertically in the vessel with SF6 glass, and the vacuum hose is attached to the top of the die. The die and glass are put in the furnace to heat at 870 K. The die is slowly filled with the softening glass under vacuum conduction until it is full. It is kept in the furnace to anneal at a rate of 20 K/h to remove the thermal stress that could lead to cracks. The outer tube of the die is taken apart when its temperature is close to room temperature, and the fused glass bundle is etched in an acidic solution to remove the heat-resisting alloy steel rods. Thus, the etched bundle is ready to use as a PCF preform. The PCF is observed in the generation of a supercontinuum, with the flat plateau in the spectrum of the output emission stretching from 400 to 1400 nm by experimental measurement. The transmission loss is 0.2-0.3 dB/m at wavelengths of 420-900 nm.

  15. Microstructure and Elevated Temperature Properties of Die-cast AZ91- xNd Magnesium Alloys

    NASA Astrophysics Data System (ADS)

    Wang, Jun; Wang, Limin; An, Jian; Liu, Yongbing

    2008-10-01

    The effect of Nd addition on the microstructure and mechanical properties of a die-cast AZ91 alloy was investigated in the present work. The results show that the die-cast AZ91 alloy is composed of α-Mg matrix and γ-Mg17Al12 phase. Nd addition into the AZ91 alloy leads to the formation of rare earth containing intermetallic phase. Al4Nd phase forms when Nd content is less than or equal to 1.0 wt.%. Al2Nd phase appears simultaneously when Nd content reaches to 3.0 wt.%. The size and volume fraction of γ-Mg17Al12 phase decrease, because of the newly formed Al-Nd phase. And the γ-Mg17Al12 phase distributes from reticular to dispersive. Nd addition has a little effect on the room temperature properties of the die-cast AZ91 alloy, but greatly improves the elevated temperature properties. The tensile strength of AZ91-0.5Nd and AZ91-1.0Nd alloy tested at 150 °C is even close to the room temperature strength. The AZ91-1.0Nd alloy has the optimal properties.

  16. Energy Saving Melting and Revert Reduction Technology: Improved Die Casting Process to Preserve the Life of the Inserts

    SciTech Connect

    David Schwam, PI; Xuejun Zhu, Sr. Research Associate

    2012-09-30

    The goal of this project was to study the combined effects of die design, proper internal cooling and efficient die lubricants on die life. The project targeted improvements in die casting insert life by: Optomized Die Design for Reduced Surface Temperature: The life of die casting dies is significantly shorter when the die is exposed to elevated temperature for significant periods of time. Any die operated under conditions leading to surface temperature in excess of 1050oF undergoes structural changes that reduce its strength. Optimized die design can improve die life significantly. This improvement can be accomplished by means of cooling lines, baffles and bubblers in the die. A key objective of the project was to establish criteria for the minimal distance of the cooling lines from the surface. This effort was supported with alloys and machining by BohlerUddeholm, Dunn Steel, HH Stark and Rex Buckeye. In plant testing and evaluation was conducted as in-kind cost share at St. Clair Die Casting. The Uddeholm Dievar steel evaluated in this program showed superior resistance to thermal fatigue resistance. Based on the experimental evidence, cooling lines could be placed as close as 0.5" from the surface. Die Life Extension by Optimized Die Lubrication: The life of die casting dies is affected by additions made to its surface with the proper lubricants. These lubricants will protect the surface from the considerable temperature peaks that occur when the molten melt enters the die. Dies will reach a significantly higher temperature without this lubricant being applied. The amount and type of the lubricant are critical variables in the die casting process. However, these lubricants must not corrode the die surface. This effort was supported with alloys and machining by BohlerUddeholm, Dunn Steel, HH Stark and Rex Buckeye. In plant testing and evaluation was conducted as in-kind cost share at St. Clair Die Casting. Chem- Trend participated in the program with die

  17. Fatigue behaviour of friction stir processed AZ91 magnesium alloy produced by high pressure die casting

    SciTech Connect

    Cavaliere, P. . E-mail: pasquale.cavaliere@unile.it; De Marco, P.P.

    2007-03-15

    The room temperature fatigue properties of AZ91 magnesium alloy produced by high pressure die casting (HPDC) as cast, heat treated, friction stir processed (FSP) and FSP and heat treated were studied. The fatigue properties of the material were evaluated for the HPDC magnesium alloy in the as-received state and after a solution treatment at 415 deg. C for 2 h and an ageing treatment at 220 deg. C for 4 h. The heat treatment resulted in a significant increase in the fatigue properties of the HPDC material, while no significance influence of heat treatment was recorded in the FSP condition. The morphology of fracture surfaces was examined by employing a field emission gun scanning electron microscope (FEGSEM)

  18. The Effects of Microstructure Heterogeneities and Casting Defects on the Mechanical Properties of High-Pressure Die-Cast AlSi9Cu3(Fe) Alloys

    NASA Astrophysics Data System (ADS)

    Timelli, Giulio; Fabrizi, Alberto

    2014-11-01

    Detailed investigations of the salient microstructural features and casting defects of the high-pressure die-cast (HPDC) AlSi9Cu3(Fe) alloy are reported. These characteristics are addressed to the mechanical properties and reliability of separate HPDC tensile bars. Metallographic and image analysis techniques have been used to quantitatively examine the microstructural changes throughout the tensile specimen. The results indicate that the die-cast microstructure consists of several microstructural heterogeneities such as positive eutectic segregation bands, externally solidified crystals (ESCs), cold flakes, primary Fe-rich intermetallics (sludge), and porosities. In addition, it results that sludge particles, gas porosity, as well as ESCs, and cold flakes are concentrated toward the casting center while low porosity and fine-grained structure is observed on the surface layer of the castings bars. The local variation of the hardness along the cross section as well as the change of tensile test results as a function of gage diameter of the tensile bars seem to be ascribed to the change of porosity content, eutectic fraction, and amount of sludge. Further, this behavior reflects upon the reliability of the die-cast alloy, as evidenced by the Weibull statistics.

  19. Secondary Al-Si-Mg High-pressure Die Casting Alloys with Enhanced Ductility

    NASA Astrophysics Data System (ADS)

    Bösch, Dominik; Pogatscher, Stefan; Hummel, Marc; Fragner, Werner; Uggowitzer, Peter J.; Göken, Mathias; Höppel, Heinz Werner

    2015-03-01

    Al-Si-Mg-based secondary cast alloys are attractive candidates for thin-walled high-pressure die castings for applications in the transport industry. The present study investigates the effect of manganese additions at high cooling rates on microstructure, mechanical properties, and on the dominating fracture mechanisms of alloy AlSi10Mg with an elevated iron concentration. Systematic variations of the Mn content from 0.20 to 0.85 wt pct at a constant Fe content of 0.55 wt pct illustrate the key changes in type, phase fraction, and shape of the Fe-containing intermetallic phases, and the corresponding influence on the alloy's ductility. For high-pressure die casting (HPDC), an optimal range of the Mn content between 0.40 and 0.60 wt pct, equivalent to a Mn/Fe ratio of approximately 1, has been identified. At these Mn and Fe contents, the high cooling rates obtained in HPDC result in the formation of fine and homogeneously distributed α-Al15(Fe,Mn)3Si2 phase, and crack initiation is transferred from AlFeSi intermetallics to eutectic silicon. The study interprets the microstructure-property relationship in the light of thermodynamic calculations which reveal a significant increase in undercooling of the α-Al15(Fe,Mn)3Si2 phase with increased Mn content. It concludes that the interdependence of the well-defined Mn/Fe ratio and the high cooling rate in HPDC can generate superior ductility in secondary AlSi10Mg cast alloys.

  20. Stationary semi-solid battery module and method of manufacture

    SciTech Connect

    Slocum, Alexander; Doherty, Tristan; Bazzarella, Ricardo; Cross, III, James C.; Limthongkul, Pimpa; Duduta, Mihai; Disko, Jeffry; Yang, Allen; Wilder, Throop; Carter, William Craig; Chiang, Yet-Ming

    2015-12-01

    A method of manufacturing an electrochemical cell includes transferring an anode semi-solid suspension to an anode compartment defined at least in part by an anode current collector and an separator spaced apart from the anode collector. The method also includes transferring a cathode semi-solid suspension to a cathode compartment defined at least in part by a cathode current collector and the separator spaced apart from the cathode collector. The transferring of the anode semi-solid suspension to the anode compartment and the cathode semi-solid to the cathode compartment is such that a difference between a minimum distance and a maximum distance between the anode current collector and the separator is maintained within a predetermined tolerance. The method includes sealing the anode compartment and the cathode compartment.

  1. Transgranular liquation cracking of grains in the semi-solid state

    PubMed Central

    Karagadde, S.; Lee, P. D.; Cai, B.; Fife, J. L.; Azeem, M. A.; Kareh, K. M.; Puncreobutr, C.; Tsivoulas, D.; Connolley, T.; Atwood, R. C.

    2015-01-01

    Grain refinement via semi-solid deformation is desired to obtain superior mechanical properties of cast components. Using quantitative in situ synchrotron X-ray tomographic microscopy, we show an additional mechanism for the reduction of grain size, via liquation assisted transgranular cracking of semi-solid globular microstructures. Here we perform localized indentation of Al-15wt.%Cu globular microstructures, with an average grain size of ∼480 μm, at 555 °C (74% solid fraction). Although transgranular fracture has been observed in brittle materials, our results show transgranular fracture can also occur in metallic alloys in semi-solid state. This transgranular liquation cracking (TLC) occurs at very low contact stresses (between 1.1 and 38 MPa). With increasing strain, TLC continues to refine the size of the microstructure until the grain distribution reaches log-normal packing. The results demonstrate that this refinement, previously attributed to fragmentation of secondary arms by melt-shearing, is also controlled by an additional TLC mechanism. PMID:26353994

  2. Transgranular liquation cracking of grains in the semi-solid state

    NASA Astrophysics Data System (ADS)

    Karagadde, S.; Lee, P. D.; Cai, B.; Fife, J. L.; Azeem, M. A.; Kareh, K. M.; Puncreobutr, C.; Tsivoulas, D.; Connolley, T.; Atwood, R. C.

    2015-09-01

    Grain refinement via semi-solid deformation is desired to obtain superior mechanical properties of cast components. Using quantitative in situ synchrotron X-ray tomographic microscopy, we show an additional mechanism for the reduction of grain size, via liquation assisted transgranular cracking of semi-solid globular microstructures. Here we perform localized indentation of Al-15wt.%Cu globular microstructures, with an average grain size of ~480 μm, at 555 °C (74% solid fraction). Although transgranular fracture has been observed in brittle materials, our results show transgranular fracture can also occur in metallic alloys in semi-solid state. This transgranular liquation cracking (TLC) occurs at very low contact stresses (between 1.1 and 38 MPa). With increasing strain, TLC continues to refine the size of the microstructure until the grain distribution reaches log-normal packing. The results demonstrate that this refinement, previously attributed to fragmentation of secondary arms by melt-shearing, is also controlled by an additional TLC mechanism.

  3. Transgranular liquation cracking of grains in the semi-solid state.

    PubMed

    Karagadde, S; Lee, P D; Cai, B; Fife, J L; Azeem, M A; Kareh, K M; Puncreobutr, C; Tsivoulas, D; Connolley, T; Atwood, R C

    2015-01-01

    Grain refinement via semi-solid deformation is desired to obtain superior mechanical properties of cast components. Using quantitative in situ synchrotron X-ray tomographic microscopy, we show an additional mechanism for the reduction of grain size, via liquation assisted transgranular cracking of semi-solid globular microstructures. Here we perform localized indentation of Al-15wt.%Cu globular microstructures, with an average grain size of ∼480 μm, at 555 °C (74% solid fraction). Although transgranular fracture has been observed in brittle materials, our results show transgranular fracture can also occur in metallic alloys in semi-solid state. This transgranular liquation cracking (TLC) occurs at very low contact stresses (between 1.1 and 38 MPa). With increasing strain, TLC continues to refine the size of the microstructure until the grain distribution reaches log-normal packing. The results demonstrate that this refinement, previously attributed to fragmentation of secondary arms by melt-shearing, is also controlled by an additional TLC mechanism. PMID:26353994

  4. Flow analysis and validation of numerical modelling for a thin walled high pressure die casting using SPH

    NASA Astrophysics Data System (ADS)

    Cleary, Paul W.; Savage, Gary; Ha, Joseph; Prakash, Mahesh

    2014-09-01

    High pressure die casting (HPDC) is an important process for high throughput manufacturing of complex shaped metallic components. The flow involves significant fragmentation and spray formation as the high pressure liquid jets into the die from the gate system. An important class of die cast components is one with large areas of thin walls. An example of this is the chassis of the laptop computer. Computational modelling provides an opportunity to both better understand the filling process and to optimize the runner, gates, flash overs and venting systems for the die. SPH has previously been found to be very suitable for predicting HPDC for bulkier automotive components. The modelling challenges arising from the very thin sections and the many flow paths in a laptop chassis require careful validation. A water analogue experiment is used to validate the predictions of the SPH model for this representative thin walled casting. SPH predictions are used to understand and characterise the filling process. Finally, comparison of flow lines visible in an etched finished casting with the high speed flow paths in the final filled SPH model show very strong agreement. Together these demonstrate that such an SPH model is able to capture substantial detail from both the water analogue system and the actual casting process and is very suitable for simulating these types of complex thin walled castings.

  5. Semi-solid electrodes having high rate capability

    DOEpatents

    Chiang, Yet-Ming; Duduta, Mihai; Holman, Richard; Limthongkul, Pimpa; Tan, Taison

    2016-06-07

    Embodiments described herein relate generally to electrochemical cells having high rate capability, and more particularly to devices, systems and methods of producing high capacity and high rate capability batteries having relatively thick semi-solid electrodes. In some embodiments, an electrochemical cell includes an anode and a semi-solid cathode. The semi-solid cathode includes a suspension of an active material of about 35% to about 75% by volume of an active material and about 0.5% to about 8% by volume of a conductive material in a non-aqueous liquid electrolyte. An ion-permeable membrane is disposed between the anode and the semi-solid cathode. The semi-solid cathode has a thickness of about 250 .mu.m to about 2,000 .mu.m, and the electrochemical cell has an area specific capacity of at least about 7 mAh/cm.sup.2 at a C-rate of C/4. In some embodiments, the semi-solid cathode slurry has a mixing index of at least about 0.9.

  6. Strategies to reduce the environmental impact of an aluminium pressure die casting plant: a scenario analysis.

    PubMed

    Neto, Belmira; Kroeze, Carolien; Hordijk, Leen; Costa, Carlos; Pulles, Tinus

    2009-02-01

    This study explores a model (MIKADO) to analyse scenarios for the reduction of the environmental impact of an aluminium die casting plant. Our model calculates the potential to reduce emissions, and the costs associated with implementation of reduction options. In an earlier paper [Neto, B., Kroeze, C., Hordijk, L., Costa, C., 2008. Modelling the environmental impact of an aluminium pressure die casting company and options for control. Environmental Modelling & Software 23 (2) 147-168] we included the model description and explored the model by applying it to a plant in which no reduction options are assumed to be implemented (so-called zero case, reflecting the current practice in the plant). Here, we perform a systematic analysis of reduction options. We analysed seven types of reduction strategies, assuming the simultaneous implementation of different reduction options. These strategies are analysed with respect to their potential to reduce emissions, environmental impact and costs associated with the implementation of options. These strategies were found to differ largely in their potential to reduce the environmental impact of the plant (10-87%), as well as in the costs associated with the implementation of options (-268 to +277keuro/year). We were able to define 11 strategies, reducing the overall environmental impact by more than 50%. Of these, two have net negative costs, indicating that the company may in fact earn money through their implementation. PMID:18342428

  7. An evaluation of direct pressure sensors for monitoring the aluminum die casting process

    SciTech Connect

    Zhang, X.

    1997-12-31

    This study was conducted as part of the US Department of Energy (DOE) sponsored project Die Cavity Instrumentation. One objective of that project was to evaluate thermal, pressure, and gas flow process monitoring sensors in or near the die cavity as a means of securing improved process monitoring and control and better resultant part quality. The objectives of this thesis are to (1) evaluate a direct cavity pressure sensor in a controlled production campaign at the GM Casting Advanced Development Center (CADC) at Bedford, Indiana; and (2) develop correlations between sensor responses and product quality in terms of the casting weight, volume, and density. A direct quartz-based pressure sensor developed and marked by Kistler Instrument Corp. was acquired for evaluating as an in-cavity liquid metal pressure sensor. This pressure sensor is designed for use up to 700 C and 2,000 bars (29,000 psi). It has a pressure overload capacity up to 2,500 bars (36,250 psi).

  8. Annealing of chromium oxycarbide coatings deposited by plasma immersion ion processing (PIIP) for aluminum die casting

    NASA Astrophysics Data System (ADS)

    Peters, A. M.; He, X. M.; Trkula, M.; Nastasi, M.

    2001-04-01

    Chromium oxycarbide coatings have been investigated for use as non-wetting coatings for aluminum die casting. This paper examines Cr-C-O coating stability and non-wetability at elevated temperatures for extended periods. Coatings were deposited onto 304 stainless steel from chromium carbonyl [Cr(CO) 6] by plasma immersion ion processing. The coatings were annealed in air at an aluminum die casting temperature of 700°C up to 8 h. Coatings were analyzed using resonant ion backscattering spectroscopy, nanoindentation and pin-on-disk tribometry. Molten aluminum was used to determine coating wetting and contact angle. Results indicate that the surface oxide layer reaches a maximum thickness of 900 nm. Oxygen concentrations in the coatings increased from 24% to 34%, while the surface concentration rose to almost 45%. Hardness values ranged from 22.1 to 6.7 GPa, wear coefficients ranged from 21 to 8×10 -6 mm3/ Nm and contact angles ranged from 156° to 127°.

  9. Modifying AM60B Magnesium Alloy Die Cast Surfaces by Friction Stir Processing

    SciTech Connect

    Santella, Michael L; Feng, Zhili; Degen, Cassandra; Pan, Dr. Tsung-Yu

    2006-01-01

    These experiments were done to evaluate the feasibility of locally modifying the surface properties of magnesium alloys with friction-stir processing. The magnesium alloy used for the study was high-pressure die-cast AM60B, nominally Mg-6Al-0.13 Mn (wt. %). Friction-stir passes were made with a translation speed of 1.7 mm/s using tool-rotation speeds of 1,250 rpm or 2,500 rpm. Stir passes with good appearance were obtained under both conditions. In some cases up to five passes were overlapped on a single bar to produce stir zones with cross-sectional dimensions of about 1.5 mm x 10 mm. Metallographic examinations indicated that the stir zones were largely comprised of a magnesium solid solution with equiaxed grains on the order of 5-10 {micro}m in size. Hardness mapping showed that the stir zones experienced increases of 16-25% compared to the as-cast metal. Room-temperature testing showed that, compared to the cast metal, the stir zones had flow stresses nearly 20% higher with about twice the tensile elongation.

  10. Plunger Kinematic Parameters Affecting Quality of High-Pressure Die-Cast Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Fiorese, Elena; Bonollo, Franco

    2016-07-01

    The selection of the optimal process parameters in high-pressure die casting has been long recognized as a complex problem due to the involvement of a large number of interconnected variables. Among these variables, the effect of the plunger motion has been proved to play a prominent role, even if a thorough and exhaustive study is still missing in the literature. To overcome this gap, this work aims at identifying the most relevant plunger kinematic parameters and estimates their correlation with the casting quality, by means of a statistically significant sample manufactured with different plunger motion profiles. In particular, slow and fast shot velocities and switching position between two stages have been varied randomly in accordance with design of experiment methodology. The quality has been assessed through the static mechanical properties and porosity percentage. As a further proof, the percentage of oxides has been estimated on the fracture surfaces. These measurements have been correlated to novel parameters, representing the mechanical energy and the inertial force related to the plunger motion, that have been extracted from the time-history of the displacement curves. The application of statistical methods demonstrates that these novel parameters accurately explain and predict the overall quality of castings.

  11. Plunger Kinematic Parameters Affecting Quality of High-Pressure Die-Cast Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Fiorese, Elena; Bonollo, Franco

    2016-04-01

    The selection of the optimal process parameters in high-pressure die casting has been long recognized as a complex problem due to the involvement of a large number of interconnected variables. Among these variables, the effect of the plunger motion has been proved to play a prominent role, even if a thorough and exhaustive study is still missing in the literature. To overcome this gap, this work aims at identifying the most relevant plunger kinematic parameters and estimates their correlation with the casting quality, by means of a statistically significant sample manufactured with different plunger motion profiles. In particular, slow and fast shot velocities and switching position between two stages have been varied randomly in accordance with design of experiment methodology. The quality has been assessed through the static mechanical properties and porosity percentage. As a further proof, the percentage of oxides has been estimated on the fracture surfaces. These measurements have been correlated to novel parameters, representing the mechanical energy and the inertial force related to the plunger motion, that have been extracted from the time-history of the displacement curves. The application of statistical methods demonstrates that these novel parameters accurately explain and predict the overall quality of castings.

  12. An automatic granular structure generation and finite element analysis of heterogeneous semi-solid materials

    NASA Astrophysics Data System (ADS)

    Sharifi, Hamid; Larouche, Daniel

    2015-09-01

    The quality of cast metal products depends on the capacity of the semi-solid metal to sustain the stresses generated during the casting. Predicting the evolution of these stresses with accuracy in the solidification interval should be highly helpful to avoid the formation of defects like hot tearing. This task is however very difficult because of the heterogeneous nature of the material. In this paper, we propose to evaluate the mechanical behaviour of a metal during solidification using a mesh generation technique of the heterogeneous semi-solid material for a finite element analysis at the microscopic level. This task is done on a two-dimensional (2D) domain in which the granular structure of the solid phase is generated surrounded by an intergranular and interdendritc liquid phase. Some basic solid grains are first constructed and projected in the 2D domain with random orientations and scale factors. Depending on their orientation, the basic grains are combined to produce larger grains or separated by a liquid film. Different basic grain shapes can produce different granular structures of the mushy zone. As a result, using this automatic grain generation procedure, we can investigate the effect of grain shapes and sizes on the thermo-mechanical behaviour of the semi-solid material. The granular models are automatically converted to the finite element meshes. The solid grains and the liquid phase are meshed properly using quadrilateral elements. This method has been used to simulate the microstructure of a binary aluminium-copper alloy (Al-5.8 wt% Cu) when the fraction solid is 0.92. Using the finite element method and the Mie-Grüneisen equation of state for the liquid phase, the transient mechanical behaviour of the mushy zone under tensile loading has been investigated. The stress distribution and the bridges, which are formed during the tensile loading, have been detected.

  13. Improved design and durability of aluminum die casting horizontal shot sleeves

    NASA Astrophysics Data System (ADS)

    Birceanu, Sebastian

    The design and performance of shot sleeves is critical in meeting the engineering requirements of aluminum die cast parts. Improvement in shot sleeve materials have a major impact on dimensional stability, reproducibility and quality of the product. This investigation was undertaken in order to improve the life of aluminum die casting horizontal shot sleeves. Preliminary pin tests were run to evaluate the soldering, wash-out and thermal fatigue behavior of commercially available materials and coatings. An experimental rig was designed and constructed for shot sleeve configuration evaluation. Fabrication and testing of experimental shot sleeves was based upon preliminary results and manufacturing costs. Three shot sleeve designs and materials were compared to a reference nitrided H13 sleeve. Nitrided H13 is the preferred material for aluminum die casting shot sleeves because of wear resistance, strength and relative good soldering and wash-out resistance. The study was directed towards damage evaluation on the area under the pouring hole. This area is the most susceptible to damage because of high temperatures and impingement of molten aluminum. The results of this study showed that tungsten and molybdenum had the least amount of soldering and wash-out damage, and the best thermal fatigue resistance. Low solubility in molten aluminum and stability of intermetallic layers are main factors that determine the soldering and wash-out behavior. Thermal conductivity and thermal expansion coefficient directly influence thermal fatigue behavior. TiAlN nanolayered coating was chosen as the material with the best damage resistance among several commercial PVD coatings, because of relatively large thickness and simple deposition conditions. The results show that molybdenum thermal sprayed coating provided the best protection against damage under the pouring hole. Improved bonding is however required for life extension of the coating. TiAlN PVD coating applied on H13 nitrided

  14. Experimental Investigations And Numerical Modelling of 210CR12 Steel in Semi-Solid State

    SciTech Connect

    Maciol, Piotr; Jakubowicz, Aleksandra; Wladislaw, Stanislaw; Zalecki, Wladyslaw; Kuziak, Roman

    2011-05-04

    Experimental investigation, including hot compression and simple closed die filling was performed. Temperature range of tests was between 1225 deg. C and 1320 deg. C. Temperature selection was adequate with liquid fraction between 20 and 60%, which is typical for thixoforming processes. In the die filling test, steel dies with ceramic layer was used (highly refractory air-setting mortar JM 3300 manufactured by Thermal Ceramics). Experiments were carried out on the Gleeble 3800 physical simulator with MCU unit. In the paper, methodology of experimental investigation is described. Dependency of forming forces on temperature and forming velocities is analysed. Obtained results are discussed. The second part of the paper concerns numerical modelling of semi-solid forming. Numerical models for both sets of test were developed. Structural and Computational Fluid Dynamics models are compared. Initial works in microstructural modelling of 210CR12 steel behaviour are described. Lattice Boltzman Method model for thixotropic flows is introduced. Microscale and macroscale models were integrated into multiscale simulation of semi-solid forming. Some fundamental issues related to multiscale modelling of thixoforming are discussed.

  15. Semi-solid electrodes having high rate capability

    DOEpatents

    Chiang, Yet-Ming; Duduta, Mihai; Holman, Richard; Limthongkul, Pimpa; Tan, Taison

    2016-07-05

    Embodiments described herein relate generally to electrochemical cells having high rate capability, and more particularly to devices, systems and methods of producing high capacity and high rate capability batteries having relatively thick semi-solid electrodes. In some embodiments, an electrochemical cell includes an anode, a semi-solid cathode that includes a suspension of an active material and a conductive material in a liquid electrolyte, and an ion permeable membrane disposed between the anode and the cathode. The semi-solid cathode has a thickness in the range of about 250 .mu.m-2,500 .mu.m, and the electrochemical cell has an area specific capacity of at least 5 mAh/cm.sup.2 at a C-rate of C/2.

  16. Semi-solid electrodes having high rate capability

    SciTech Connect

    Chiang, Yet-Ming; Duduta, Mihai; Holman, Richard; Limthongkul, Pimpa; Tan, Taison

    2015-11-10

    Embodiments described herein relate generally to electrochemical cells having high rate capability, and more particularly to devices, systems and methods of producing high capacity and high rate capability batteries having relatively thick semi-solid electrodes. In some embodiments, an electrochemical cell includes an anode, a semi-solid cathode that includes a suspension of an active material and a conductive material in a liquid electrolyte, and an ion permeable membrane disposed between the anode and the cathode. The semi-solid cathode has a thickness in the range of about 250 .mu.m-2,500 .mu.m, and the electrochemical cell has an area specific capacity of at least 5 mAh/cm.sup.2 at a C-rate of C/2.

  17. The Effect of Porosity on Fatigue of Die Cast AM60

    NASA Astrophysics Data System (ADS)

    Yang, Zhuofei; Kang, Jidong; Wilkinson, David S.

    2016-07-01

    AM60 high-pressure die castings are known to contain significant porosity which can affect fatigue life. We have studied this using samples drawn from prototype AM60 shock towers by conducting strain-controlled fatigue tests accompanied by X-ray computed tomography analysis. The results show that the machined surface is the preferential location for fatigue crack development, with pores close to these surfaces serving as initiation sites. Fatigue life shows a strong inverse correlation with the size of the fatigue-crack-initiating pore. Pore shape and pore orientation also influence the response. A supplemental study on surface roughness shows that porosity is the dominant factor in fatigue. Tomography enables the link between porosity and fatigue crack initiation to be clearly identified. These data are complemented by SEM observations of the fracture surfaces which are generally flat and full of randomly oriented serration patterns but without long-range fatigue striations.

  18. Case study of lean manufacturing application in a die casting manufacturing company

    NASA Astrophysics Data System (ADS)

    Ching, Ng Tan; Hoe, Clarence Chan Kok; Hong, Tang Sai; Ghobakhloo, Morteza; Pin, Chen Kah

    2015-05-01

    The case study of lean manufacturing aims to study the application of lean manufacturing in a die casting manufacturing company located in Pulau Penang, Malaysia. This case study describes mainly about the important concepts and applications of lean manufacturing which could gradually help the company in increasing the profit by studying and analyzing their current manufacturing process and company culture. Many approaches of lean manufacturing are studied in this project which includes: 5S housekeeping, Kaizen, and Takt Time. Besides, the lean tools mentioned, quality tool such as the House of Quality is being used as an analysis tool to continuously improve the product quality. In short, the existing lean culture in the company is studied and analyzed, with recommendations written at the end of this paper.

  19. The Effect of Porosity on Fatigue of Die Cast AM60

    NASA Astrophysics Data System (ADS)

    Yang, Zhuofei; Kang, Jidong; Wilkinson, David S.

    2016-04-01

    AM60 high-pressure die castings are known to contain significant porosity which can affect fatigue life. We have studied this using samples drawn from prototype AM60 shock towers by conducting strain-controlled fatigue tests accompanied by X-ray computed tomography analysis. The results show that the machined surface is the preferential location for fatigue crack development, with pores close to these surfaces serving as initiation sites. Fatigue life shows a strong inverse correlation with the size of the fatigue-crack-initiating pore. Pore shape and pore orientation also influence the response. A supplemental study on surface roughness shows that porosity is the dominant factor in fatigue. Tomography enables the link between porosity and fatigue crack initiation to be clearly identified. These data are complemented by SEM observations of the fracture surfaces which are generally flat and full of randomly oriented serration patterns but without long-range fatigue striations.

  20. Effect of Viscosity Measurement Method to Simulate High Pressure Die Casting of Thin-Wall AlSi10MnMg Alloy Castings

    NASA Astrophysics Data System (ADS)

    Zhu, B. W.; Li, L. X.; Liu, X.; Zhang, L. Q.; Xu, R.

    2015-12-01

    In the present study, a rotating cylinder viscometer (RCV) was adopted to measure the viscosity of AlSi10MnMg aluminum alloy. The results show that the measured viscosity is much higher than previously reported viscosity of aluminum alloys measured by oscillation vessel viscometer. The viscosity measured by RCV was introduced into the simulation of the filling progress of high pressure die casting (HPDC) for thin-walled castings of aluminum alloy (TWCA). The simulated results match well with the experimental results indicating that the RCV is the most appropriate to use for simulations of HPDC for TWCA.

  1. Effects of Pore Distributions on Ductility of Thin-Walled High Pressure Die-Cast Magnesium

    SciTech Connect

    Choi, Kyoo Sil; Li, Dongsheng; Sun, Xin; Li, Mei; Allison, John

    2013-06-01

    In this paper, a microstructure-based three-dimensional (3D) finite element modeling method is adopted to investigate the effects of porosity in thin-walled high pressure die-cast (HPDC) Magnesium alloys on their ductility. For this purpose, the cross-sections of AM60 casting samples are first examined using optical microscope and X-ray tomography to obtain the general information on the pore distribution features. The experimentally observed pore distribution features are then used to generate a series of synthetic microstructure-based 3D finite element models with different pore volume fractions and pore distribution features. Shear and ductile damage models are adopted in the finite element analyses to induce the fracture by element removal, leading to the prediction of ductility. The results in this study show that the ductility monotonically decreases as the pore volume fraction increases and that the effect of ‘skin region’ on the ductility is noticeable under the condition of same local pore volume fraction in the center region of the sample and its existence can be beneficial for the improvement of ductility. The further synthetic microstructure-based 3D finite element analyses are planned to investigate the effects of pore size and pore size distribution.

  2. Quantitative characterization of processing-microstructure-properties relationships in pressure die-cast magnesium alloys

    NASA Astrophysics Data System (ADS)

    Lee, Soon Gi

    The central goal of this research is to quantitatively characterize the relationships between processing, microstructure, and mechanical properties of important high-pressure die-cast (HPDC) Mg-alloys. For this purpose, a new digital image processing technique for automatic detection and segmentation of gas and shrinkage pores in the cast microstructure is developed and it is applied to quantitatively characterize the effects of HPDC process parameters on the size distribution and spatial arrangement of porosity. To get better insights into detailed geometry and distribution of porosity and other microstructural features, an efficient and unbiased montage based serial sectioning technique is applied for reconstruction of three-dimensional microstructures. The quantitative microstructural data have been correlated to the HPDC process parameters and the mechanical properties. The analysis has led to hypothesis of formation of new type of shrinkage porosity called, "gas induced shrinkage porosity" that has been substantiated via simple heat transfer simulations. The presence of inverse surface macrosegregation has been also shown for the first time in the HPDC Mg-alloys. An image analysis based technique has been proposed for simulations of realistic virtual microstructures that have realistic complex pore morphologies. These virtual microstructures can be implemented in the object oriented finite elements framework to model the variability in the fracture sensitive mechanical properties of the HPDC alloys.

  3. A three-die cast technique for duplicating free gingival form in zirconia crowns: two case reports.

    PubMed

    Nozawa, Takeshi; Tanaka, Koji; Tsurumaki, Shunzo; Ookame, Yasuhisa; Enomoto, Hiroaki; Ito, Koichi

    2012-08-01

    This report describes a duplication technique of free gingival form from a provisional restoration to a zirconia crown. Three die casts were manufactured from a silicone impression with an acrylic resin ring tray. The first die cast was for the zirconia framework, the second for the provisionalized transfer coping, and the third for relining the provisional restoration. A free gingival impression was taken using a provisionalized transfer coping, and a soft gingival cast was manufactured. The depth of free gingival transparency was measured using a zirconia shade plate. Then, the zirconia framework was customized to allow for subgingival porcelain space. This technique seems to contribute to the clinical-laboratory interface in computer-aided design/computer-assisted manufacture restorations. PMID:22577656

  4. Casting dimensional control and fatigue life prediction for permanent mold casting dies. Technical progress report, September 29, 1993-- September 30, 1994

    SciTech Connect

    1994-11-01

    First year efforts as part of a three year program to address metal casting dimensional control and fatigue life prediction for permanent mold casting dies are described. Procedures have been developed and implemented to collect dimensional variability data from production steel castings. The influence of process variation and casting geometry variables on dimensional tolerances have been investigated. Preliminary results have shown that these factors have a significant influence on dimensional variability, although this variability is considerably less than the variability indicated in current tolerance standards. Gage repeatability and reproducibility testing must precede dimensional studies to insure that measurement system errors are acceptably small. Also initial efforts leading to the development and validation of a CAD/CAE model to predict the thermal fatigue life of permanent molds for aluminum castings are described. An appropriate thermomechanical property database for metal, mold and coating materials has been constructed. A finite element model has been developed to simulate the mold temperature distribution during repeated casting cycles. Initial validation trials have indicated the validity of the temperature distribution model developed.

  5. Final report to USAMP on the use of EBPVD in the light metal die casting industry

    SciTech Connect

    Heestand, G.M.

    1996-02-02

    This is the final report to the United States Automotive Materials Partnership (USAMP) on the use of Electron Beam Physical Vapor Deposition (EBPVD) to make rapid tooling for functional prototyping of metal mold processes. Historically this process has been successfully applied to the production of mold inserts for the plastics injection mold industry. Our approach for this project was to use the same technique to produce dies which could be used to make a few thousand light metal (aluminum and magnesium) prototype parts. The difficulty encountered in this project was that the requirements for the die casting industry, both in size and material requirements, were considerably more stringent than those encountered in the plastics injection industry. Consequently our technique, within the allotted time and budget constraints, was not able to meet the requirements set forth by USAMP. The remainder of this report is organized into five sections. The first discusses the technique in some detail while the second discusses a successful application. The third section discusses issues with this process while the fourth specifically discusses the work done in this project. The last is a short summary and conclusion section.

  6. The study of flow pattern and phase-change problem in die casting process

    NASA Technical Reports Server (NTRS)

    Wang, T. S.; Wei, H.; Chen, Y. S.; Shang, H. M.

    1996-01-01

    The flow pattern and solidification phenomena in die casting process have been investigated in the first phase study. The flow pattern in filling process is predicted by using a VOF (volume of fluid) method. A good agreement with experimental observation is obtained for filling the water into a die cavity with different gate geometry and with an obstacle in the cavity. An enthalpy method has been applied to solve the solidification problem. By treating the latent heat implicitly into the enthalpy instead of explicitly into the source term, the CPU time can be reduced at least 20 times. The effect of material properties on solidification fronts is tested. It concludes that the dependence of properties on temperature is significant. The influence of the natural convection over the diffusion has also been studied. The result shows that the liquid metal solidification phenomena is diffusion dominant, and the natural convection can affect the shape of the interface. In the second phase study, the filling and solidification processes will be considered simultaneously.

  7. Measurement of Heat Flux and Heat Transfer Coefficient Due to Spray Application for the Die Casting Process

    SciTech Connect

    Sabau, Adrian S

    2007-01-01

    Lubricant spray application experiments were conducted for the die casting process. The heat flux was measured in situ using a differential thermopile sensor for three application techniques. First, the lubricant was applied under a constant flowrate while the nozzle was held in the same position. Second, the lubricant was applied in a pulsed, static manner, in which the nozzle was held over the same surface while it was turned on and off several times. Third, the lubricant was applied in a sweeping manner, in which the nozzle was moved along the die surface while it was held open. The experiments were conducted at several die temperatures and at sweep speeds of 20, 23, and 68 cm/s. The heat flux data, which were obtained with a sensor that was located in the centre of the test plate, were presented and discussed. The sensor can be used to evaluate lubricants, monitor the consistency of die lubrication process, and obtain useful process data, such as surface temperature, heat flux, and heat transfer coefficients. The heat removed from the die surface during lubricant application is necessary for (a) designing the cooling channels in the die, i.e. their size and placement, and (b) performing accurate numerical simulations of the die casting process.

  8. Influence of the fabrication process on the functionality of piezoceramic patch transducers embedded in aluminum die castings

    NASA Astrophysics Data System (ADS)

    Klassen, Alexander; Rübner, Matthias; Ilg, Jürgen; Rupitsch, Stefan J.; Lerch, Reinhard; Singer, Robert F.; Körner, Carolin

    2012-11-01

    Piezoceramic patch transducers are integrated into aluminum components using high-pressure die casting. Expanded metal has proven suitable as a supporting structure for placing the patch transducers inside the die cavity and for stabilization during the injection of molten metal. However, difficulties arise when the transducers are positioned off the neutral axis within the wall of the casting. Numerical simulations of the die filling are performed to analyse the evolution of the integration process. The asymmetric infiltration of the supporting structure is identified as the major factor contributing to the formation of cracks and perforations inside the piezoceramic transducer. By means of measurements and numerical calculations of the electrical impedance of the transducer, a close relation is established between mechanical damage patterns observed in radiographs of the patch transducers and loss of performance.

  9. Low-Cycle Fatigue Behavior of Die-Cast Mg Alloys AZ91 and AM60

    NASA Astrophysics Data System (ADS)

    Rettberg, Luke H.; Jordon, J. Brian; Horstemeyer, Mark F.; Jones, J. Wayne

    2012-07-01

    The influence of microstructure and artificial aging response (T6) on the low-cycle fatigue behavior of super vacuum die-cast (SVDC) AZ91 and AM60 has been investigated. Fatigue lifetimes were determined from the total strain-controlled fatigue tests for strain amplitudes of 0.2 pct, 0.4 pct, 0.6 pct, 0.8 pct, and 1.0 pct under fully reversed loading at a frequency of 5 Hz. Cyclic stress-strain behavior was determined using an incremental step test (IST) and compared with the more traditional constant amplitude test. Two locations in a prototype casting were investigated to examine the role of microstructure and porosity on fatigue behavior. At all total strain amplitudes microstructure refinement had a negligible impact on fatigue life because of significant levels of porosity. AM60 showed an improvement in fatigue life at higher strain amplitudes when compared with AZ91 because of higher ductility. T6 heat treatment had no impact on fatigue life. Cyclic stress-strain behavior obtained via the incremental step test varied from constant amplitude test results due to load history effects. The constant amplitude test is believed to be the more accurate test method. In general, larger initiation pores led to shorter fatigue life. The fatigue life of AZ91 was more sensitive to initiation pore size and pore location than AM60 at the lowest tested strain amplitude of 0.2 pct. Fatigue crack paths did not favor any specific phase, interdentritic structure or eutectic structure. A multistage fatigue (MSF) model showed good correlation to the experimental strain-life results. The MSF model reinforced the dominant role of inclusion (pore) size on the scatter in fatigue life.

  10. Improved Life of Die Casting Dies of H13 Steel by Attaining Improved Mechanical Properties and Distortion Control During Heat Treatment

    SciTech Connect

    J. F. Wallace; D. Schwam

    1998-10-01

    The ultimate goal of this project is to increase die casting die life by using fast enough quenching rates to obtain good toughness and fatigue resistance in premium grade H-13 steel dies. The main tasks of the project were to compile a database on physical and mechanical properties of H-13; conduct gas quenching experiments to determine cooling rates of dies in difference vacuum furnaces; measure the as-quenched distortion of dies and the residual stresses; generate finite element analysis models to predict cooling rates, distortion, and residual stress of gas quenched dies; and establish rules and create PC-based expert system for prediction of cooling rates, distortion, and residual stress in vacuum/gas quenched H-13 dies. Cooling curves during gas quenching of H-13 blocks and die shapes have been measured under a variety of gas pressure. Dimensional changes caused by the gas quenching processes have been determined by accurate mapping of all surfaces with coordinate measuring machines before and after the quench. Residual stresses were determined by the ASTM E837 hole-drilling strain gage method. To facilitate the computer modeling work, a comprehensive database of H-13 mechanical and physical properties has been compiled. Finite element analysis of the heat treated shapes has been conducted using the TRAST/ABAQUS codes. There is a good fit between the predicted and measured distortion contours. However, the magnitude of the predicted distortion and residual stresses does not match well the measured values. Further fine tuning of the model is required before it can be used to predict distortion and residual stress in a quantitative manner. This last step is a prerequisite to generating rules for a reliable expert system.

  11. Mechanical Properties of Carbon Fiber-Reinforced Aluminum Manufactured by High-Pressure Die Casting

    NASA Astrophysics Data System (ADS)

    Kachold, Franziska; Singer, Robert

    2016-03-01

    Carbon fiber reinforced aluminum was produced by a specially adapted high-pressure die casting process. The MMC has a fiber volume fraction of 27%. Complete infiltration was achieved by preheating the bidirectional, PAN-based carbon fiber body with IR-emitters to temperatures of around 750 °C. The degradation of the fibers, due to attack of atmospheric oxygen at temperatures above 600 °C, was limited by heating them in argon-rich atmosphere. Additionally, the optimization of heating time and temperature prevented fiber degradation. Only the strength of the outer fibers is reduced by 40% at the most. The fibers in core of fiber body are nearly undamaged. In spite of successful manufacturing, the tensile strength of the MMC is below strength of the matrix material. Also unidirectional MMCs with a fiber volume fraction of 8% produced under the same conditions, lack of the reinforcing effect. Two main reasons for the unsatisfactory mechanical properties were identified: First, the fiber-free matrix, which covers the reinforced core, prevents effective load transfer from the matrix to the fibers. And second, the residual stresses in the fiber-free zones are as high as 100 MPa. This causes premature failure in the matrix. From this, it follows that the local reinforcement of an actual part is limited. The stress distribution caused by residual stresses and by loading needs to be known. In this way, the reinforcing phase can be placed and aligned accordingly. Otherwise delamination and premature failure might occur.

  12. Cradle-to-Gate Impact Assessment of a High-Pressure Die-Casting Safety-Relevant Automotive Component

    NASA Astrophysics Data System (ADS)

    Cecchel, Silvia; Cornacchia, Giovanna; Panvini, Andrea

    2016-08-01

    The mass of automotive components has a direct influence on several aspects of vehicle performance, including both fuel consumption and tailpipe emissions, but the real environmental benefit has to be evaluated considering the entire life of the products with a proper life cycle assessment. In this context, the present paper analyzes the environmental burden connected to the production of a safety-relevant aluminum high-pressure die-casting component for commercial vehicles (a suspension cross-beam) considering all the phases connected to its manufacture. The focus on aluminum high-pressure die casting reflects the current trend of the industry and its high energy consumption. This work shows a new method that deeply analyzes every single step of the component's production through the implementation of a wide database of primary data collected thanks to collaborations of some automotive supplier companies. This energy analysis shows significant environmental benefits of aluminum recycling.

  13. Semi-solid processing and its as yet unexplored potential

    NASA Astrophysics Data System (ADS)

    Aisman, D.; Rubesova, K.; Masek, B.

    2016-03-01

    Thanks to the available advanced control technology, manufacturing processes which have been described in the past but their hidden potential remained untapped are now continuing to be developed. As a result, even conventional materials which have been around for years can be manipulated to obtain unusual microstructures with specific mechanical and physical properties. Semi-solid processing belongs to the above-described group: it had been studied in the past but, due to complicated process control, it gradually lost its appeal. However, advanced techniques of temperature field control enable engineers to control this complex process accurately. One of the innovative methods of semi-solid processing is mini- thixoforming. As it focuses on very small-size products, it offers very steep heating curves and extremely high solidification and cooling rates, when compared to conventional thixoforming. The capabilities of this process were tested on X210Cr12 ledeburitic tool steel. After the optimum processing conditions were found, additional materials were tried, ranging from low- carbon microalloyed steels through medium-alloy steels to high-alloy tool steels. The microstructure evolution upon the mini-thixoforming process is an issue of its own. The final microstructure of X210Cr12 consisted of more than 90% of austenite and chromium carbides. Semi-solid processing of a steel with a high vanadium content led to a microstructure comprising MA matrix and globular vanadium carbides. In a low-alloy steel, martensitic microstructure was obtained.

  14. The effects of intensification pressure, gate velocity, and intermediate shot velocity on the internal quality of aluminum die castings

    NASA Astrophysics Data System (ADS)

    Karban, Robert, Jr.

    The purpose of this study was to investigate the effects of intensification pressure, gate velocity, and intermediate shot velocity on the internal quality of aluminum die castings. An experimental design was developed to analyze two levels of intensification pressure, two levels of gate velocity, and four levels of intermediate shot velocity. These parameters were chosen because of the ease of their manipulation on the manufacturing floor in an effort to develop an optimum process for a given die design. Internal casting quality is measured by the density of the casting produced as compared to the theoretical density of the alloy being molded. The study also included monitoring of the biscuit length of the samples collected. A statistical analysis was conducted to determine any correlation between or among any of the independent variables or the other parameter monitored. The results of this study indicate that there is a statistical significance among and between the independent variables that were controlled in this experiment. The results also indicated a significant positive relationship between biscuit length and the density of the resultant castings.

  15. Semi-Solid Metal Freeform Fabrication - Phase I Final Report for Period September 4, 1999--June 14, 2000

    SciTech Connect

    Chris S. Rice

    2000-07-25

    Semi-Solid Technologies, Inc. developed a semi-solid deposition system for semi-solid aluminum alloys. This technology addresses the direct, rapid, freeform fabrication of relatively large metallic components.

  16. Semi-Solid Flowable Battery Electrodes: Semi-Solid Flow Cells for Automotive and Grid-Level Energy Storage

    SciTech Connect

    2010-09-01

    BEEST Project: Scientists at 24M are crossing a Li-Ion battery with a fuel cell to develop a semi-solid flow battery. This system relies on some of the same basic chemistry as a standard Li-Ion battery, but in a flow battery the energy storage material is held in external tanks, so storage capacity is not limited by the size of the battery itself. The design makes it easier to add storage capacity by simply increasing the size of the tanks and adding more paste. In addition, 24M's design also is able to extract more energy from the semi-solid paste than conventional Li-Ion batteries. This creates a cost-effective, energy-dense battery that can improve the driving range of EVs or be used to store energy on the electric grid.

  17. Wear Properties of Thixoformed and High Pressure Die Cast Aluminium Alloys for Connecting Rod Applications in Compressors

    NASA Astrophysics Data System (ADS)

    Birol, Yücel; Birol, Feriha

    2007-04-01

    Hypereutectic aluminium casting alloys are attractive candidates for connecting rod applications in compressors. The wear properties of these alloys are largely controlled by their microstructural features which in turn are affected by the processing route. Several hypo- and hypereutectic Al-Si alloys were produced by high pressure die casting and thixoforming in the present work. The former route produced a very fine microstructure while relatively coarser, globular α-Al matrix dominated in thixoformed grades. A modified Falex Block on Ring equipment was employed to investigate the wear properties of these alloys. Wear tests were carried out under service conditions in the lubricated state at 75°C. The superior wear properties of hypereutectic alloys produced by high pressure die casting with respect to the thixoformed variety is accounted for by the very fine microstructure with a fine dispersion of primary Si particles in the former. Of the two production routes employed, thixoforming had a favorable effect on wear properties at equal Si levels.

  18. Aqueous semi-solid flow cell: demonstration and analysis

    SciTech Connect

    Li, Z; Smith, KC; Dong, YJ; Baram, N; Fan, FY; Xie, J; Limthongkul, P; Carter, WC; Chiang, YM

    2013-01-01

    An aqueous Li-ion flow cell using suspension-based flow electrodes based on the LiTi2(PO4)(3)-LiFePO4 couple is demonstrated. Unlike conventional flow batteries, the semi-solid approach utilizes fluid electrodes that are electronically conductive. A model of simultaneous advection and electrochemical transport is developed and used to separate flow-induced losses from those due to underlying side reactions. The importance of plug flow to achieving high energy efficiency in flow batteries utilizing highly non-Newtonian flow electrodes is emphasized.

  19. Development of a 3D Filling Model of Low-Pressure Die-Cast Aluminum Alloy Wheels

    NASA Astrophysics Data System (ADS)

    Duan, Jianglan; Maijer, Daan; Cockcroft, Steve; Reilly, Carl

    2013-12-01

    A two-phase computational fluid dynamics model of the low-pressure die-cast process for the production of A356 aluminum alloy wheels has been developed to predict the flow conditions during die filling. The filling model represents a 36-deg section of a production wheel, and was developed within the commercial finite-volume package, ANSYS CFX, assuming isothermal conditions. To fully understand the behavior of the free surface, a novel technique was developed to approximate the vent resistances as they impact on the development of a backpressure within the die cavity. The filling model was first validated against experimental data, and then was used to investigate the effects of venting conditions and pressure curves during die filling. It was found that vent resistance and vent location strongly affected die filling time, free surface topography, and air entrainment for a given pressure fill-curve. With regard to the pressure curve, the model revealed a strong relation between the pressure curve and the flow behavior in the hub, which is an area prone to defect formation.

  20. Thermal fatigue behavior of H-13 die steel for aluminum die casting with various ion sputtered coatings

    NASA Technical Reports Server (NTRS)

    Nieh, C. Y.; Wallace, J. F.

    1981-01-01

    Sputtered coatings of Mo, W, Pt, Ag, Au, Co, Cr, Ni, Ag + Cu, Mo + Pt, Si3N4, A1N, Cr3C2, Ta5Si3, and ZrO2 were applied to a 2-inch-square, 7-inch-long thermal fatigue test specimen which was then internally water cooled and alternately immersed in molten aluminum and cooled in air. After 15,000 cycles the thermal fatigue cracks at the specimen corners were measured. Results indicate that a significant improvement in thermal fatigue resistance was obtained with platinum, molybdenum, and tungsten coatings. Metallographic examination indicates that the improvement in thermal fatigue resistance resulted from protection of the surface of the die steel from oxidation. The high yield strength and ductility of molybdenum and tungsten contributed to the better thermal fatigue resistance.

  1. Characterization of Pore Defects and Fatigue Cracks in Die Cast AM60 Using 3D X-ray Computed Tomography

    NASA Astrophysics Data System (ADS)

    Yang, Zhuofei; Kang, Jidong; Wilkinson, David S.

    2015-08-01

    AM60 high pressure die castings have been used in automobile applications to reduce the weight of vehicles. However, the pore defects that are inherent in die casting may negatively affect mechanical properties, especially the fatigue properties. Here we have studied damage ( e.g., pore defects, fatigue cracks) during strained-controlled fatigue using 3-dimensional X-ray computed tomography (XCT). The fatigue test was interrupted every 2000 cycles and the specimen was removed to be scanned using a desktop micro-CT system. XCT reveals pore defects, cracks, and fracture surfaces. The results show that pores can be accurately measured and modeled in 3D. Defect bands are found to be made of pores under 50 µm (based on volume-equivalent sphere diameter). Larger pores are randomly distributed in the region between the defect bands. Observation of fatigue cracks by XCT is performed in three ways such that the 3D model gives the best illustration of crack-porosity interaction while the other two methods, with the cracks being viewed on transverse or longitudinal cross sections, have better detectability on crack initiation and crack tip observation. XCT is also of value in failure analysis on fracture surfaces. By assessing XCT data during fatigue testing and observing fracture surfaces on a 3D model, a better understanding on the crack initiation, crack-porosity interaction, and the morphology of fracture surface is achieved.

  2. Process Modeling of Low-Pressure Die Casting of Aluminum Alloy Automotive Wheels

    NASA Astrophysics Data System (ADS)

    Reilly, C.; Duan, J.; Yao, L.; Maijer, D. M.; Cockcroft, S. L.

    2013-09-01

    Although on initial inspection, the aluminum alloy automotive wheel seems to be a relatively simple component to cast based on its shape, further insight reveals that this is not the case. Automotive wheels are in a select group of cast components that have strict specifications for both mechanical and aesthetic characteristics due to their important structural requirements and their visibility on a vehicle. The modern aluminum alloy automotive wheel continues to experience tightened tolerances relating to defects to improve mechanical performance and/or the physical appearance. Automotive aluminum alloy wheels are assessed against three main criteria: wheel cosmetics, mechanical performance, and air tightness. Failure to achieve the required standards in any one of these categories will lead to the wheel either requiring costly repair or being rejected and remelted. Manufacturers are becoming more reliant on computational process modeling as a design tool for the wheel casting process. This article discusses and details examples of the use of computational process modeling as a predictive tool to optimize the casting process from the standpoint of defect minimization with the emphasis on those defects that lead to failure of aluminum automotive wheels, namely, macroporosity, microporosity, and oxide films. The current state of applied computational process modeling and its limitations with regard to wheel casting are discussed.

  3. Application of TPM indicators for analyzing work time of machines used in the pressure die casting

    NASA Astrophysics Data System (ADS)

    Borkowski, Stanisław; Czajkowska, Agnieszka; Stasiak-Betlejewska, Renata; Borade, Atul B.

    2014-05-01

    The article presents the application of total productive maintenance (TPM) to analyze the working time indicators of casting machines with particular emphasis on failures and unplanned downtime to reduce the proportion of emergency operation for preventive maintenance and diagnostics. The article presents that the influence of individual factors of complex machinery maintenance (TPM) is different and depends on the machines' modernity level. In an original way, by using correlation graphs, research findings on the impact of individual TPM factors on the castings quality were presented and interpreted. The examination results conducted for machines with varying modernity degrees allowed to determine changes within the impact of individual TPM factors depending on machine parameters. These results provide a rich source of information for the improvement processes on casting quality of the foundry industry that satisfies the automotive industry demand.

  4. Fabrication of ZnO Nanowires Arrays by Anodization and High-Vacuum Die Casting Technique, and Their Piezoelectric Properties.

    PubMed

    Kuo, Chin-Guo; Chang, Ho; Wang, Jian-Hao

    2016-01-01

    In this investigation, anodic aluminum oxide (AAO) with arrayed and regularly arranged nanopores is used as a template in the high-vacuum die casting of molten zinc metal (Zn) into the nanopores. The proposed technique yields arrayed Zn nanowires with an aspect ratio of over 600. After annealing, arrayed zinc oxide (ZnO) nanowires are obtained. Varying the anodizing time yields AAO templates with thicknesses of approximately 50 μm, 60 μm, and 70 μm that can be used in the fabrication of nanowires of three lengths with high aspect ratios. Experimental results reveal that a longer nanowire generates a greater measured piezoelectric current. The ZnO nanowires that are fabricated using an alumina template are anodized for 7 h and produce higher piezoelectric current of up to 69 pA. PMID:27023546

  5. Effect of strontium modification on near-threshold fatigue crack growth in an Al-Si-Cu die cast alloy

    SciTech Connect

    Schaefer, M.; Fournelle, R.A.

    1996-05-01

    The effects of strontium modification on microstructure and fatigue properties in a die cast commercial aluminum-silicon alloy are demonstrated. Strontium additions of 0.010 and 0.018 wt pct drastically change the morphology of the eutectic silicon. The influence of these microstructural changes on fatigue properties is evaluated through fatigue crack growth testing. Examination of the fracture surfaces and the crack path establish distinct fatigue fracture modes for the modified and unmodified eutectic structures. Changes in fracture mode and crack path are correlated to the microstructure changes. A higher energy fracture mode and increased crack path tortuosity explain the observed improvement in fatigue properties for the modified alloys. Strontium modified alloys exhibit a 10 to 20 pct higher fatigue crack growth threshold compared to an unmodified alloy for testing at a load ratio of 0.5. No difference was observed for testing at a load ratio of 0.1.

  6. Fabrication of ZnO Nanowires Arrays by Anodization and High-Vacuum Die Casting Technique, and Their Piezoelectric Properties

    PubMed Central

    Kuo, Chin-Guo; Chang, Ho; Wang, Jian-Hao

    2016-01-01

    In this investigation, anodic aluminum oxide (AAO) with arrayed and regularly arranged nanopores is used as a template in the high-vacuum die casting of molten zinc metal (Zn) into the nanopores. The proposed technique yields arrayed Zn nanowires with an aspect ratio of over 600. After annealing, arrayed zinc oxide (ZnO) nanowires are obtained. Varying the anodizing time yields AAO templates with thicknesses of approximately 50 μm, 60 μm, and 70 μm that can be used in the fabrication of nanowires of three lengths with high aspect ratios. Experimental results reveal that a longer nanowire generates a greater measured piezoelectric current. The ZnO nanowires that are fabricated using an alumina template are anodized for 7 h and produce higher piezoelectric current of up to 69 pA. PMID:27023546

  7. Heat transfer during quenching of modified and unmodified gravity die-cast A357 cylindrical bars

    NASA Astrophysics Data System (ADS)

    Prabhu, K. N.; Hemanna, P.

    2006-06-01

    Heat transfer during quenching of chill-cast modified and unmodified A357 Al-Si alloy was examined using a computer-aided cooling curve analysis. Water at 60 °C and a vegetable oil (palm oil) were used as quench media. The measured temperatures inside cylindrical probes of the A357 alloy were used as inputs in an inverse heat-conduction model to estimate heat flux transients at the probe/quenchant interface and the surface temperature of the probe in contact with the quench medium. It was observed that modified alloy probes yielded higher cooling rates and heat flux transients. The investigation clearly showed that the heat transfer during quenching depends on the casting history. The increase in the cooling rate and peak heat flux was attributed to the increase in the thermal conductivity of the material on modification melt treatment owing to the change in silicon morphology. Fine and fibrous silicon particles in modified A357 probes increase the conductance of the probe resulting in higher heat transfer rates. This was confirmed by measuring the electrical conductivity of modified samples, which were found to be higher than those of unmodified samples. The ultrasound velocity in the probes decreased on modification.

  8. An investigation on the rheological behavior of metallic semi-solid slurries of Al-6.5 pct Si and semi-solid composite slurries of SiC particulates in an Al-6.5 pct Si alloy matrix

    NASA Technical Reports Server (NTRS)

    Moon, H.-K.; Ito, Y.; Cornie, J. A.; Flemings, M. C.

    1993-01-01

    The rheology of SiC particulate/Al-6.5 pct Si composite slurries was explored. The rheological behavior of the composite slurries shows both thixotropic and pseudoplastic behaviors. Isostructural experiments on the composite slurries revealed a Newtonian behavior beyond a high shear rate limit. The rheology of fully molten composite slurries over the low to high shear rate range indicates the existence of a low shear rate Newtonian region, an intermediate pseudoplastic region and a high shear rate Newtonian region. The isostructural studies indicate that the viscosity of a composite slurry depends upon the shearing history of a given volume of material. An unexpected shear thinning was noted for SiC particulate + alpha slurries as compared to semi-solid metallic slurries at the same fraction solid. The implications of these findings for the processing of slurries into cast components is discussed.

  9. On the performance of low pressure die-cast Al-Cu based automotive alloys: Role of additives

    NASA Astrophysics Data System (ADS)

    Zaki, Gergis Adel

    The present study focuses on the effect of alloying elements, namely, strontium (Sr), titanium (Ti), zirconium (Zr), scandium (Sc) and silver(Ag) individually or in combination, on the performance of a newly developed Al-2%Cu based alloy. A total of thirteen alloy compositions were used in the study. Tensile test bar castings were prepared employing the low pressure die casting (LPDC) technique. The test bars were solution heat treated at 495°C for 8 hours, followed by quenching in warm water, and then subjected to different isochronal aging treatments using an aging time of 5 hours and aging temperatures of 155°C, 180°C, 200°C, 240°C and 300°C. Tensile testing of as-cast and heat-treated test bars was carried out at room temperature using a strain rate of 4 x 10-4s-1. Five test bars were used per alloy composition/condition. Hardness measurements were also carried out on these alloys using a Brinell hardness tester. The microstructures of selected samples were examined using optical microscopy and electron probe microanalysis (EPMA). The results showed that adding Ti in the amount of 0.15 wt% in the form of Al-5%Ti-1%B master alloy is sufficient to refine the grains in the cast structure in the presence of 200 ppm Sr (0.02 wt%). Addition of Zr and Sc did not contribute further to the grain refining effect. The main role of addition of these two elements appeared in the formation of complex compounds with Al and Ti. Their presence resulted in extending the aging temperature range before the onset of softening. Mathematical analysis of the hardness and tensile data was carried out using the Minitab statistical software program. It was determined that the alloy containing (0.5wt% Zr + 0.15wt% Ti) is the most effective in maximizing the alloy tensile strength over the range of aging temperatures, from 155°C to 300°C. Addition of Ag is beneficial at high aging temperatures, in the range of 240°C-300°C. However, it is less effective compared to the (Zr + Ti

  10. Spray-formed tooling for injection molding and die casting applications

    SciTech Connect

    K. M. McHugh; B. R. Wickham

    2000-06-26

    Rapid Solidification Process (RSP) Tooling{trademark} is a spray forming technology tailored for producing molds and dies. The approach combines rapid solidification processing and net-shape materials processing in a single step. The ability of the sprayed deposit to capture features of the tool pattern eliminates costly machining operations in conventional mold making and reduces turnaround time. Moreover, rapid solidification suppresses carbide precipitation and growth, allowing many ferritic tool steels to be artificially aged, an alternative to conventional heat treatment that offers unique benefits. Material properties and microstructure transformation during heat treatment of spray-formed H13 tool steel are described.

  11. Spray-formed Tooling for Injection Molding and Die Casting Applications

    SciTech Connect

    Mc Hugh, Kevin Matthew

    2000-06-01

    Rapid Solidification Process (RSP) ToolingTM is a spray forming technology tailored for producing molds and dies. The approach combines rapid solidification processing and net-shape materials processing in a single step. The ability of the sprayed deposit to capture features of the tool pattern eliminates costly machining operations in conventional mold making and reduces turnaround time. Moreover, rapid solidification suppresses carbide precipitation and growth, allowing many ferritic tool steels to be artificially aged, an alternative to conventional heat treatment that offers unique benefits. Material properties and microstructure transformation during heat treatment of spray-formed H13 tool steel are described.

  12. Revealing the micromechanisms behind semi-solid metal deformation with time-resolved X-ray tomography.

    PubMed

    Kareh, K M; Lee, P D; Atwood, R C; Connolley, T; Gourlay, C M

    2014-01-01

    The behaviour of granular solid-liquid mixtures is key when deforming a wide range of materials from cornstarch slurries to soils, rock and magma flows. Here we demonstrate that treating semi-solid alloys as a granular fluid is critical to understanding flow behaviour and defect formation during casting. Using synchrotron X-ray tomography, we directly measure the discrete grain response during uniaxial compression. We show that the stress-strain response at 64-93% solid is due to the shear-induced dilation of discrete rearranging grains. This leads to the counter-intuitive result that, in unfed samples, compression can open internal pores and draw the free surface into the liquid, resulting in cracking. A soil mechanics approach shows that, irrespective of initial solid fraction, the solid packing density moves towards a constant value during deformation, consistent with the existence of a critical state in mushy alloys analogous to soils. PMID:25034408

  13. Revealing the micromechanisms behind semi-solid metal deformation with time-resolved X-ray tomography

    PubMed Central

    Kareh, K. M.; Lee, P. D.; Atwood, R. C.; Connolley, T.; Gourlay, C. M.

    2014-01-01

    The behaviour of granular solid–liquid mixtures is key when deforming a wide range of materials from cornstarch slurries to soils, rock and magma flows. Here we demonstrate that treating semi-solid alloys as a granular fluid is critical to understanding flow behaviour and defect formation during casting. Using synchrotron X-ray tomography, we directly measure the discrete grain response during uniaxial compression. We show that the stress–strain response at 64–93% solid is due to the shear-induced dilation of discrete rearranging grains. This leads to the counter-intuitive result that, in unfed samples, compression can open internal pores and draw the free surface into the liquid, resulting in cracking. A soil mechanics approach shows that, irrespective of initial solid fraction, the solid packing density moves towards a constant value during deformation, consistent with the existence of a critical state in mushy alloys analogous to soils. PMID:25034408

  14. The effect of microstructure on the thermal fatigue resistance of investment cast and wrought AISI H13 hot work die steel

    SciTech Connect

    Hochanadel, P.W.; Edwards, G.R.; Maguire, M.C.; Baldwin, M.D.

    1995-07-01

    Variable thickness plate investment castings of AISI H13 hot work die steel were pour and characterized in the as-cast and heat treated conditions. The characterization included light microscopy and mechanical testing. Wrought samples of standard and premium grade H13 steel were heat treated and characterized similarly for comparison. Microstructural differences were observed in as-cast samples poured to different section thicknesses. Dendrite cell size and carbide morphology constituted the most prominent microstructural differences observed. After a full heat treatment, however, Microstructural differences between the wrought material and cast materials were slight regardless of section thickness. The mechanical properties of the cast and heat treated material proved similar to the properties of the standard heat treated wrought material. A thermal fatigue testing unit was designed and built to correlate the heat checking susceptibility of AISI H13 steel to its processing and consequent microstructural condition. Surface hardness decreased significantly with thermal cycling, and heat checking was noticed in as few as 50 cycles. Thermal softening and thermal fatigue susceptibility were quantified and discussed relative to the microstructural conditions created by processing and heat treatment. It was found that the premium grade wrought H13 steel provided the best overall resistance to heat checking; however, the heat-treat cast and as-cast H13 tool steel (made from standard grade wrought H13 tool steel) provided comparable resistance to heat checking in terms Of area fraction of heat checking and maximum crack length.

  15. Predicting the Influence of Pore Characteristics on Ductility of Thin-Walled High Pressure Die Casting Magnesium

    SciTech Connect

    Sun, Xin; Choi, Kyoo Sil; Li, Dongsheng

    2013-06-10

    In this paper, a two-dimensional microstructure-based finite element modeling method is adopted to investigate the effects of porosity in thin-walled high pressure die casting Mg materials on their ductility. For this purpose, the cross-sections of AM50 and AM60 casting samples are first examined using optical microscope to obtain the overall information on the pore characteristics. The experimentally quantified pore characteristics are then used to generate a series of synthetic microstructures with different pore sizes, pore volume fractions and pore size distributions. Pores are explicitly represented in the synthetic microstructures and meshed out for the subsequent finite element analysis. In the finite element analysis, an intrinsic critical strain value is used for the Mg matrix material, beyond which work-hardening is no longer permissible. With no artificial failure criterion prescribed, ductility levels are predicted for the various microstructures in the form of strain localization. Mesh size effect study is also conducted, from which a mesh size dependent critical strain curve is determined. A concept of scalability of pore size effects is then presented and examined with the use of the mesh size dependent critical strain curve. The results in this study show that, for the regions with lower pore size and lower volume fraction, the ductility generally decreases as the pore size and pore volume fraction increase whereas, for the regions with larger pore size and larger pore volume fraction, other factors such as the mean distance between the pores begin to have some substantial influence on the ductility. The results also indicate that the pore size effects may be scalable for the models with good-representative pore shape and distribution with the use of the mesh size dependent critical strain curve.

  16. Effects of Solid-Liquid Mixing on Microstructure of Semi-Solid A356 Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Guo, H. M.; Wang, L. J.; Wang, Q.; Yang, X. J.

    2014-08-01

    The desired starting material for semi-solid processing is the semi-solid slurry in which the solid phase is present as fine and globular particles. A modified solid-liquid mixing (SLM) is reported wherein semi-solid slurry can be produced by mixing a solid alloy block into a liquid alloy, and mechanical vibration is utilized to enhance the mixing. Effects such as liquid alloy temperature, mass ratio, and mixing intensity on the microstructure and the cooling curves during SLM were evaluated. 2D and 3D microstructure analysis of treated A356 aluminum alloy shows that microstructure can be refined significantly with a considerable morphology change in primary Al phase. It is critical that the temperature of mixture after mixing is lower than its liquidus temperature to obtain a valid SLM process. Specially, mixing intensity is identified as a primary factor for a favorable microstructure of semi-solid slurry.

  17. Neurobehavioral testing of subjects exposed residentially to groundwater contaminated from an aluminum die-casting plant and local referents.

    PubMed

    Kilburn, K H; Warshaw, R H

    1993-08-01

    Residents adjoining a die-casting plant had excessive headaches, numbness of hands and feet, dizziness, blurred vision, staggering, sweating, abnormal heart rhythm, and depression, which led to measurements of neurobehavioral performance, affective status, and the frequency of symptoms. They had all been exposed via well water and proximity to the plant to volatile organic chemicals (VOC) and to polychlorinated biphenyls (PCBs). The 117 exposed women and men and 46 unexposed referents were studied together for simple and choice visual reaction time, body sway speed, blink reflex latency, color discrimination, Culture Fair (a nonverbal nonarithmetic intelligence test), recall of stories, figures, and numbers, cognitive and psychomotor control (slotted pegboard and trail making A and B), long-term memory, profile of mood states (POMS), and scores and frequencies of 34 symptoms. Choice reaction time, sway speed, and blink latency were impaired in both sexes of the exposed group and trail making B was impaired in exposed women. The POMS scores and frequencies of 30 of 34 symptoms were elevated in both sexes, compared to referents. Recall, long-term memory, psychomotor speed, and other cognitive function tests were reduced in exposed subjects and in the referents as compared to national referents. Neurophysiological impairment, and cognitive and psychomotor dysfunction and affective disorders, especially depression and excessive frequency of symptoms, were associated with the use of wells contaminated with VOCs, TCE and PCBs. PMID:8345533

  18. Fatigue characterization of high pressure die-cast magnesium AM60B alloy using experimental and computational investigations

    NASA Astrophysics Data System (ADS)

    Lu, You

    The object of the current dissertation is to foster fundamental advances in microstructure-fatigue characteristics of a high pressure die cast magnesium AM60B alloy. First, high cycle fatigue staircase experiments were conducted on specimens extracted from automobile instrument panels. The resulting fracture surfaces were then examined with scanning electron microscopic imaging to elucidate the fatigue crack initiation sites and propagation paths at different stages of the fatigue life. Due to the fact that the qualification of the crack initiation and propagation mechanisms through experiment alone is difficult, complementary micromechanical finite element simulations were conducted. Particularly, the effects of different applied loading conditions and the porosity morphology (e.g. pore shape, pore size, pore spacing, proximity to the free surface) on the maximum plastic shear strain range, as a driving force for crack initiation, were analyzed. Moreover, at the microstructually small crack (MSC) propagation stage, the shielding effects of beta-phase Mg17Al12 particles were systematically studied. Based on the distribution of the maximum principal stress within the particles and the maximum hydrostatic stress along the particle/matrix interfaces, the relative influence of the pre-damaged (fractured or debonded) particles and various particle cluster morphologies were carefully investigated. In the finite element simulations, the constitutive behaviours of AM60B alloy and the alpha-matrix were simulated by the advanced kinematic hardening law tuned with experimentally determined material parameters under cyclic loading.

  19. Influence of Electrolytic Plasma Oxidation Coating on Tensile Behavior of Die-Cast AM50 Alloy Subjected to Salt Corrosion

    NASA Astrophysics Data System (ADS)

    Han, Lihong; Nie, Xueyuan; Zhang, Peng; Zhang, Qiang; Hu, Henry

    Three different thickness ceramic coatings were deposited on die-cast AM50 magnesium alloy in KOH and NaAlO2 solution using electrolytic plasma oxidation (EPO) technology for corrosion prevention. Immersion corrosion tests were carried out in 3.5% NaCl solution for 336 hours to investigate the effect of coating thicknesses on tensile and fracture behaviors of the coated AM50 alloys. The results show that the yield strength (YS) and ultimate tensile strength (UTS) of the coated AM50 alloy subjected to immersion corrosion increase with an increase in coating thicknesses. Further analyses on stress and strain curves indicate that the coating enhances the strain-hardening rates of the corroded alloy during its plastic deformation. SEM examination on the fractured surface manifests that the substrate AM50 alloys exhibit characteristics of ductile deformation with deep dimples. However, brittle features prevail on the fractured surface of the mixed layer of coating plus oxidation corrosion product. Micro cracks were observed between the mixed layer and the AM50 alloy substrate induced by corrosion and within the mixed layer induced by EPO process, which could be responsible for the brittle fracture.

  20. Neurobehavioral testing of subjects exposed residentially to groundwater contaminated from an aluminum die-casting plant and local referents

    SciTech Connect

    Kilburn, K.H.; Warshaw, R.H. )

    1993-08-01

    Residents adjoining a die-casting plant had excessive headaches, numbness of hands and feet, dizziness, blurred vision, staggering, sweating, abnormal heart rhythm, and depression, which led to measurements of neurobehavioral performance, affective status, and the frequency of symptoms. They had all been exposed via well water and proximity to the plant to volatile organic chemicals (VOC) and to polychlorinated biphenyls (PCBs). The 117 exposed women and men and 46 unexposed referents were studied together for simple and choice visual reaction time, body sway speed, blink reflex latency, color discrimination, Culture Fair (a nonverbal nonarithmetic intelligence test), recall of stories, figures, and numbers, cognitive and psychomotor control (slotted pegboard and trail making A and B), long-term memory, profile of mood states (POMS), and scores and frequencies of 34 symptoms. Choice reaction time, sway speed, and blink latency were impaired in both sexes of the exposed group and trail making B was impaired in exposed women. The POMS scores and frequencies of 30 of 34 symptoms were elevated in both sexes, compared to referents. Recall, long-term memory, psychomotor speed, and other cognitive function tests were reduced in exposed subjects and in the referents as compared to national referents. Neurophysiological impairment, and cognitive and psychomotor dysfunction and affective disorders, especially depression and excessive frequency of symptoms, were associated with the use of wells contaminated with VOCs, TCE and PCBs.

  1. Microstructure and corrosion behavior of die-cast AM60B magnesium alloys in a complex salt solution. A slow positron beam study

    SciTech Connect

    Liu, Y. F.; Yang, W.; Qin, Q. L.; Wen, W.; Zhai, T.; Yu, B.; Liu, D. Y.; Luo, A.; Song, GuangLing

    2013-12-15

    The microstructure and corrosion behavior of high pressure die-cast (HPDC) and super vacuum die-cast (SVDC) AM60B magnesium alloys were investigated in a complex salt solution using slow positron beam technique and potentiodynamic polarization tests. The experiments revealed that a CaCO3 film was formed on the surface of the alloys and that the rate of CaCO3 formation for the SVDC alloy with immersion time was slower than that of the HPDC alloy. The larger volume fraction of b-phase in the skin layer of the SVDC alloy than that of the HPDC alloy was responsible for the better corrosion resistance.

  2. Caracterisation rheologique des gelees semi-solides des alliages aluminium-silicium renforces

    NASA Astrophysics Data System (ADS)

    Azzi, Lhoucine

    Semi-solid processing is an attractive alternative to replace the traditional methods of forming materials. To be effective, processing in the semi-solid state must be carried out on alloys with a microstructure whose primary phase is globular. Such structures, commonly called semi-solid slurries, are obtained by mixing of the primary phase during solidification. The knowledge of the rheological properties of the semi-solid slurries is of primary importance for process modeling. Various approaches, some of them reviewed in this work, have been proposed to describe such properties. The main goal of our research is to contribute to the better understanding of the mechanisms involved during semi-solid processing of alloys and composites. A close attention is paid to a new class of aluminium based hybrid composites reinforced by graphite and alumina (Al2O3) or silicon-carbide (SiC), known as GrA-NiRTM. The rheological properties of the semi-solid slurries under investigation were evaluated using two simple techniques of viscosimetry. A rotating spindle viscometer was used to assess the viscosity of the slurries in the liquid and the semi-solid state under various conditions of solidification and shearing rates. The spindle geometries were chosen in order to assure a good quality of mixing of the silicon-carbide-graphite suspension. Apparent viscosities were measured in continuous cooling conditions, for isothermal conditions with different shear rates, for isothermal conditions with a linear increase and step changes in shear rates in the semi-solid temperature range. These experiments allowed us to establish the relationships between the viscosity and the solid fraction for different shear rates. The rheological behaviour of partially remelted alloys and composites was also evaluated using a parallel plate viscometer. Specimen with dendritic and globular structures were deformed at different solid fractions and shear rates. The viscosity, at low shear rates, was

  3. Advances in aluminum casting technology

    SciTech Connect

    Tiryakioglu, M.; Campbell, J.

    1998-01-01

    This symposium focuses on the improvements of aluminum casting quality and reliability through a better understanding of processes and process variables, and explores the latest innovations in casting-process design that allow increasing use of the castings to replace complex assemblies and heavy steel and cast-iron components in aerospace and automotive applications. Presented are 35 papers by international experts in the various aspects of the subject. The contents include: Semisolid casting; Computer-aided designing of molds and castings; Casting-process modeling; Aluminum-matrix composite castings; HIPing of castings; Progress in the US car project; Die casting and die design; and Solidification and properties.

  4. Development of a Fluid-Particle Model in Simulating the Motion of External Solidified Crystals and the Evolution of Defect Bands in High-Pressure Die Casting

    NASA Astrophysics Data System (ADS)

    Bi, Cheng; Xiong, Shoumei; Li, Xiaobo; Guo, Zhipeng

    2016-04-01

    A numerical fluid-particle model was developed to simulate the motion of external solidified crystals (ESCs) in the melt during the filling process of high-pressure die casting (HPDC). Simulation results on a tensile bar casting with two types of ingates (semi-circle and circle) revealed that for a long time scale the ESCs tended to distribute in a ring pattern around the specimen center, whereas for a short time scale the ESC distribution changed constantly from the ring pattern to either the center pattern or the ring-center pattern. It was proposed that the defect bands would form at these areas where two solidification fronts met (where solidification shrinkage occurred), including one originating from the skin layer of the specimen and the other from the ESC region. Accordingly, three types of defect band patterns, which were commonly observed in HPDC experiment, could be successfully simulated and explained using this model.

  5. The Structure and Properties of Inductively Coupled Plasma Assisted Magnetron Sputtered Nanocrystalline NbN Coatings in Corrosion Protective Die Casting Molds.

    PubMed

    Chun, Sung-Yong

    2016-02-01

    Niobium nitride coatings for the surface modified die casting molds with various ICP powers have been prepared using ICP assisted magnetron sputtering. The applied ICP power was varied from 0 to 200 W. The deposited coatings were characterized post-deposition using X-ray diffractometry (XRD) and atomic force microscopy (AFM). Single NbN phased coatings with nano-grain sized (<7.6 nm) were identified. The corrosion resistance and hardness of each coating were evaluated from potentiostat and nanoindentator. Superior corrosion protective coatings in excess of 13.9 GPa were deposited with assistance of ICP plasma during sputtering. PMID:27433719

  6. Improved life of die casting dies of H13 steel by attaining improved mechanical properties and distortion control during heat treatment. Year 1 report, October 1994--September 1995

    SciTech Connect

    Wallace, J.F.; Schwam, D.

    1995-03-01

    Optimum heat treatment of dies (quenching) is critical in ensuring satisfactory service performance: rapid cooling rates increase the thermal fatigue/heat checking resistance of the steel, although very fast cooling rates can also lead to distortion and lower fracture toughness, increasing the danger of catastrophic fracture. Goal of this project is to increase die life by using fast enough quenching rates (> 30 F/min ave cooling rate from 1750 to 550 F, 1/2 in. below working surfaces) to obtain good toughness and fatigue resistance in Premium grade H-13 steel dies. An iterative approach of computer modeling validated by experiment was taken. Cooling curves during gas quenching of H-13 blocks and die shapes were measured under 2, 5, and 7.5 bar N2 and 4 bar Ar. Resulting dimensional changes and residual stresses were determined. To facilitate the computer modeling work, a database of H-13 mechanical and physical properties was compiled. Finite element analysis of the heat treated shapes was conducted. Good fit of modeled vs measured quenched rates was demonstrated for simple die shapes. The models predict well the phase transformation products from the quench. There is good fit between predicted and measured distortion contours; however magnitude of predicted distortion and residual stresses does not match well the measured values. Further fine tuning of the model is required.

  7. Evaluation of the Deformation Behavior of a Semi-solid Hypereutectic Al-Si Alloy Compressed in a Drop-Forge Viscometer

    NASA Astrophysics Data System (ADS)

    Fukui, Yasuyoshi; Nara, Daisaku; Kumazawa, Noriyoshi

    2015-05-01

    The rheological behavior of an Al-25 mass pct Si alloy, i.e., a hypereutectic Al-Si alloy, was investigated to determine its processability under semi-solid forming conditions. To measure the viscosity of the semi-solid alloy, a parallel-plate drop-forge viscometer similar to that devised by Yurko and Flemings was developed. Drop-forge experiments revealed that the viscosity initially decreased as the shear rate increased and subsequently increased as the shear rate decreased. Thus, the viscosity reached a minimum at approximately the maximum shear rate. The summarized relationship between the viscosity, μ [Pa s], and the shear rate, [s-1], can be described by the power-law model μ = 1.78 × 107 -1.5. The decrease in viscosity as a function of the shear rate derived from this equation depends on both the temperature and the applied force but not the duration of deformation. A convex curve was obtained when the effective duration of deformation, i.e., the actual compression time, was plotted as a function of the viscosity and the effective duration of deformation reached a maximum at approximately μ = 30 kPa s ( = 70 s-1). The origin of this profile can be attributed to a combination of both a moderate working time and an adequate deformation, which resulted from a decrease in the deformation resistance accompanied by a lowering of the viscosity. The viscosity at the maximum effective duration of deformation thus corresponds to the transition point for the change in the flow process dominant factor from plastic forming (forging) to casting. Therefore, the viscosity μ = 30 kPa s is believed to be the optimum viscosity for the semi-solid forming of the Al-25 mass pct Si alloy. The approximate temperature condition can be ranged from 855 K to 859 K (582 °C to 586 °C).

  8. The corrosion performance of die-cast magnesium alloy MRI230D in 3.5% NaCl solution saturated with Mg(OH){sub 2}

    SciTech Connect

    Aghion, E. Lulu, N.

    2010-11-15

    The environmental behavior of die-cast magnesium alloy MRI230D designated for high-temperature applications was evaluated in comparison with regular AZ91D alloy. The microstructure examination was carried out using SEM, TEM, and X-ray diffraction analysis; the corrosion performance in 3.5% NaCl solution was evaluated by immersion test, salt spray testing, potentiodynamic polarization analysis, and stress corrosion behavior by Slow Strain Rate Testing (SSRT). Although the general corrosion resistance of MRI230D was slightly improved compared to that of AZ91D alloy its stress corrosion resistance was relatively reduced. The variations in the environmental behavior of the two alloys were mainly due to the differences in their chemical composition and microstructure after die casting. In particular, the differences were related to the reduced Al content in MRI230D and the addition of Ca to this alloy, which consequently affected its relative microstructure and electrochemical characteristics. - Research Highlights: {yields}Corrosion and SCC resistance of a new Mg alloy MRI230D was evaluated vs. regular AZ91D. {yields}MRI230D has a minor advantage in corrosion performance compared with AZ91D. {yields}The SCC resistance of MRI230D by SSRT analysis was relatively reduced. {yields}The reduced SCC resistance of MRI230D was due to the detrimental effect of Ca on ductility.

  9. An analysis of HS6-5-2 steel viscosity in the semi-solid state

    SciTech Connect

    Solek, Krzysztof; Korolczuk-Hejnak, Marta; Slezak, Wojciech; Karbowniczek, Miroslaw

    2011-05-04

    The main objective of this study was an analysis of the rheological properties of selected steel alloy in the semi-solid state. A knowledge of the rheological properties of material is crucial for the numerical modeling of the shaping technology. Semi-solid processing of metal alloys, also known as thixoforming processes, is an innovative method which has many advantages in comparison with classical metal forming and foundry processes. The most significant achievement of this particular study is the application of a viscometer which was specially designed for material tests executed at extremely high temperatures, such as the measurement of liquid or semi-liquid steel viscosity. This paper presents the results of a rheological analysis of HS6-5-2 (PN SW7M) tool steel. It was performed using a rotational viscometer with a stationary external cup. The results were used for the development of mathematical models of the apparent viscosity.

  10. Ultrasonic semi-solid coating soldering 6061 aluminum alloys with Sn-Pb-Zn alloys.

    PubMed

    Yu, Xin-ye; Xing, Wen-qing; Ding, Min

    2016-07-01

    In this paper, 6061 aluminum alloys were soldered without a flux by the ultrasonic semi-solid coating soldering at a low temperature. According to the analyses, it could be obtained that the following results. The effect of ultrasound on the coating which promoted processes of metallurgical reaction between the components of the solder and 6061 aluminum alloys due to the thermal effect. Al2Zn3 was obtained near the interface. When the solder was in semi-solid state, the connection was completed. Ultimately, the interlayer mainly composed of three kinds of microstructure zones: α-Pb solid solution phases, β-Sn phases and Sn-Pb eutectic phases. The strength of the joints was improved significantly with the minimum shear strength approaching 101MPa. PMID:26964943

  11. Research on the Semi-Solid Compressive Deformation Behavior of Ti-7Cu Alloy

    NASA Astrophysics Data System (ADS)

    Chen, Yongnan; Luo, Chuang; Wang, Jiao; Zhao, Yongqing; Chen, Hong

    2016-01-01

    The semi-solid deformation behavior of Ti-7Cu titanium alloy in the temperature range of 1,223 K to 1,473 K and strain rate range of 0.005 to 5 s-1 have been investigated by hot compressive testing. The results show that the maximum and stability stresses decrease with decreasing strain rate and increasing temperature. A yielding occurred to the alloy at a higher strain rate under all experimental temperatures. The flow behaviors were described by a constitutive equation based on the Arrhenius equations and the deformation activate energies is also calculated. By comparing with microstructure of the solid deformation, the liquid in semi-solid deformation can overcome the restriction of the movement of solid particle, which reduced the dislocation pile-up during deformation and caused low deformation resistant stress.

  12. Corrosion Behaviour of A380 Aluminiun Alloy by Semi-Solid Rheocasting

    SciTech Connect

    Forn, A.; Ruperez, E.; Baile, M. T.; Campillo, M.; Menargues, S.; Espinosa, I.

    2007-04-07

    A comparative study was performed on the corrosion behavior of a component of A380 aluminium alloy obtained by Semi-Solid Rheocasting (SSR). The effect of heat treatments T5 and T6 on corrosion resistance was compared with components without heat treatment by SSR processes. Corrosion studies were performed using an acetic acid salt spray test, impedance measurements and polarization curves using a 3,5%Na Cl test solution. The corrosion progress is described by micrographic analysis.

  13. A genetic approach to improved semi-solid forming of metals. Final report for period September 4, 1999 - March 4, 2000

    SciTech Connect

    Klier, Eric M.

    2000-05-04

    Lack of technology for the production of large inexpensive feedstock, with uniform spherical primary phase throughout as required for semi-solid forming, has restricted realization of the full potential for the semi-solid forming process. Furthermore narrow process windows and alloy chemistry restrictions increase process costs and limit performance attributes possible with existing semi-metal systems. Successful semi-solid forming trials utilizing Chesapeake Composites Corporation's DSC{sup TM} Metals for feedstock indicate that this represents a generic approach to providing a permanent highly uniform, spherical solid phase, without electromagnetic or mechanical shearing. This approach also provides for further growth of semi-solid forming by providing for: low cost large diameter billet stock, reduced semi-solid forming costs, extension of semi-solid forming to new alloy systems, and semi-solid formed components with substantially enhanced physical and mechanical properties.

  14. Semi-solid Sucrose Stearate-Based Emulsions as Dermal Drug Delivery Systems

    PubMed Central

    Klang, Victoria; Schwarz, Julia C.; Matsko, Nadejda; Rezvani, Elham; El-Hagin, Nivine; Wirth, Michael; Valenta, Claudia

    2011-01-01

    Mild non-ionic sucrose ester surfactants can be employed to produce lipid-based drug delivery systems for dermal application. Moreover, sucrose esters of intermediate lipophilicity such as sucrose stearate S-970 possess a peculiar rheological behavior which can be employed to create highly viscous semi-solid formulations without any further additives. Interestingly, it was possible to develop both viscous macroemulsions and fluid nanoemulsions with the same chemical composition merely by slight alteration of the production process. Optical light microscopy and cryo transmission electron microscopy (TEM) revealed that the sucrose ester led to the formation of an astonishing hydrophilic network at a concentration of only 5% w/w in the macroemulsion system. A small number of more finely structured aggregates composed of surplus surfactant were likewise detected in the nanoemulsions. These discoveries offer interesting possibilities to adapt the low viscosity of fluid O/W nanoemulsions for a more convenient application. Moreover, a simple and rapid production method for skin-friendly creamy O/W emulsions with excellent visual long-term stability is presented. It could be shown by franz-cell diffusion studies and in vitro tape stripping that the microviscosity within the semi-solid formulations was apparently not influenced by their increased macroviscosity: the release of three model drugs was not impaired by the complex network-like internal structure of the macroemulsions. These results indicate that the developed semi-solid emulsions with advantageous application properties are highly suitable for the unhindered delivery of lipophilic drugs despite their comparatively large particle size and high viscosity. PMID:24310496

  15. Development of microstructure in high-alloy steel K390 using semi-solid forming

    NASA Astrophysics Data System (ADS)

    Opatova, K.; Aisman, D.; Rubesova, K.; Ibrahim, K.; Jenicek, S.

    2016-03-01

    Semi-solid processing of light alloys, namely aluminium and magnesium alloys, is a widely known and well-established process. By contrast, processing of powder steels which have high levels of alloying elements is a rather new subject of research. Thixoforming of high-alloy steels entails a number of technical difficulties. If these are overcome, the method can offer a variety of benefits. First of all, the final product shape and the desired mechanical properties can be obtained using a single forming operation. Semi-solid forming can produce unusual powder steel microstructures unattainable by any other route. Generally, the microstructures, which are normally found in thixoformed steels, consist of large fractions of globular or polygonal particles of metastable austenite embedded in a carbide network. An example is the X210Cr12 steel which is often used for semi-solid processing experiments. A disadvantage of the normal microstructure configuration is the brittleness of the carbide network, in which cracks initiate and propagate, causing low energy fractures. However, there is a newly-developed mini-thixoforming route which produces microstructures with an inverted configuration. Here, the material chosen for this purpose was K390 steel, in which the content of alloying elements is up to 24%. Its microstructure which was obtained by mini- thixoforming did not contain polyhedral austenite grains but hard carbides embedded in a ductile austenitic matrix. This provided the material with improved toughness. The spaces between the austenite grains were filled with a eutectic in which chromium, molybdenum and cobalt were distributed uniformly. After the processing parameters were optimized, complexshaped demonstration products were manufactured by this route. These products showed an extraordinary compressive strength and high wear resistance, thanks to the hardness of their microstructure constituents, predominantly the carbides.

  16. Determination of Material Properties in the Semi-Solid State Using Gleeble Simulator

    SciTech Connect

    Solek, Krzysztof; Kuziak, Roman; Kapranos, Plato

    2007-04-07

    This work shows that the Gleeble thermomechanical simulator can be used to carry out controlled material tests. Although originally the simulator was not designed for testing materials in the semi-solid state, it could be adapted to such tests with only minor changes based on the construction of a special chamber for material heating and moulds for material shaping. To achieve this, a special resistance heating system was developed and installed in the Gleeble simulator. The design of a heating chamber that allows uniform heating of the material was achieved by computer simulations. The numerical model of the resistance heating developed and the results of calculations are described in detail.

  17. A Candida albicans cell wall-linked protein promotes invasive filamentation into semi-solid medium

    PubMed Central

    Zucchi, Paola C.; Davis, Talya R.; Kumamoto, Carol A.

    2011-01-01

    SUMMARY Growth of cells in contact with an abiotic or biological surface profoundly affects cellular physiology. In the opportunistic human pathogen, Candida albicans, growth on a semi-solid matrix such as agar results in invasive filamentation, a process in which cells change their morphology to highly elongated filamentous hyphae that grow into the matrix. We hypothesized that a plasma membrane receptor-type protein would sense the presence of matrix and activate a signal transduction cascade, thus promoting invasive filamentation. In this communication, we demonstrate that during growth in contact with a semi-solid surface, activation of a MAP kinase, Cek1p, is promoted, in part, by a plasma membrane protein termed Dfi1p and results in invasive filamentation. A C. albicans mutant lacking Dfi1p showed reduced virulence in a murine model of disseminated candidiasis. Dfi1p is a relatively small, integral membrane protein that localizes to the plasma membrane. Some Dfi1p molecules become cross-linked to the carbohydrate polymers of the cell wall. Thus, Dfi1p is capable of linking the cell wall to the plasma membrane and cytoplasm. PMID:20384695

  18. Modeling the hydrodynamic and electrochemical efficiency of semi-solid flow batteries

    SciTech Connect

    Brunini, VE; Chiang, YM; Carter, WC

    2012-05-01

    A mathematical model of flow cell operation incorporating hydrodynamic and electrochemical effects in three dimensions is developed. The model and resulting simulations apply to recently demonstrated high energy-density semi-solid flow cells. In particular, state of charge gradients that develop during low flow rate operation and their effects on the spatial non-uniformity of current density within flow cells are quantified. A one-dimensional scaling model is also developed and compared to the full three-dimensional simulation. The models are used to demonstrate the impact of the choice of electrochemical couple on flow cell performance. For semi-solid flow electrodes, which can use solid active materials with a wide variety of voltage-capacity responses, we find that cell efficiency is maximized for electrochemical couples that have a relatively flat voltage vs. capacity curve, operated under slow flow conditions. For example, in flow electrodes limited by macroscopic charge transport, an LiFePO4-based system requires one-third the polarization to reach the same cycling rate as an LiCoO2-based system, all else being equal. Our conclusions are generally applicable to high energy density flow battery systems, in which flow rates can be comparatively low for a given required power. (C) 2012 Elsevier Ltd. All rights reserved.

  19. State transformations and ice nucleation in amorphous (semi-)solid organic aerosol

    NASA Astrophysics Data System (ADS)

    Baustian, K. J.; Wise, M. E.; Jensen, E. J.; Schill, G. P.; Freedman, M. A.; Tolbert, M. A.

    2013-06-01

    Amorphous (semi-)solid organic aerosol particles have the potential to serve as surfaces for heterogeneous ice nucleation in cirrus clouds. Raman spectroscopy and optical microscopy have been used in conjunction with a cold stage to examine water uptake and ice nucleation on individual amorphous (semi-)solid particles at atmospherically relevant temperatures (200-273 K). Three organic compounds considered proxies for atmospheric secondary organic aerosol (SOA) were used in this investigation: sucrose, citric acid and glucose. Internally mixed particles consisting of each organic and ammonium sulfate were also investigated. Results from water uptake experiments followed the shape of a humidity-induced glass transition (Tg(RH)) curve and were used to construct state diagrams for each organic and corresponding mixture. Experimentally derived Tg(RH) curves are in good agreement with theoretical predictions of Tg(RH) following the approach of Koop et al. (2011). A unique humidity-induced glass transition point on each state diagram, Tg'(RH), was used to quantify and compare results from this study to previous works. Values of Tg'(RH) determined for sucrose, glucose and citric acid glasses were 236, 230 and 220 K, respectively. Values of Tg'(RH) for internally mixed organic/sulfate particles were always significantly lower; 210, 207 and 215 K for sucrose/sulfate, glucose/sulfate and citric acid/sulfate, respectively. All investigated SOA proxies were observed to act as heterogeneous ice nuclei at tropospheric temperatures. Heterogeneous ice nucleation on pure organic particles occurred at Sice = 1.1-1.4 for temperatures below 235 K. Particles consisting of 1:1 organic-sulfate mixtures took up water over a greater range of conditions but were in some cases also observed to heterogeneously nucleate ice at temperatures below 202 K (Sice= 1.25-1.38). Polynomial curves were fitted to experimental water uptake data and then incorporated into the Community Aerosol Radiation

  20. Fabrication of metal matrix composite by semi-solid powder processing

    SciTech Connect

    Wu, Yufeng

    2011-01-01

    Various metal matrix composites (MMCs) are widely used in the automotive, aerospace and electrical industries due to their capability and flexibility in improving the mechanical, thermal and electrical properties of a component. However, current manufacturing technologies may suffer from insufficient process stability and reliability and inadequate economic efficiency and may not be able to satisfy the increasing demands placed on MMCs. Semi-solid powder processing (SPP), a technology that combines traditional powder metallurgy and semi-solid forming methods, has potential to produce MMCs with low cost and high efficiency. In this work, the analytical study and experimental investigation of SPP on the fabrication of MMCs were explored. An analytical model was developed to understand the deformation mechanism of the powder compact in the semi-solid state. The densification behavior of the Al6061 and SiC powder mixtures was investigated with different liquid fractions and SiC volume fractions. The limits of SPP were analyzed in terms of reinforcement phase loading and its impact on the composite microstructure. To explore adoption of new materials, carbon nanotube (CNT) was investigated as a reinforcing material in aluminum matrix using SPP. The process was successfully modeled for the mono-phase powder (Al6061) compaction and the density and density distribution were predicted. The deformation mechanism at low and high liquid fractions was discussed. In addition, the compaction behavior of the ceramic-metal powder mixture was understood, and the SiC loading limit was identified by parametric study. For the fabrication of CNT reinforced Al6061 composite, the mechanical alloying of Al6061-CNT powders was first investigated. A mathematical model was developed to predict the CNT length change during the mechanical alloying process. The effects of mechanical alloying time and processing temperature during SPP were studied on the mechanical, microstructural and

  1. Analytical Electron Microscopy for Characterization of Fluid or Semi-Solid Multiphase Systems Containing Nanoparticulate Material

    PubMed Central

    Klang, Victoria; Valenta, Claudia; Matsko, Nadejda B.

    2013-01-01

    The analysis of nanomaterials in pharmaceutical or cosmetic preparations is an important aspect both in formulation development and quality control of marketed products. Despite the increased popularity of nanoparticulate compounds especially in dermal preparations such as emulsions, methods and protocols of analysis for the characterization of such systems are scarce. This work combines an original sample preparation procedure along with different methods of analytical electron microscopy for the comprehensive analysis of fluid or semi-solid dermal preparations containing nanoparticulate material. Energy-filtered transmission electron microscopy, energy-dispersive X-ray spectroscopy, electron energy loss spectroscopy and high resolution imaging were performed on model emulsions and a marketed product to reveal different structural aspects of both the emulsion bulk phase and incorporated nanosized material. An innovative analytical approach for the determination of the physical stability of the emulsion under investigation is presented. Advantages and limitations of the employed analytical imaging techniques are highlighted. PMID:24300401

  2. Semi-solid-state fermentation: a promising alternative for neomycin production by the actinomycete Streptomyces fradiae.

    PubMed

    Machado, Isabel; Teixeira, José A; Rodríguez-Couto, Susana

    2013-06-10

    The production of neomycin by the actinomycete Streptomyces fradiae, under semi-solid-state fermentation conditions was the main subject of this study. Two supports (nylon sponge and orange peelings) were tested in order to determine the most suitable one for the production of neomycin by the above-mentioned microorganism. Nylon sponge led to the highest neomycin production, reaching a maximum value of 13,903 μg/mL on the 10th day of cultivation. As a control, the same experiment was performed under submerged fermentation (SmF) conditions, without solid support. Here the production of neomycin by S. fradiae was about 55-fold lower (i.e. 250 μg/mL) than that obtained for SSF. PMID:23570968

  3. Synchrotron X-ray Tomographic Quantification of Deformation Induced Strain Localisation in Semi-solid Al- 15wt.%Cu

    NASA Astrophysics Data System (ADS)

    Cai, B.; Karagadde, S.; Marrow, T. J.; Connolley, T.; Lee, P. D.

    2015-06-01

    Uniaxial compression and indentation of a semi-solid Al-15wt.%Cu alloy was investigated by high speed synchrotron X-ray microtomography, quantifying the microstructural response of a solidifying alloy to applied strain. Tomograms were continuously acquired whilst performing deformation using a precision thermal-mechanical rig on a synchrotron beamline. The results illustrate how defects and shear bands can form in response to different loading conditions. Using digital volume correlation, the global and localised strains were measured, providing quantitative datasets for granular flow models of semi-solid deformation.

  4. Instrumental and sensory quantification of oral coatings retained after swallowing semi-solid foods.

    PubMed

    Prinz, J F; Huntjens, L; de Wijk, R A

    2006-12-01

    After a mouthful of food has been swallowed, some food material is always retained in the mouth. With semi-solid foods this is in the form of a coating that adheres to the oral mucosa. The amount and location of this material may play an important role in food sensations. In this study two quantitative methods of describing the coatings, generated by a set of 16 model custards varying in degree of lubrication (fat content) and degree of viscosity (starch concentration) are investigated. In the first method, a trained quantitative descriptive analysis panel (N=8) was instructed to take single mouthfuls of semi-solid foods, swallow and then rinse twice for 5s with water and spit out. The turbidity of the rinse water was then measured. During the same session, sensory assessments of the products were obtained. In the second method the thickness of the coating on the anterior and middle one-thirds of the tongue was quantified using a pair of opto-electronic reflectance sensors mounted on a probe which was placed on the tongue, one sensor measuring the anterior part of the tongue the other the posterior (middle third) of the tongue. Turbidity of the first rinse related strongly to the food's viscosity, as well as to sensory attributes associated with the food's fat content and viscosity, such as perceived thickness, creaminess and fattiness. Turbidity of subsequent rinses related primarily to fat content. These results indicate that turbidity of rinse water is a useful tool in fundamental (e.g., food texture research) as well as applied research (e.g., product development and quality assurance in food industry). Reflectance varied primarily with fat content and did not relate well to sensory attributes. PMID:17045954

  5. Urinary casts

    MedlinePlus

    ... Casts in the urine; Fatty casts; Red blood cell casts; White blood cell casts ... The absence of cellular casts or presence of a few hyaline casts is normal. The examples above are common measurements for results of ...

  6. Urinary casts

    MedlinePlus

    ... people with advanced kidney disease and chronic kidney failure . White blood cell (WBC) casts are more common ... Hyaline casts; Granular casts; Renal tubular epithelial casts; Waxy casts; Casts in the ...

  7. Materials for suspension (semi-solid) electrodes for energy and water technologies.

    PubMed

    Hatzell, Kelsey B; Boota, Muhammad; Gogotsi, Yury

    2015-12-01

    Suspension or semi-solid electrodes have recently gained increased attention for large-scale applications such as grid energy storage, capacitive water deionization, and wastewater treatment. A suspension electrode is a multiphase material system comprised of an active (charge storing) material suspended in ionic solution (electrolyte). Gravimetrically, the electrolyte is the majority component and aids in physical transport of the active material. This principle enables, for the first time, scalability of electrochemical energy storage devices (supercapacitors and batteries) previously limited to small and medium scale applications. This critical review describes the ongoing material challenges encompassing suspension-based systems. The research described here combines classical aspects of electrochemistry, colloidal science, material science, fluid mechanics, and rheology to describe ion and charge percolation, adsorption of ions, and redox charge storage processes in suspension electrodes. This review summarizes the growing inventory of material systems, methods and practices used to characterize suspension electrodes, and describes universal material system properties (rheological, electrical, and electrochemical) that are pivotal in the design of high performing systems. A discussion of the primary challenges and future research directions is included. PMID:26412441

  8. The Formulation of Bacteriophage in a Semi Solid Preparation for Control of Propionibacterium acnes Growth

    PubMed Central

    Brown, Teagan L.; Petrovski, Steve; Dyson, Zoe A.; Seviour, Robert; Tucci, Joseph

    2016-01-01

    Aims To isolate and characterise phage which could lyse P. acnes and to formulate the phage into a delivery form for potential application in topical treatment of acne infection. Methods and Results Using standard phage isolation techniques, ten phage capable of lysing P. acnes were isolated from human skin microflora. Their genomes showed high homology to previously reported P. acnes phage. These phage were formulated into cetomacrogol cream aqueous at a concentration of 2.5x108 PFU per gram, and shown to lyse underlying P. acnes cells grown as lawn cultures. These phage formulations remained active for at least 90 days when stored at four degrees Celsius in a light protected container. Conclusions P. acnes phage formulated into cetomacrogol cream aqueous will lyse surrounding and underlying P. acnes bacteria, and are effective for at least 90 days if stored appropriately. Significance and Impact of the Study There are few reports of phage formulation into semi solid preparations for application as phage therapy. The formulation method described here could potentially be applied topically to treat human acne infections. The potential exists for this model to be extended to other phage applied to treat other bacterial skin infections. PMID:26964063

  9. Semi solid matrix formulations of meloxicam and tenoxicam: an in vitro and in vivo evaluation.

    PubMed

    Alladi, Saritha; Shastri, Nalini R

    2015-01-01

    The objective of this study was to improve the dissolution and subsequently the therapeutic efficacy of poorly water soluble BCS class-II drugs meloxicam and tenoxicam, by lipid semi solid matrix (SSM) systems filled in hard gelatin capsules by liquid fill technology. The present research involved preparation of SSM formulations using Gelucire 44/14 as a carrier due to its self emulsifying, wetting and hydrophilic properties. The SSM capsules were characterized by assay, in vitro dissolution studies, moisture uptake, FTIR and DSC. The optimized formulations were also evaluated for their in vivo anti inflammatory activity in rat model. Six to ten fold enhancement in vitro drug release, in both acidic and basic media, was obtained with formulations containing drug to carrier in 1:6 ratio. The absence of drug peak in DSC scans indicated complete dissolution of the drug in carrier, while IR revealed no chemical interaction of pure drug and Gelucire 44/14. The optimized SSM formulations of meloxicam and tenoxicam showed a rapid decrease in paw edema with a significant increase in anti-inflammatory activity. The SSM formulations were successful in providing rapid release of drugs with improved dissolution and in vivo anti-inflammatory activity by liquid fill technology in hard gelatin capsules. PMID:24752862

  10. A Process for Semi-Solid Moulding of High Viscosity Thermoplastic Polymers

    NASA Astrophysics Data System (ADS)

    Frick, Achim; Rochman, Arif; Martin, Peter

    2011-05-01

    A new moulding process for manufacturing micro parts made from high viscosity polymers has been developed as a result of a feasibility study. The process basically involves compression moulding of a polymeric preform by heating it up to its semi-solid state, i.e. between its glass transition temperature and melting temperature. The apparatus is made up of three main parts: a forming device, a single cavity micro mould and an induction heating system. The processing technique was successfully tested in the manufacturing of 10 mm round discs with a flange and inner bore using high viscosity polymers such as polyphenylene sulfide (PPS), polyetheretherketone (PEEK), ultra-high molecular weight polyethylene (UHMW PE) and polytetrafluoroethylene (PTFE). In a further miniaturization study, U-shaped micro seals with an outer diameter up to 2.5 mm were also successfully manufactured from non-injection mouldable PTFE. Thus, the new process is a realistic alternative technique to the existing micro moulding processes with respect to its capability to process a huge variety of polymers, even ultra high viscosity materials and the possibility to create micro parts with non-uniform wall thickness distributions.

  11. Comment on the reported fiber attenuations in the visible regime in 'Fabrication of glass photonic crystal fibers with a die-cast process'

    SciTech Connect

    Feng Xian; Loh, Wei H.; Richardson, David J

    2008-10-01

    We comment on the recent paper by Zhou et al. [Appl. Opt.45, 4433 (2006)APOPAI0003-693510.1364/AO.45.004433], in which transmission losses of 0.2-0.3 dB/m were claimed across the wavelength range 420-900 nm in a high-index (nd=1.80518 at 587.6 nm) SF6 glass-based photonic crystal fiber fabricated by novel die-cast technique. If confirmed, these losses are at least 1 order of magnitude lower than previous reported losses of SF6 photonic crystal fibers from other fabrication approaches. Here we present a statistic survey on the relationship between the refractive index and the bulk material attenuation, based on a large number of commercial Schott optical glasses with the nd ranging between 1.40 and 2.05. It shows that the loss of a high-index (nd=1.80) glass optical fiber should be at the levels of 10-50 dB/m at 420 nm and 1-10 dB/m at 500 nm, respectively. Moreover, the material attenuation of such a high-index glass fiber should intrinsically show a large decay, from 10-50 dB/m at 420 nm to the level of 1 dB/m at 700 nm, which arises from the tail on the UV absorption edge of the high-index glass extending to the visible region. Therefore, we conclude that: (1) the low loss of 0.2-0.3 dB/m reported in the cited paper is abnormally one or two magnitudes lower than the material attenuation that a high-index (nd=1.80) glass optical fiber should have in the range between 420 and 500 nm and that (2) the flat loss curve between 420 and 700 nm in the cited paper deviates greatly from the intrinsic behavior of a high-index (nd=1.80) glass fiber.

  12. Stability, clinical efficacy, and antioxidant properties of Honeybush extracts in semi-solid formulations

    PubMed Central

    Gerber, Gezina S. F. W.; Fox, Lizelle T.; Gerber, Minja; du Preez, Jan L.; van Zyl, Sterna; Boneschans, Banie; du Plessis, Jeanetta

    2015-01-01

    Background: Honeybush extracts (Cyclopia spp.) can be incorporated into skin care products to treat conditions such as skin dryness and can function as an anti-oxidant. Objective: To formulate Honeybush formulations and test it for antioxidant activity, skin penetration, and skin hydrating effects. Materials and Methods: Semi-solid formulations containing either Cyclopia maculata (2%) or Cyclopia genistoides (2%) underwent accelerated stability studies. Membrane release studies, Franz cell skin diffusion and tape stripping studies were performed. Antioxidant potential was determined with the 2-thiobarbituric acid-assay and clinical efficacy studies were performed to determine the formulations' effect on skin hydration, scaliness, and smoothness after 2 weeks of treatment on the volar forearm. Results: The formulations were unstable over 3 months. Membrane release, skin diffusion studies, and tape stripping showed that both formulations had inconclusive results due to extremely low concentrations mangiferin and hesperidin present in the Franz cell receptor compartments, stratum corneum-epidermis, and epidermis-dermis layers of the skin. Honeybush extracts showed antioxidant activity with concentrations above 0.6250 mg/ml when compared to the toxin; whereas mangiferin and hesperidin did not show any antioxidant activity on their own. The semisolid formulations showed the potential to emit their own antioxidant activity. Both formulations improved skin smoothness, although they did not improve skin hydration compared to the placebos. C. maculata reduced the skin scaliness to a larger extent than the placebos and C. genistoides. Conclusion: Honeybush formulations did not penetrate the skin but did, however, show antioxidant activity and the potential to be used to improve skin scaliness and smoothness. PMID:26664024

  13. Evaluation and enhancement of physical stability of semi-solid dispersions containing piroxicam into hard gelatin capsules.

    PubMed

    Karataş, Ayşegül; Bekmezci, Serife

    2013-01-01

    The aim of the study was to investigate the physical stability of the semi-solid dispersions into the hard gelatine capsules prepared with Gelucire 44/14, Labrasol and different additives such as microcrystalline cellulose (MCC), mannitol and lactose (alpha-monohydrate) used for enhancing the stability of the formulations. The master dispersion prepared with only Gelucire 44/14 (20% w/w) and Labrasol (80% w/w) was stored in a refrigerator (5 +/- 3 degrees C), while the modified dispersions with the additives (2% w/w) were kept in a climatic chamber (25 +/- 2 degrees C / 60 +/- 5% RH) for 12 months. Dissolution tests of the semi-solid dispersions were performed in media with different pH's immediatly after preparation and after 3, 6 and 12 months of storage. FTIR and DSC studies were also carried out at the same time points. The ideal storage condition for the master dispersion was found to be at 5 degrees C. The addition of MCC, mannitol and lactose (alpha-monohydrate) to the original dispersion afforded a solidification effect on the formulation at room temperature and showed the same dissolution behavior (not less than 85% of piroxicam within 30 min in pH 1.2, 4.5 and 6.8; and water) with the master. The dispersion including lactose was stable at 25 degrees C for 12 months. However, the ideal period of storage for the modified dispersions including MCC and mannitol was 6 months at 25 degrees C. FTIR and DSC results both confirmed the amorphous state of piroxicam in all semi-solid dispersions under storage conditions for 12 months. PMID:24147368

  14. Purity and stability assessment of a semi-solid poly(ortho ester) used in drug delivery systems.

    PubMed

    Merkli, A; Heller, J; Tabatabay, C; Gurny, R

    1996-05-01

    The research work carried out for developing bioerodible drug delivery devices in which the erosion process was to be confined to the polymer-water interface is at the origin of the discovery of a class of polymers known as poly(ortho esters) (POEs). Thus far, three POE systems have been described. The latest POE was prepared by a transesterification reaction between a triol and an ortho ester, followed by a self-condensation of the reaction product. This polymer, which exhibits viscous characteristics at room temperature, was investigated for use as a drug delivery system in glaucoma filtering surgery. The assessment of POE purity and stability was carried out by a detailed analysis of the influence of the purification procedure and storage conditions. This bioerodible semi-solid POE was purified by a repeated precipitation procedure. Elimination of the small molecular weight oligomers and monomers and of the catalysts and stabilizers used in the synthesis, as well as a decrease of the polydispersity, were obtained with this method. Fourier transform infrared analysis also verified the disappearance of degradation products after the first precipitation. Drying of the precipitated polymer was performed at 40 degrees C in order to avoid thermal degradation of the POE at higher temperatures and to facilitate solvent evaporation through the polymer network by a reduction of polymer viscosity. Water vapour uptake of the polymers stored at different relative humidities has demonstrated the high moisture sensitivity of these semi-solid POEs. The average molecular weight of the polymer and hence its viscosity, as well as the solubility characteristics of the incorporated drug, were found to have a considerable influence on the rate of water vapour absorption and on polymer degradation. The use of inert gas or vacuum to maintain the polymer under anhydrous conditions has been studied. Storage of the semi-solid POE under argon in sealed glass bottles provides good

  15. Effect of Particle Size on the Mechanical Properties of Semi-Solid, Powder-Rolled AA7050 Strips

    NASA Astrophysics Data System (ADS)

    Luo, Xia; Liu, Yunzhong

    2016-07-01

    The AA7050 alloy strips can be successfully prepared by semi-solid powder rolling. The effect and factors of particle size on the microstructure, relative density, and mechanical properties were discussed. The results show that coarse starting powders require less liquid to achieve high relative density, and the formed strips have lower elongation compared with that prepared with the fine starting powders. The strength is more related to defects, whereas elongation partially depends on the grain size. Additionally, the fracture mechanism of strips prepared with fine powders is the ductile fracture because many dimples are observed. For relative density, when the initial liquid fraction is lower than 10%, the difference of deformation degree is the main factor. When the liquid fraction is higher than 10-20%, premature solidification and more particle interfaces are the two main factors.

  16. 75 FR 20387 - Contech Castings, LLC, Including Workers Whose Unemployment Insurance (UI) Wages Are Reported...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2010-04-19

    ... workers are engaged in activities related to the production of aluminum and magnesium die casted component... who were adversely affected by increased imports of aluminum and magnesium die casted component...

  17. Modeling and control of casting and welding processes

    SciTech Connect

    Kou, S.; Mehrabian, R.

    1986-01-01

    This book contains papers divided among the following sections: process monitor and control in welding; plasma processing and refining; strip casting; modelling of welding processes; CAD/CAM in casting; investment and die casting; ingot, continuous and other shape casting; and rapid solidification and microstructural evolution.

  18. Clean Metal Casting

    SciTech Connect

    Makhlouf M. Makhlouf; Diran Apelian

    2002-02-05

    The objective of this project is to develop a technology for clean metal processing that is capable of consistently providing a metal cleanliness level that is fit for a given application. The program has five tasks: Development of melt cleanliness assessment technology, development of melt contamination avoidance technology, development of high temperature phase separation technology, establishment of a correlation between the level of melt cleanliness and as cast mechanical properties, and transfer of technology to the industrial sector. Within the context of the first task, WPI has developed a standardized Reduced Pressure Test that has been endorsed by AFS as a recommended practice. In addition, within the context of task1, WPI has developed a melt cleanliness sensor based on the principles of electromagnetic separation. An industrial partner is commercializing the sensor. Within the context of the second task, WPI has developed environmentally friendly fluxes that do not contain fluorine. Within the context of the third task, WPI modeled the process of rotary degassing and verified the model predictions with experimental data. This model may be used to optimize the performance of industrial rotary degassers. Within the context of the fourth task, WPI has correlated the level of melt cleanliness at various foundries, including a sand casting foundry, a permanent mold casting foundry, and a die casting foundry, to the casting process and the resultant mechanical properties. This is useful in tailoring the melt cleansing operations at foundries to the particular casting process and the desired properties of cast components.

  19. Rheological behavior and microstructural evolution of semi-solid hypereutectic aluminum-silicon-magnesium-copper alloys using rheoforming process

    NASA Astrophysics Data System (ADS)

    Tebib, Mehand

    The aim of the current study was to investigate the rheological behavior and microstructural evolution of hypereutectic Al-Si-Cu and Al-Si-Mg-Cu alloys using conventional and modified SEED process (Swirled Enthalpy Equilibration Device). In the first part; the feasibility of semi-solid processing of hypereutectic Al-Si-Cu A390 alloys using a novel rheoforming process was investigated. A combination of the SEED process, isothermal holding using insulation and addition of solid alloy during swirling was introduced as a novel method to improve the processability of semi-solid A390 slurries. The effects of isothermal holding and the addition of solid alloy on the temperature gradient between the centre and the wall and on the formation of alpha-Al particles were examined. In addition, phosphorus and strontium were added to the molten metal to refine the primary and eutectic silicon structure to facilitate semi-solid processing. It was found that the combination of the SEED process with two additional processing steps can produce semisolid 390 alloys that can be rheoformed. In the second part, the effects of Mg additions ranging from 6 to 15% on the solidification behaviour of hypereutectic Al-155i-xMg-4Cu alloys was investigated using thermodynamic calculations, thermal analysis and extensive microstructural examination. The Mg level strongly influenced the microstructural evolution of the primary Mg2Si phase as well as the solidification behaviour. Thermodynamic predictions using ThermoCalc software reported the occurrence of six reactions, comprising the formation of primary Mg2 Si, two pre-eutectic binary reactions, forming either Mg2Si + Si or Mg2Si + alpha-Al phases, the main ternary eutectic reaction forming Mg2Si + Si + alpha-Al, and two post-eutectic reactions resulting in the precipitation of the Q-Al5Mg8Cu 2Si6 and theta-Al2Cu phases, respectively. Microstructures of the four alloys studied confirmed the presence of these phases, in addition to that of the pi

  20. Preparation and evaluation of valsartan by a novel semi-solid self-microemulsifying delivery system using Gelucire 44/14.

    PubMed

    Zhao, Kun; Yuan, Yue; Wang, Hui; Li, Panpan; Bao, Zhihong; Li, Yue

    2016-10-01

    The aim of the present study was to develop a novel semi-solid self-microemulsifying drug delivery system (SMEDDS) using Gelucire(®) 44/14 as oil with strong solid character to improve the oral bioavailability of poorly soluble drug valsartan. The solubility of valsartan in various excipients was determined, the pseudo-ternary phase diagram was constructed in order to screen the optimal excipients, and DSC analysis was performed to evaluate the melting point of SMEDDS. The optimal drug-loaded SMEDDS formulation was consisted of 30% Gelucire(®) 44/14 (oil), 40% Solutol(®) HS 15 (surfactant), and 30% Transcutol(®) P (cosurfactant) (w/w) with 80 mg valsartan/g excipients. The average droplet sizes of the optimized blank and drug-loaded SMEDDS formulations were 26.20 ± 1.43 and 33.34 ± 2.15 nm, and the melting points of them were 35.6 and 36.8 °C, respectively. The in vitro dissolution rate of optimal semi-solid SMEDDS was increased compared with commercial capsules, resulting in the 2.72-fold and 2.97-fold enhancement of Cmax and AUC0-t after oral administration in rats, respectively. These results indicated that the novel semi-solid SMEDDS formulation could potentially improve the oral bioavailability of valsartan, and the semi-solid SMEDDS was a desirable system than the traditional liquid SMEDDS because it was convenient for preparation, storage and transportation due to semi-solid state at room temperature and melted state at body temperature. PMID:26857923

  1. Production of Trametes pubescens Laccase under Submerged and Semi-Solid Culture Conditions on Agro-Industrial Wastes

    PubMed Central

    Rodriguez, Alexander; Osma, Johann F.; Alméciga-Díaz, Carlos J.; Sánchez, Oscar F.

    2013-01-01

    Laccases are copper-containing enzymes involved in the degradation of lignocellulosic materials and used in the treatment of phenol-containing wastewater. In this study we investigated the effect of culture conditions, i.e. submerged or semi-solid, and copper supplementation on laccase production by Trametespubescens grown on coffee husk, soybean pod husk, or cedar sawdust. The highest specific laccase activity was achieved when the culture was conducted under submerged conditions supplemented with copper (5 mM), and using coffee husk as substrate. The crude extracts presented two laccase isoforms with molecular mass of 120 (Lac1) and 60 kDa (Lac2). Regardless of the substrate, enzymatic crude extract and purified fractions behaved similarly at different temperatures and pHs, most of them presented the maximum activity at 55 °C and a pH range between 2 and 3. In addition, they showed similar stability and electro-chemical properties. At optimal culture conditions laccase activity was 7.69±0.28 U mg-1 of protein for the crude extract, and 0.08±0.001 and 2.86±0.05 U mg-1 of protein for Lac1 and Lac2, respectively. In summary, these results show the potential of coffee husk as an important and economical growth medium to produce laccase, offering a new alternative use for this common agro-industrial byproduct. PMID:24019936

  2. Production of Trametes pubescens laccase under submerged and semi-solid culture conditions on agro-industrial wastes.

    PubMed

    Gonzalez, Juan C; Medina, Sandra C; Rodriguez, Alexander; Osma, Johann F; Alméciga-Díaz, Carlos J; Sánchez, Oscar F

    2013-01-01

    Laccases are copper-containing enzymes involved in the degradation of lignocellulosic materials and used in the treatment of phenol-containing wastewater. In this study we investigated the effect of culture conditions, i.e. submerged or semi-solid, and copper supplementation on laccase production by Trametespubescens grown on coffee husk, soybean pod husk, or cedar sawdust. The highest specific laccase activity was achieved when the culture was conducted under submerged conditions supplemented with copper (5 mM), and using coffee husk as substrate. The crude extracts presented two laccase isoforms with molecular mass of 120 (Lac1) and 60 kDa (Lac2). Regardless of the substrate, enzymatic crude extract and purified fractions behaved similarly at different temperatures and pHs, most of them presented the maximum activity at 55 °C and a pH range between 2 and 3. In addition, they showed similar stability and electro-chemical properties. At optimal culture conditions laccase activity was 7.69 ± 0.28 U mg(-1) of protein for the crude extract, and 0.08 ± 0.001 and 2.86 ± 0.05 U mg(-1) of protein for Lac1 and Lac2, respectively. In summary, these results show the potential of coffee husk as an important and economical growth medium to produce laccase, offering a new alternative use for this common agro-industrial byproduct. PMID:24019936

  3. Controlled delivery of metoclopramide using an injectable semi-solid poly(ortho ester) for veterinary application.

    PubMed

    Schwach-Abdellaoui, Khadija; Moreau, Marinette; Schneider, Marc; Boisramć, Bernard; Gurny, Robert

    2002-11-01

    In animal health care, current therapeutic regimens for gastrointestinal disorders require repeated oral or parenteral dosage forms of anti-emetic agents. However, fluctuations of plasma concentrations produce severe side effects. The aim of this work is to develop a subcutaneous and biodegradable controlled release system containing metoclopramide (MTC). Semi-solid poly(ortho ester)s (POE) prepared by a transesterification reaction between trimethyl orthoacetate and 1,2,6,-hexanetriol were investigated as injectable bioerodible polymers for the controlled release of MTC. MTC is present in the polymeric matrix as a solubilised form and it is released rapidly from the POE by erosion and diffusion because of its acidic character and its high hydrosolubility. If a manual injection is desired, only low molecular weight can be used. However, low molecular weight POEs release the drug rapidly. In order to extend polymer lifetime and decrease drug release rate, a sparingly water-soluble base Mg(OH)(2) was incorporated to the formulation. It was possible to produce low molecular weight POE that can be manually injected and releasing MTC over a period of several days. PMID:12429457

  4. Anodizing Effect on the Wear and Corrosion Behavior of EN AC-46500 Components Produced by Semi-Solid Rheocasting (SSR)

    SciTech Connect

    Forn, A.; Baile, M. T.; Picas, J. A.; Martin, E.; Menargues, S.

    2011-05-04

    In this work the effect of the anodizing process on the surface properties of SSR components was investigated. EN AC-46500 aluminium alloy components were formed using a 700 Ton high pressure machine and an Idra Semi Solid Rheocasting Station (SSR). The samples were heat treated with the aim of modifying the form and distribution of the eutectic silicon phase and after the heat treatment they were shotpeened in different conditions to obtain different surface roughness. Finally, the components were anodized with the purpose of improving the tribological properties and corrosion resistance. Surface modifications were investigated as they might have beneficial effects on the wear and corrosion behaviour.Experiments using a tribometer (ball on disc configuration) were performed in order to evaluate the tribological properties of the material and salt spray corrosion tests were used to study the corrosion resistance. These studies were carried out before and after the anodizing process. The anodized components show a significant improvement of the corrosion and wear resistance under the tested conditions, in spite of the high percentage of intermetallics compounds present in the AC-46500 alloy.

  5. Anodizing Effect on the Wear and Corrosion Behavior of EN AC-46500 Components Produced by Semi-Solid Rheocasting (SSR)

    NASA Astrophysics Data System (ADS)

    Forn, A.; Baile, M. T.; Picas, J. A.; Martín, E.; Menargues, S.

    2011-05-01

    In this work the effect of the anodizing process on the surface properties of SSR components was investigated. EN AC-46500 aluminium alloy components were formed using a 700 Ton high pressure machine and an Idra Semi Solid Rheocasting Station (SSR). The samples were heat treated with the aim of modifying the form and distribution of the eutectic silicon phase and after the heat treatment they were shotpeened in different conditions to obtain different surface roughness. Finally, the components were anodized with the purpose of improving the tribological properties and corrosion resistance. Surface modifications were investigated as they might have beneficial effects on the wear and corrosion behaviour. Experiments using a tribometer (ball on disc configuration) were performed in order to evaluate the tribological properties of the material and salt spray corrosion tests were used to study the corrosion resistance. These studies were carried out before and after the anodizing process. The anodized components show a significant improvement of the corrosion and wear resistance under the tested conditions, in spite of the high percentage of intermetallics compounds present in the AC-46500 alloy.

  6. Nifedipine in semi-solid formulations for topical use in peripheral vascular disease: preparation, characterization, and permeation assay.

    PubMed

    Santis, Ana Karla; de Freitas, Zaida Maria Faria; Ricci-Junior, Eduardo; de Brito-Gitirana, Lycia; Fonseca, Laís Bastos; Santos, Elisabete Pereira

    2013-07-01

    Nifedipine (NFD) has been used for the treatment of cutaneous lesions caused by peripheral vascular disease and diabetic ulcers. NFD was formulated at 8% in three semi-solid formulations: Polaxamer 407 Lecithin Organogel (PLO), PLO plus Transcutol(®), and an oil-in-water (o/w) emulsion. In vitro release and permeation tests were carried out using a synthetic (cellulose acetate) or natural membrane (pig ear skin), respectively, mounted in a Franz-type diffusion cell at 37°C in a constant water bath. As a receptor solution, isotonic phosphate buffer at pH 7.4 was used. All samples were analyzed by high-performance liquid chromatography by employing a previously validated method. The drug flow values were 6.126 ± 0.288, 4.030 ± 0.081, and 6.660 ± 0.254 μg/cm(2)/h for PLO, PLO plus Transcutol(®), and o/w emulsion, respectively. The three formulations did not show significant differences in drug flow, considering p > 0.05. Furthermore, their penetration profiles in both the epidermis and dermis were statistically different. Thus, the incorporation of NFD in PLO, PLO plus Transcutol(®), and o/w emulsion changed the drug thermodynamic activity, as expected. In addition, Transcutol(®) increased the solubility of NFD in the formulation and promoted its penetration in both the epidermis and dermis. PMID:22901029

  7. Exploratory study on H13 steel dies

    SciTech Connect

    Sunwoo, A.J.

    1994-04-01

    Ultrahigh-strength H13 steel is a recommended die material for aluminum die casting; dies made from H13 steel can be safely water- cooled during hot working operations without cracking. However, after time the dies exhibited surface cracking and excessive wear. Erosive wear also occurs owing to high pressure injection of molten Al. An exploratory study was made of the causes for surface cracking of H13 dies. Results suggest that surface cracking is caused by interrelated factors, internal to the die material as well as externally induced conditions.

  8. The usefulness of semi-solid medium in the isolation of highly virulent Leptospira strains from wild rats in an urban area of Fukuoka, Japan.

    PubMed

    Saito, Mitsumasa; Villanueva, Sharon Y A M; Masuzawa, Toshiyuki; Haraguchi, Yusuke; Ita, Shuhei; Miyahara, Satoshi; Ozuru, Ryo; Yamaguchi, Takayoshi; Yoshimura, Michinobu; Ikejiri, Mami; Aramaki, Natsumi; Amran, Muhammad Yunus; Muslich, Lisa Tenriesa; Iida, Ken-ichiro; Yanagihara, Yasutake; Gloriani, Nina G; Yoshida, Shin-ichi

    2015-06-01

    Leptospirosis is a worldwide zoonosis. The importance of urban leptospirosis is recognized in Japan: urban rats carry pathogenic leptospires and people acquire these pathogens through contact with surface water or soil contaminated by the urine of the infected animals. To determine the current Leptospira carriage rate in urban rats, 29 wild rats were trapped in the central area of Fukuoka and strains isolated from their kidneys and urine analyzed. When semi-solid Korthof's medium containing 0.1% agar was used for isolation, 72.2% and 30.8% of the kidney and urine cultures, respectively, were found to be Leptospira-positive. The isolates belonged to Leptospira interrogans, and were classified into two groups (serogroups Pomona and Icterohaemorrhagiae) based on the results of gyrB sequence analysis and microscopic agglutination testing (MAT). Strains belonging to serogroup Icterohemorrhagiae grew well in liquid medium. On the other hand, serogroup Pomona isolates multiplied very little in liquid medium, but did grow in a semi-solid medium. Although strains belonging to serogroup Pomona have not been recognized as native to Japan, this strain may be widely distributed in urban rats. Representative strains from each group were found to be highly pathogenic to hamsters. Our findings should serve as a warning that it is still possible to become infected with leptospires from wild rats living in inner cities of Japan. Furthermore, the use of semi-solid medium for culture will improve the isolation rate of leptospires from the kidneys of wild rats. PMID:25890990

  9. Influence of drug content, type of semi-solid vehicle and rheological properties on the skin penetration of the model drug fludrocortisone acetate.

    PubMed

    Nagelreiter, C; Raffeiner, S; Geyerhofer, C; Klang, V; Valenta, C

    2013-05-01

    Throughout Europe, topical creams containing corticosteroids are diluted with various neutral cream bases to meet the specific needs of patients. Even though this practice has been common for years, its effect has not been thoroughly investigated and so the effectiveness of the diluted topical steroidal creams is difficult to predict. In the present study, the model drug fludrocortisone acetate was incorporated into three cream bases of different hydrophilicity that are commonly used in Austria. Different final drug concentrations were chosen for comparative studies. Additionally, a semi-solid preparation developed by our group was investigated for comparison. These formulations were tested in diffusion and tape stripping experiments. Diffusion cell studies showed that changes in drug concentration do not necessarily change the skin permeation behaviour in vitro. The tape stripping protocol was successfully optimised for investigation of semi-solid preparations to provide reproducible and accurate results despite the challenges of investigating semi-solid formulations. The results showed that tape stripping experiments are more suitable to elucidate subtle differences between formulations. The composition of the cream bases exhibited stronger effects on the skin penetration of the steroidal drug irrespective of its concentration than the rheological properties. No correlation between formulation viscosity and skin penetration was found. PMID:23541986

  10. Optimization of Composition and Heat Treating of Die Steels for Extended Lifetime

    SciTech Connect

    David Schwam; John F. Wallace; Quanyou Zhou

    2002-01-30

    An ''average'' die casting die costs fifty thousand dollars. A die used in making die cast aluminum engine blocks can cost well over one million dollars. These costs provide a strong incentive for extension of die life. While vacuum quenched Premium Grade H13 dies have become the most widely used in the United States, tool makers and die casters are constantly searching for new steels and heat treating procedures to extend die life. This project was undertaken to investigate the effects of composition and heat treating on die life and optimize these parameters.

  11. Impact properties of zinc die cast alloys

    SciTech Connect

    Schrems, Karol K.; Dogan, Omer N.; Manahan, M.P.; Goodwin, F.E.

    2005-01-01

    Alloys 3, 5, AcuZinc 5, and ZA-8 were tested at five temperatures between -40 C and room temperature to determine impact properties. Izod impact energy data was obtained in accordance with ASTM D256. Unlike ASTM E23, these samples were tested with a milled notch in order to compare with plastic samples. In addition, flexural data was obtained for design use.

  12. Qualitative Reasoning for Additional Die Casting Applications

    SciTech Connect

    R. Allen Miller; Dehua Cui; Yuming Ma

    2003-05-28

    If manufacturing incompatibility of a product can be evaluated at the early product design stage, the designers can modify their design to reduce the effect of potential manufacturing problems. This will result in fewer manufacturing problems, less redsign, less expensive tooling, lower cost, better quality, and shorter development time. For a given design, geometric reasoning can predict qualitatively the behaviors of a physical manufacturing process by representing and reasoning with incomplete knowledge of the physical phenomena. It integrates a design with manufacturing processes to help designers simultaneously consider design goals and manufacturing constraints during the early design stage. The geometric reasoning approach can encourage design engineers to qualitatively evaluate the compatibility of their design with manufacturing limitations and requirements.

  13. Factors Associated with Early Introduction of Formula and/or Solid, Semi-Solid or Soft Foods in Seven Francophone West African Countries

    PubMed Central

    Issaka, Abukari I.; Agho, Kingsley E.; Page, Andrew N.; Burns, Penelope L.; Stevens, Garry J.; Dibley, Michael J.

    2015-01-01

    The aim of this study was to identify factors associated with early introduction of formula and/or solid, semi-solid or soft foods to infants aged three to five months in seven Francophone West African countries. The sources of data for the analyses were the most recent Demographic and Health Survey datasets of the seven countries, namely Benin (BDHS, 2012), Burkina Faso (BFDHS, 2010), Cote d’Ivoire (CIDHS, 2011–2012), Guinea (GDHS, 2012), Mali (MDHS, 2012–2013), Niger (NDHS, 2012) and Senegal (SDHS, 2010). The study used multiple logistic regression methods to analyse the factors associated with early introduction of complementary feeding using individual-, household- and community-level determinants. The sample was composed of 4158 infants aged between three and five months with: 671 from Benin, 811 from Burkina Faso, 362 from Cote d’Ivoire, 398 from Guinea, 519 from Mali, 767 from Niger and 630 from Senegal. Multiple analyses indicated that in three of the seven countries (Benin, Guinea and Senegal), infants who suffered illnesses, such as diarrhoea and acute respiratory infection, were significantly more likely to be introduced to formula and/or solid, semi-solid or soft foods between the age of three and five months. Other significant factors included infants who: were born in second to fourth position (Benin), whose mothers did not attend any antenatal clinics (Burkina Faso and Niger), were male (Cote d’Ivoire and Senegal), lived in an urban areas (Senegal), or were delivered by traditional birth attendants (Guinea, Niger and Senegal). Programmes to discourage early introduction of formula and/or solid, semi-solid or soft foods in these countries should target the most vulnerable segments of the population in order to improve exclusive breastfeeding practices and reduce infant mortality. PMID:25647663

  14. SPHERICAL DIE

    DOEpatents

    Livingston, J.P.

    1959-01-27

    A die is presented for pressing powdered materials into a hemispherical shape of uniforin density and wall thickness comprising a fcmale and male die element held in a stationary spaced relation with the space being equivalent to the wall thickness and defining the hemispherical shape, a pressing ring linearly moveable along the male die element, an inlet to fill the space with powdered materials, a guiding system for moving the pressing ring along the male die element so as to press the powdered material and a heating system for heating the male element so that the powdered material is heated while being pressed.

  15. Rapid Tooling via Investment Casting and Rapid Prototype Patterns

    SciTech Connect

    Baldwin, Michael D.

    1999-06-01

    The objective of this work to develop the materials processing and design technologies required to reduce the die development time for metal mold processes from 12 months to 3 months, using die casting of Al and Mg as the example process. Sandia demonstrated that investment casting, using rapid prototype patterns produced from Stereo lithography or Selective laser Sintering, was a viable alternative/supplement to the current technology of machining form wrought stock. A demonstration die insert (ejector halt) was investment cast and subsequently tested in the die casting environment. The stationary half of the die insert was machined from wrought material to benchmark the cast half. The two inserts were run in a die casting machine for 3,100 shots of aluminum and at the end of the run no visible difference could be detected between the cast and machined inserts. Inspection concluded that the cast insert performed identically to the machined insert. Both inserts had no indications of heat checking or degradation.

  16. Flow simulation and solidification phenomena of AC4CH aluminum alloy in semi-solid forging process by explicit MPS method

    NASA Astrophysics Data System (ADS)

    Regmi, Amit; Shintaku, Hiroki; Sasaki, Tsutomu; Koshizuka, Seiichi

    2015-09-01

    Semi-solid forging (SSF) is a powerful manufacturing technology to fabricate near-net shaped products in automotive industries. During SSF process, the filling behavior and solidification process of AC4CH aluminum alloy is presented in this paper. The explicit MPS method program solving Navier-Stokes equation is coupled with heat transfer and solidification has been used to predict the filling pattern and temperature distribution of semi-solid material (SSM). The non-Newtonian rheological model was used as the constitutive equation of SSM. In this study, numerical analysis of SSF was carried out in box cavity with various flange thickness (4, 8, 12 and 16 mm) and corresponding experiments were undertaken for AC4CH aluminum alloy with solid fraction less than 0.5. The numerical results of SSM filling pattern and solidification phenomena in flange were validated with the experimental results. During solidification process, flow calculation was stopped and only thermal calculation was carried out. The shrinkage defect was well predicted near the lower mid area of the box cavity with flange thickness 16 mm.

  17. Pigmented casts.

    PubMed

    Miteva, Mariya; Romanelli, Paolo; Tosti, Antonella

    2014-01-01

    Pigmented casts have been reported with variable frequency in scalp biopsies from alopecia areata, trichotillomania, chemotherapy-induced alopecia and postoperative (pressure induced) alopecia. Their presence and morphology in other scalp disorders has not been described. The authors assessed for the presence and morphology of pigmented casts in 308 transversely bisected scalp biopsies from nonscarring and scarring alopecia, referred to the Department of Dermatology, University of Miami within a year. The pigmented casts were present in 21 of 29 cases of alopecia areata (72%), 7 of 7 cases of trichotillomania (100%), 1 case of friction alopecia, 4 of 28 cases of central centrifugal cicatricial alopecia (14%), and 4 of 4 cases of dissecting cellulitis (100%). They did not show any distinguishing features except for the morphology in trichotillomania, which included twisted, linear (zip), and "button"-like pigment aggregation. The linear arrangement was found also in friction alopecia and dissecting cellulitis. Pigmented casts in the hair canals of miniaturized/vellus hairs was a clue to alopecia areata. Pigmented casts can be observed in biopsies of different hair disorders, but they are not specific for the diagnosis. Horizontal sections allow to better assess their morphology and the follicular level of presence of pigmented casts, which in the context of the other follicular findings may be a clue to the diagnosis. PMID:23823025

  18. Predicting Pattern Tooling and Casting Dimensions for Investment Casting - Phase II

    SciTech Connect

    Sabau, Adrian S

    2005-09-01

    The investment casting process allows the production of complex-shape parts and close dimensional tolerances. One of the most important phases in the investment casting process is the design of the pattern die. Pattern dies are used to create wax patterns by injecting wax into dies. The wax patterns are used to create a ceramic shell by the application of a series of ceramic coatings, and the alloy is cast into the dewaxed shell mold (Fig. 1.1). However, the complexity of shape and the close dimensional tolerances required in the final casting make it difficult to determine tooling dimensions. The final linear dimension of the casting depends on the cumulative effects of the linear expansions or contractions in each step of the investment casting process (Fig. 1.2). In most cases, the mold geometry or cores restrict the shrinkage of the pattern or the cast part, and the final casting dimensions may be affected by time-dependent processes such as viscoelastic deformation of the wax, and viscoplastic creep and plastic deformations of the shell and alloy. The pattern die is often reworked several times to produce castings whose dimensions are within acceptable tolerances. To date, investment casting technology has been based on hands-on training and experience. Technical literature is limited to experimental, phenomenological studies aimed at obtaining empirical correlations for quick and easy application in industry. The goal of this project was to predict casting dimensions for investment castings in order to meet blueprint nominal during the first casting run. Several interactions have to be considered in a coupled manner to determine the shrinkage factors: these are the die-wax, wax-shell, and shell-alloy interactions (as illustrated in Fig. 1.3). In this work, the deformations of the die-wax and shell-alloy systems were considered in a coupled manner, while the coupled deformation of the wax-shell system was not considered. Future work is needed in order to

  19. Mechanical properties and constitutive behaviors of as-cast 7050 aluminum alloy from room temperature to above the solidus temperature

    NASA Astrophysics Data System (ADS)

    Bai, Qing-ling; Li, Hong-xiang; Du, Qiang; Zhang, Ji-shan; Zhuang, Lin-zhong

    2016-08-01

    The mechanical properties and constitutive behaviors of as-cast AA7050 in both the solid and semi-solid states were determined using the on-cooling and in situ solidification approaches, respectively. The results show that the strength in the solid state tends to increase with decreasing temperature. The strain rate plays an important role in the stress-strain behaviors at higher temperatures, whereas the influence becomes less pronounced and irregular when the temperature is less than 250°C. The experimental data were fitted to the extended Ludwik equation, which is suitable to describe the mechanical behavior of the materials in the as-cast state. In the semi-solid state, both the strength and ductility of the alloy are high near the solidus temperature and decrease drastically with decreasing solid fraction. As the solid fraction is less than 0.97, the maximum strength only slightly decreases, whereas the post-peak ductility begins to increase. The experimental data were fitted to the modified creep law, which is used to describe the mechanical behavior of semi-solid materials, to determine the equivalent parameter f GBWL, i.e., the fraction of grain boundaries covered by liquid phase.

  20. Application of the Eyring Equation in the Evaluation of Semi-Solid Forming-Induced Si Particle Refinement in the Hypereutectic Al-Si Alloys

    NASA Astrophysics Data System (ADS)

    Fukui, Yasuyoshi; Nara, Daisaku; Fushimi, Kazuyo; Kumazawa, Noriyoshi

    2015-12-01

    On the basis of Eyring's theory of absolute reaction rate, an approach to modeling Si particle refinement acceleration in the semi-solid forming of a hypereutectic Al-Si alloy has been developed. The acceleration variable data used in the present analysis were obtained from a semi-solid compression test using Al-25 mass pct Si alloy cylindrical specimens with a diameter of 15 mm and a height of 15 mm; the test conditions comprised a combination of compression displacements ∆ h = 5, 10, and 12 mm; compression rates v = 5, 25, and 125 mm/min; and test temperatures T = 853 K and 863 K (580 °C and 590 °C). The coarse primary Si particle refinement depends on a complex interaction among variables, such as compression displacement, compression rate, and test temperature. The performance of Si particle refinement degraded under higher temperature, slower strain rates, and slower shear rates. The results of the Si particle size are suitably summarized by the Eyring equation as a function of the temperature and the shear rate. The baseline Si particle size and the baseline temperature of Si particle refinement, i.e., the reference temperature, were G N = 0.27 mm and T N = 866.4 K (593.4 °C), respectively. The calculated results using this equation correlated well with the observed results. An acceleration factor of Si particle refinement was successfully derived on the basis of this equation and indicated that operating at a higher shear rate and a temperature just above the melting point of eutectic Al-Si alloy are the optimum conditions for refining Si particles.

  1. Project CAST.

    ERIC Educational Resources Information Center

    Charles County Board of Education, La Plata, MD. Office of Special Education.

    The document outlines procedures for implementing Project CAST (Community and School Together), a community-based career education program for secondary special education students in Charles County, Maryland. Initial sections discuss the role of a learning coordinator, (including relevant travel reimbursement and mileage forms) and an overview of…

  2. A comparative study of the centrifugal and vacuum-pressure techniques of casting removable partial denture frameworks.

    PubMed

    Shanley, J J; Ancowitz, S J; Fenster, R K; Pelleu, G B

    1981-01-01

    A study was undertaken to evaluate two techniques for casting accuracy on removable partial denture frameworks: centrifugal casting and vacuum-pressure casting. A standard metal die with predetermined reference points in a horizontal plane was duplicated in refractory investment. The casts were waxed, and castings of nickel-chrome alloy were fabricated by the two techniques. Both the casts and the castings were measured between the reference points with a measuring microscope. With both casting methods, the differences between the casts and the castings were significant, but no significant differences were found between castings produced by the two techniques. Vertical measurements at three designated points also showed no significant differences between the castings. Our findings indicate that dental laboratories should be able to use the vacuum-pressure method of casting removable partial denture frameworks and achieve accuracy similar to that obtained by the centrifugal method of casting. PMID:7007622

  3. Energy and Technolgy Assessment of Zinc and Magnesium Casting Plants, Technical Report Close-out, August 25,2006

    SciTech Connect

    Twin City Die Castings Company; Tom Heider; North American Die Castings Association

    2006-08-25

    Twin City Die Castings Company of Minneapolis, Minnesota, Twin City Die Castings Company was awarded project No. DE-FG36-05GO15097 to perform plant wide assessments of ten (10) die casting facilities that produce zinc and magnesium alloy castings in order to determine improvements and potential cost savings in energy use. Mr. Heider filled the role of team leader for the project and utilized the North American Die Casting Association (NADCA) to conduct audits at team participant plants so as to hold findings specific to each plant proprietary. The intended benefits of the project were to improve energy use through higher operational and process efficiency for the plants assessed. An improvement in energy efficiency of 5 – 15% was targeted. The primary objectives of the project was to: 1) Expand an energy and technology tool developed by the NADCA under a previous DOE project titled, “Energy and Technology Assessment for Die Casting Plants” for assessing aluminum die casting plants to be more specifically applicable to zinc and magnesium die casting facilities. 2) Conduct ten (10) assessments of zinc and magnesium die casting plants, within eight (8) companies, utilizing the assessment tool to identify, evaluate and recommend opportunities to enhance energy efficiency, minimize waste, and improve productivity. 3) Transfer the assessment tool to the die casting industry at large.

  4. Casting methods

    DOEpatents

    Marsden, Kenneth C.; Meyer, Mitchell K.; Grover, Blair K.; Fielding, Randall S.; Wolfensberger, Billy W.

    2012-12-18

    A casting device includes a covered crucible having a top opening and a bottom orifice, a lid covering the top opening, a stopper rod sealing the bottom orifice, and a reusable mold having at least one chamber, a top end of the chamber being open to and positioned below the bottom orifice and a vacuum tap into the chamber being below the top end of the chamber. A casting method includes charging a crucible with a solid material and covering the crucible, heating the crucible, melting the material, evacuating a chamber of a mold to less than 1 atm absolute through a vacuum tap into the chamber, draining the melted material into the evacuated chamber, solidifying the material in the chamber, and removing the solidified material from the chamber without damaging the chamber.

  5. CASTING APPARATUS

    DOEpatents

    Gray, C.F.; Thompson, R.H.

    1958-09-23

    An apparatus is described for casting small quantities of uranlum. It consists of a crucible having a hole in the bottom with a mold positioned below. A vertical rcd passes through the hole in the crucible and has at its upper end a piercing head adapted to break the oxide skin encasing a molten uranium body. An air tight cylinder surrounds the crucible and mold, and is arranged to be evacuated.

  6. Simulating the deformation of dies in the foundry

    NASA Astrophysics Data System (ADS)

    Chabod, A.; Longa, Y.; Dracon, J. M.; Chailler, K.; Hairy, P.; Da Silva, A.

    2012-07-01

    Digital simulation (QuikCAST, ProCAST) is already used extensively when designing metallic dies for founding, in particular to design filling and gating systems. Simulation of the steady-state temperature cycles of dies has also been mastered. With large castings, the temperature gradient induced between the moulding surface and the rear surfaces of the die leads to deformations that may be large enough to measure, and incompatible with the required dimensional accuracy. The temperature gradient also creates thermal fatigue stresses that cause crazing of the die surface. In the study conducted by CTIF, aimed at measuring tooling deformations, various ways of measuring displacements at high temperatures (with and without contact) were investigated in order to evaluate their capabilities and limitations. An experimental device was designed - a test bench combining a metallic die having a simple geometry, in which an aluminium part could be cast, and instrumentation (temperature and displacement sensors). The deformations of the die were measured during first cycles of temperature homogenization. Concurrently, thermomechanical calculations were carried out on the same geometry using PROCAST. The calculation results are well correlated with the experimental measurements and validate the tools and the calculation methods. This thermomechanical approach makes it possible to optimize die design in the foundry and to predict high-temperature deformations as early as the design stage. Knowledge of these deformations makes it possible in turn to anticipate the geometrical and dimensional variations undergone by the castings themselves and so to improve their accuracy. The designer can act on the temperature of the die or the design of the casting, or create a die in which the expected thermal deformation is reversed so as to produce a casting having the correct dimensions. In short, thermomechanical simulation can be applied to this problem to achieve a better understanding

  7. A new insight into high-strength Ti62Nb12.2Fe13.6Co6.4Al5.8 alloys with bimodal microstructure fabricated by semi-solid sintering.

    PubMed

    Liu, L H; Yang, C; Kang, L M; Qu, S G; Li, X Q; Zhang, W W; Chen, W P; Li, Y Y; Li, P J; Zhang, L C

    2016-01-01

    It is well known that semi-solid forming could only obtain coarse-grained microstructure in a few alloy systems with a low melting point, such as aluminum and magnesium alloys. This work presents that semi-solid forming could also produce novel bimodal microstructure composed of nanostructured matrix and micro-sized (CoFe)Ti2 twins in a titanium alloy, Ti62Nb12.2Fe13.6Co6.4Al5.8. The semi-solid sintering induced by eutectic transformation to form a bimodal microstructure in Ti62Nb12.2Fe13.6Co6.4Al5.8 alloy is a fundamentally different approach from other known methods. The fabricated alloy exhibits high yield strength of 1790 MPa and plastic strain of 15.5%. The novel idea provides a new insight into obtaining nano-grain or bimodal microstructure in alloy systems with high melting point by semi-solid forming and into fabricating high-performance metallic alloys in structural applications. PMID:27029858

  8. A new insight into high-strength Ti62Nb12.2Fe13.6Co6.4Al5.8 alloys with bimodal microstructure fabricated by semi-solid sintering

    PubMed Central

    Liu, L. H.; Yang, C.; Kang, L. M.; Qu, S. G.; Li, X. Q.; Zhang, W. W.; Chen, W. P.; Li, Y. Y.; Li, P. J.; Zhang, L. C.

    2016-01-01

    It is well known that semi-solid forming could only obtain coarse-grained microstructure in a few alloy systems with a low melting point, such as aluminum and magnesium alloys. This work presents that semi-solid forming could also produce novel bimodal microstructure composed of nanostructured matrix and micro-sized (CoFe)Ti2 twins in a titanium alloy, Ti62Nb12.2Fe13.6Co6.4Al5.8. The semi-solid sintering induced by eutectic transformation to form a bimodal microstructure in Ti62Nb12.2Fe13.6Co6.4Al5.8 alloy is a fundamentally different approach from other known methods. The fabricated alloy exhibits high yield strength of 1790 MPa and plastic strain of 15.5%. The novel idea provides a new insight into obtaining nano-grain or bimodal microstructure in alloy systems with high melting point by semi-solid forming and into fabricating high-performance metallic alloys in structural applications. PMID:27029858

  9. A new insight into high-strength Ti62Nb12.2Fe13.6Co6.4Al5.8 alloys with bimodal microstructure fabricated by semi-solid sintering

    NASA Astrophysics Data System (ADS)

    Liu, L. H.; Yang, C.; Kang, L. M.; Qu, S. G.; Li, X. Q.; Zhang, W. W.; Chen, W. P.; Li, Y. Y.; Li, P. J.; Zhang, L. C.

    2016-03-01

    It is well known that semi-solid forming could only obtain coarse-grained microstructure in a few alloy systems with a low melting point, such as aluminum and magnesium alloys. This work presents that semi-solid forming could also produce novel bimodal microstructure composed of nanostructured matrix and micro-sized (CoFe)Ti2 twins in a titanium alloy, Ti62Nb12.2Fe13.6Co6.4Al5.8. The semi-solid sintering induced by eutectic transformation to form a bimodal microstructure in Ti62Nb12.2Fe13.6Co6.4Al5.8 alloy is a fundamentally different approach from other known methods. The fabricated alloy exhibits high yield strength of 1790 MPa and plastic strain of 15.5%. The novel idea provides a new insight into obtaining nano-grain or bimodal microstructure in alloy systems with high melting point by semi-solid forming and into fabricating high-performance metallic alloys in structural applications.

  10. Investment cast AISI H13 tooling for automotive applications

    SciTech Connect

    Maguire, M.C.; Baldwin, M.D.; Hochanadel, P.W.; Edwards, G.R.

    1995-07-01

    While many techniques exist for production of soft tooling, for die casting there is limited recent experience with cast tooling. The most common US alloy used for manufacture of die casting tooling is wrought AISI H13. If the performance of the cast material is comparable to the wrought counterpart, the use of investment cast HI 3 tooling directly from patterns made via rapid prototyping is of considerable interest. A metallurgical study of investment cast H13 was conducted to evaluate the mechanical behavior in simulated die casting applications. Variable thickness plate investment castings of AISI H13 hot work die steel were produced and characterized in the as-cast and heat-treated conditions. The characterization included light microscopy and mechanical testing. Wrought samples of standard and premium grade H13 were heat-treated and characterized similarly for comparison. Microstructural differences were observed in as-cast samples produced in different section thicknesses. Dendrite cell size and carbide morphology constituted the most prominent microstructural differences observed. After a full heat-treatment, microstructural differences between the wrought material and cast materials were slight regardless of section thickness.The mechanical properties of the cast and heat-treated material proved similar to the properties of the standard heat-treated wrought material. A thermal fatigue testing unit was to con-elate the heat checking susceptibility of H13 steel to its processing and consequent microstructural condition. Surface hardness decreased significantly with thermal cycling, and heat checking was observed in as few as 50 cycles. Thermal softening and thermal fatigue susceptibility were quantified and discussed relative to the microstructural conditions created by processing and heat-treatment. It was found that the premium grade wrought H13 steel provided the best overall resistance to heat checking.

  11. Cast aluminum denture base.

    PubMed

    Barco, M T; Dembert, M L

    1987-08-01

    The laboratory procedures for a cast aluminum base denture have been presented. If an induction casting machine is not available, the "two-oven technique" works well, provided the casting arm is kept spinning manually for 4 minutes after casting. If laboratory procedures are executed precisely and with care, the aluminum base denture can be cast with good results. PMID:3305884

  12. Casting the Spirit: A Handmade Legacy

    ERIC Educational Resources Information Center

    Rutenberg, Mona

    2008-01-01

    This article discusses how an art therapist working in a hospital palliative care unit has incorporated a ritual of hand casting to help bring closure to dying patients and family members who are grieving as death approaches. The finished hand sculptures depict the hands of the patients and, sometimes, of their loved ones. They are faithful and…

  13. Casting materials

    DOEpatents

    Chaudhry, Anil R.; Dzugan, Robert; Harrington, Richard M.; Neece, Faurice D.; Singh, Nipendra P.

    2011-06-14

    A foam material comprises a liquid polymer and a liquid isocyanate which is mixed to make a solution that is poured, injected or otherwise deposited into a corresponding mold. A reaction from the mixture of the liquid polymer and liquid isocyanate inside the mold forms a thermally collapsible foam structure having a shape that corresponds to the inside surface configuration of the mold and a skin that is continuous and unbroken. Once the reaction is complete, the foam pattern is removed from the mold and may be used as a pattern in any number of conventional casting processes.

  14. Steel castings by the electroslag casting technique

    NASA Astrophysics Data System (ADS)

    Sikka, V. K.; Mitchell, A.

    1984-10-01

    Electroslag casting facilities in Canada and the United States were reviewed. Several value body castings of 2 1/4 Cr-1 Mo, 9 Cr-1 Mo, and 18% Cr-8% Ni (Mo) steels were made at the University of British Columbia facility. These castings were examined for surface finish, chemical segregation, and macrostructure in the as-cast condition and after various heat treatments. Castings were subjected to tensile, charpy impact, and creep testing. Results of these tests were compared with similar data on wrought material and where applicable, with data on sand castings.

  15. Steel castings by the electroslag casting technique

    SciTech Connect

    Sikka, V.K.; Mitchell, A.

    1984-10-01

    Electroslag casting facilities in Canada and the United States were reviewed. Several valve body castings of 2 1/4 Cr-1 Mo, 9 Cr-1 Mo, and 18% Cr-8% Ni(Mo) steels were made at the University of British Columbia facility. These castings were examined for surface finish, chemical segregation, and macrostructure in the as-cast condition and after various heat treatments. Castings were subjected to tensile, Charpy impact, and creep testing. Results of these tests were compared with similar data on wrought material and, where applicable, with data on sand castings. 22 figures.

  16. Influence of Unmodified and β-Glycerophosphate Cross-Linked Chitosan on Anti-Candida Activity of Clotrimazole in Semi-Solid Delivery Systems

    PubMed Central

    Szymańska, Emilia; Winnicka, Katarzyna; Wieczorek, Piotr; Sacha, Paweł Tomasz; Tryniszewska, Elżbieta Anna

    2014-01-01

    The combination of an antifungal agent and drug carrier with adjunctive antimicrobial properties represents novel strategy of complex therapy in pharmaceutical technology. The goal of this study was to investigate the unmodified and ion cross-linked chitosan’s influence on anti-Candida activity of clotrimazole used as a model drug in hydrogels. It was particularly crucial to explore whether the chitosans’ structure modification by β-glycerophosphate altered its antifungal properties. Antifungal studies (performed by plate diffusion method according to CLSI reference protocol) revealed that hydrogels obtained with chitosan/β-glycerophosphate displayed lower anti-Candida effect, probably as a result of weakened polycationic properties of chitosan in the presence of ion cross-linker. Designed chitosan hydrogels with clotrimazole were found to be more efficient against tested Candida strains and showed more favorable drug release profile compared to commercially available product. These observations indicate that novel chitosan formulations may be considered as promising semi-solid delivery system of clotrimazole. PMID:25272230

  17. Flow-FISH analysis and isolation of clostridial strains in an anaerobic semi-solid bio-hydrogen producing system by hydrogenase gene target.

    PubMed

    Jen, Chang Jui; Chou, Chia-Hung; Hsu, Ping-Chi; Yu, Sian-Jhong; Chen, Wei-En; Lay, Jiunn-Jyi; Huang, Chieh-Chen; Wen, Fu-Shyan

    2007-04-01

    By using hydrogenase gene-targeted polymerase chain reaction (PCR) and reverse transcriptase PCR (RT-PCR), the predominant clostridial hydrogenase that may have contributed to biohydrogen production in an anaerobic semi-solid fermentation system has been monitored. The results revealed that a Clostridium pasteurianum-like hydrogenase gene sequence can be detected by both PCR and RT-PCR and suggested that the bacterial strain possessing this specific hydrogenase gene was dominant in hydrogenase activity and population. Whereas another Clostridium saccharobutylicum-like hydrogenase gene can be detected only by RT-PCR and suggest that the bacterial strain possessing this specific hydrogenase gene may be less dominant in population. In this study, hydrogenase gene-targeted fluorescence in situ hybridization (FISH) and flow cytometry analysis confirmed that only 6.6% of the total eubacterial cells in a hydrogen-producing culture were detected to express the C. saccharobutylicum-like hydrogenase, whereas the eubacteria that expressed the C. pasteurianum-like hydrogenase was 25.6%. A clostridial strain M1 possessing the identical nucleotide sequences of the C. saccharobutylicum-like hydrogenase gene was then isolated and identified as Clostridium butyricum based on 16S rRNA sequence. Comparing to the original inoculum with mixed microflora, either using C. butyricum M1 as the only inoculum or co-culturing with a Bacillus thermoamylovorans isolate will guarantee an effective and even better production of hydrogen from brewery yeast waste. PMID:17277963

  18. Influence of unmodified and β-glycerophosphate cross-linked chitosan on anti-Candida activity of clotrimazole in semi-solid delivery systems.

    PubMed

    Szymańska, Emilia; Winnicka, Katarzyna; Wieczorek, Piotr; Sacha, Paweł Tomasz; Tryniszewska, Elżbieta Anna

    2014-01-01

    The combination of an antifungal agent and drug carrier with adjunctive antimicrobial properties represents novel strategy of complex therapy in pharmaceutical technology. The goal of this study was to investigate the unmodified and ion cross-linked chitosan's influence on anti-Candida activity of clotrimazole used as a model drug in hydrogels. It was particularly crucial to explore whether the chitosans' structure modification by β-glycerophosphate altered its antifungal properties. Antifungal studies (performed by plate diffusion method according to CLSI reference protocol) revealed that hydrogels obtained with chitosan/β-glycerophosphate displayed lower anti-Candida effect, probably as a result of weakened polycationic properties of chitosan in the presence of ion cross-linker. Designed chitosan hydrogels with clotrimazole were found to be more efficient against tested Candida strains and showed more favorable drug release profile compared to commercially available product. These observations indicate that novel chitosan formulations may be considered as promising semi-solid delivery system of clotrimazole. PMID:25272230

  19. Modeling of cast systems using smoothed-particle hydrodynamics

    NASA Astrophysics Data System (ADS)

    Cleary, Paul; Prakash, Mahesh; Ha, Joseph; Sinnott, Matthew; Nguyen, Thang; Grandfield, John

    2004-03-01

    To understand and control the filling process for metals in high-pressure die casting and ingot casting, researchers have used new flow-simulation software for the modeling of mold filling. Smoothed-particle hydrodynamics (SPH) is a non-conventional computational fluid dynamics method that has been successfully applied to these problems. Due to its mesh-free nature, it can handle complex splashing free surface flows and the differential motion of multiple solid-casting equipment components relatively easily. The ability of SPH to predict the detailed filling patterns of real large-scale automotive die castings is demonstrated in this study, and the use of SPH simulation for wheel shape optimization in ingot casting based on minimizing oxide generation while increasing the throughput is also presented.

  20. Thin Wall Iron Castings

    SciTech Connect

    J.F. Cuttino; D.M. Stefanescu; T.S. Piwonka

    2001-10-31

    Results of an investigation made to develop methods of making iron castings having wall thicknesses as small as 2.5 mm in green sand molds are presented. It was found that thin wall ductile and compacted graphite iron castings can be made and have properties consistent with heavier castings. Green sand molding variables that affect casting dimensions were also identified.

  1. Optimization of Squeeze Casting for Aluminum Alloy Parts

    SciTech Connect

    David Schwam; John F. Wallace; Qingming Chang; Yulong Zhu

    2002-07-30

    This study was initiated with the installation of a new production size UBE 350 Ton VSC Squeeze Casting system in the Metal Casting Laboratory at Case Western University. A Lindberg 75k W electrical melting furnace was installed alongside. The challenge of installation and operation of such industrial-size equipment in an academic environment was met successfully. Subsequently, a Sterling oil die heater and a Visi-Track shot monitoring system were added. A significant number of inserts were designed and fabricated over the span of the project, primarily for squeeze casting different configurations of test bars and plates. A spiral ''ribbon insert'' for evaluation of molten metal fluidity was also fabricated. These inserts were used to generate a broad range of processing conditions and determine their effect on the quality of the squeeze cast parts. This investigation has studied the influence of the various casting variables on the quality of indirect squeeze castings primarily of aluminum alloys. The variables studied include gating design, fill time and fill patter, metal pressure and die temperature variations. The quality of the die casting was assessed by an analysis of both their surface condition and internal soundness. The primary metal tested was an aluminum 356 alloy. In addition to determining the effect of these casting variables on casting quality as measured by a flat plate die of various thickness, a number of test bar inserts with different gating designs have been inserted in the squeeze casting machine. The mechanical properties of these test bars produced under different squeeze casting conditions were measured and reported. The investigation of the resulting properties also included an analysis of the microstructure of the squeeze castings and the effect of the various structural constituents on the resulting properties. The main conclusions from this investigation are as follows: The ingate size and shape are very important since it must

  2. Die Materials for Critical Applications and Increased Production Rates

    SciTech Connect

    David Schwam; John Wallace; Sebastian Birceanu

    2002-11-30

    Die materials for aluminum die-casting need to be resistant to heat checking, and have good resistance to washout and to soldering in a fast flow of molten aluminum. To resist heat checking, die materials should have a low coefficient of thermal expansion, high thermal conductivity, high hot yield strength, good temper softening resistance, high creep strength, and adequate ductility. To resist the washout and soldering, die materials should have high hot hardness, good temper resistance, low solubility in molten aluminum and good oxidation resistance. It is difficult for one material to satisfy with all above requirements. In practice, H13 steel is the most popular material for aluminum die casting dies. While it is not an ideal choice, it is substantially less expensive to use than alternative materials. However, in very demanding applications, it is sometimes necessary to use alternative materials to ensure a reasonable die life. Copper-base, nickel-base alloys and superalloys, titanium-,molybdenum-, tungsten-base alloys, and to some extent yttrium and niobium alloys, have all been considered as potential materials for demanding die casting applications. Most of these alloys exhibit superior thermal fatigue resistance, but suffer from other shortcomings.

  3. Evaluation of Heat Checking and Washout of Heat Resistant Superalloys and Coatings for Die inserts

    SciTech Connect

    David Schwam; John F. Wallace; Yulong Zhu; Edward Courtright; Harold Adkins

    2005-01-30

    This project had two main objectives: (1) To design, fabricate and run a full size test for evaluating soldering and washout in die insert materials. This test utilizes the unique capabilities of the 350 Ton Squeeze Casting machine available in the Case Meal Casting Laboratory. Apply the test to evaluate resistance of die materials and coating, including heat resistant alloys to soldering and washout damage. (2) To evaluate materials and coatings, including heat resistant superalloys, for use as inserts in die casting of aluminum alloys.

  4. DIE Deflection Modeling: Empirical Validation and Tech Transfer

    SciTech Connect

    R. Allen Miller

    2003-05-28

    This report summarizes computer modeling work that was designed to help understand how the die casting die and machine contribute to parting plane separation during operation. Techniques developed in earlier research (8) were applied to complete a large computational experiment that systematically explored the relationship between the stiffness of the machine platens and key dimensional and structural variables (platen area covered, die thickness, platen thickness, thickness of insert and the location of the die with respect to the platen) describing the die/machine system. The results consistently show that there are many significant interactions among the variables and it is the interactions, more than the individual variables themselves, which determine the performance of the machine/die system. That said, the results consistently show that it is the stiffness of the machine platens that has the largest single impact on die separation.

  5. Wege in die Zukunft

    NASA Astrophysics Data System (ADS)

    Kauermann, Göran; Mosler, Karl

    Die Zukunft stellt große Herausforderungen an die Arbeit der Deutschen Statistischen Gesellschaft. Sie betreffen die gestiegenen Anforderungen der Nutzer von Statistik, die Kommunikationsmöglichkeiten des Internets sowie die Dynamik der statistischen Wissenschaften und ihrer Anwendungsgebiete. Das Kapitel 5 beschreibt, wie sich die Gesellschaft diesen Herausforderungen stellt und welche Ziele sie sich in der wissenschaftlichen Zusammenarbeit und im Kampf gegen das Innumeratentum gesetzt hat.

  6. Interfacial heat transfer in squeeze casting of magnesium alloy AM60 with variation of applied pressures and casting wall-thicknesses

    NASA Astrophysics Data System (ADS)

    Zhang, Xuezhi; Fang, Li; Sun, Zhizhong; Hu, Henry; Nie, Xueyuan; Tjong, Jimi

    2015-12-01

    The heat transfer coefficient at the casting-die interface is the most important factor on the solidification process. With the 75-ton hydraulic press machine and P20 steel die mold, 5-step castings of magnesium alloy AM60 with different wall-thicknesses (3, 5, 8, 12, 20 mm) were poured under various hydraulic pressures (30, 60, and 90 MPa) using an indirect squeeze casting process. Thermal histories throughout the die wall and the casting surface have been recorded by fine type-K thermocouples. The in-cavity local pressures measured by pressure transducers were explored at the casting-die interfaces of 5 steps. The casting-die interfacial heat transfer coefficients (IHTC) initially reached a maximum peak value followed by a gradually decline to the lower level. Similar characteristics of IHTC peak values can be observed at the applied pressures of 30, 60 and 90 MPa. With the applied pressure of 90 MPa, the peak IHTC values from steps 1 to 5 varied from 5623 to 10,649 W/m2 K. As the applied hydraulic pressure increased, the IHTC peak value of each step was increased accordingly. The wall thickness also affected IHTC peak values significantly. The peak IHTC value and heat flux increased as the step became thicker. The empirical equations relating the IHTCs to the local pressures and the solidification temperature at the casting surface were developed based on the multivariate linear and polynomial regression.

  7. Cool Cast Facts

    MedlinePlus

    ... outer layer is usually made of plaster or fiberglass. Fiberglass casts are made of fiberglass, which is a plastic that can be shaped. Fiberglass casts come in many different colors — if you' ...

  8. LLNL casting technology

    SciTech Connect

    Shapiro, A.B.; Comfort, W.J. III

    1994-01-01

    Competition to produce cast parts of higher quality, lower rejection rate, and lower cost is a fundamental factor in the global economy. To gain an edge on foreign competitors, the US casting industry must cut manufacturing costs and reduce the time from design to market. Casting research and development (R&D) are the key to increasing US compentiveness in the casting arena. Lawrence Livermore National Laboratory (LLNL) is the home of a wide range of R&D projects that push the boundaries of state-of-the art casting. LLNL casting expertise and technology include: casting modeling research and development, including numerical simulation of fluid flow, heat transfer, reaction/solidification kinetics, and part distortion with residual stresses; special facilities to cast toxic material; extensive experience casting metals and nonmetals; advanced measurement and instrumentation systems. Department of Energy (DOE) funding provides the leverage for LLNL to collaborate with industrial partners to share this advanced casting expertise and technology. At the same time, collaboration with industrial partners provides LLNL technologists with broader insights into casting industry issues, casting process data, and the collective, experience of industry experts. Casting R&D is also an excellent example of dual-use technology; it is the cornerstone for increasing US industrial competitiveness and minimizing waste nuclear material in weapon component production. Annual funding for casting projects at LLNL is $10M, which represents 1% of the total LLNL budget. Metal casting accounts for about 80% of the funding. Funding is nearly equally divided between development directed toward US industrial competitiveness and weapon component casting.

  9. LLNL casting technology

    NASA Astrophysics Data System (ADS)

    Shapiro, A. B.; Comfort, W. J., III

    1994-01-01

    Competition to produce cast parts of higher quality, lower rejection rate, and lower cost is a fundamental factor in the global economy. To gain an edge on foreign competitors, the US casting industry must cut manufacturing costs and reduce the time from design to market. Casting research and development (R&D) are the key to increasing US competiveness in the casting arena. Lawrence Livermore National Laboratory (LLNL) is the home of a wide range of R&D projects that push the boundaries of state-of-the art casting. LLNL casting expertise and technology include: casting modeling research and development, including numerical simulation of fluid flow, heat transfer, reaction/solidification kinetics, and part distortion with residual stresses; special facilities to cast toxic material; extensive experience casting metals and nonmetals; advanced measurement and instrumentation systems. Department of Energy (DOE) funding provides the leverage for LLNL to collaborate with industrial partners to share this advanced casting expertise and technology. At the same time, collaboration with industrial partners provides LLNL technologists with broader insights into casting industry issues, casting process data, and the collective experience of industry experts. Casting R&D is also an excellent example of dual-use technology; it is the cornerstone for increasing US industrial competitiveness and minimizing waste nuclear material in weapon component production. Annual funding for casting projects at LLNL is $10M, which represents 1% of the total LLNL budget. Metal casting accounts for about 80% of the funding. Funding is nearly equally divided between development directed toward US industrial competitiveness and weapon component casting.

  10. Rapid tooling for functional prototyping of metal mold processes: Literature review on cast tooling

    SciTech Connect

    Baldwin, M.D.; Hochanadel, P.W.

    1995-11-01

    This report is a literature review on cast tooling with the general focus on AISI H13 tool steel. The review includes processing of both wrought and cast H13 steel along with the accompanying microstructures. Also included is the incorporation of new rapid prototyping technologies, such as Stereolithography and Selective Laser Sintering, into the investment casting of tool steel. The limiting property of using wrought or cast tool steel for die casting is heat checking. Heat checking is addressed in terms of testing procedures, theories regarding the mechanism, and microstructural aspects related to the cracking.

  11. Evaluation of electroslag castings

    SciTech Connect

    Judkins, R.R.; Sikka, V.K.

    1985-01-01

    Results of evaluations of electroslag castings of ferritic (2-1/4 Cr-1 Mo and 9 Cr-1 Mo) and austenitic (CF8M or type 316) steels are presented. The castings have been characterized for surface finish, cracking, solidification structure, chemical composition, hardness, ferrite distribution, tensile properties, Charpy impact properties, and creep properties. Pertinent data are compared with equivalent data for sand castings and wrought products of the same materials. Based on the results of these studies, the properties of electroslag castings compare favorably with those of sand castings and wrought materials.

  12. Shrinkage Prediction for the Investment Casting of Stainless Steels

    SciTech Connect

    Sabau, Adrian S

    2007-01-01

    In this study, the alloy shrinkage factors were obtained for the investment casting of 17-4PH stainless steel parts. For the investment casting process, unfilled wax and fused silica with a zircon prime coat were used for patterns and shell molds, respectively. Dimensions of the die tooling, wax pattern, and casting were measured using a Coordinate Measurement Machine in order to obtain the actual tooling allowances. The alloy dimensions were obtained from numerical simulation results of solidification, heat transfer, and deformation phenomena. The numerical simulation results for the shrinkage factors were compared with experimental results.

  13. Prediction of ALLOY SHRINKAGE FACTORS FOR THE INVESTMENT CASTING PROCESS

    SciTech Connect

    Sabau, Adrian S

    2006-01-01

    This study deals with the experimental measurements and numerical predictions of alloy shrinkage factors (SFs) related to the investment casting process. The dimensions of the A356 aluminum alloy casting were determined from the numerical simulation results of solidification, heat transfer, fluid dynamics, and deformation phenomena. The investment casting process was carried out using wax patterns of unfilled wax and shell molds that were made of fused silica with a zircon prime coat. The dimensions of the die tooling, wax pattern, and casting were measured, in order to determine the actual tooling allowances. Several numerical simulations were carried out, to assess the level of accuracy for the casting shrinkage. The solid fraction threshold, at which the transition from the fluid dynamics to the solid dynamics occurs, was found to be important in predicting shrinkage factors (SFs). It was found that accurate predictions were obtained for all measued dimensions when the shell mold was considered a deformable material.

  14. Numerical Simulation on the Die Filling Process of the Thixo-Forging of Al-7 wt pct Si/Al-22 wt pct Si Bimetal Composite

    NASA Astrophysics Data System (ADS)

    Wang, Guangxu; Huang, Honghua; Yang, Zhao; Shi, Xiaocheng; He, Xiaolong

    2015-10-01

    A bimetal semi-solid fluid has more complicated flow behaviors than a normal semi-solid fluid during thixo-forging. In order to clarify the detailed properties of the bimetal thixo-forging, the effects of billet temperatures and frictions on flow behaviors of the Al-7 wt pct Si/Al-22 wt pct Si bimetal thixo-forging were investigated by commercial software DEFORM-3D. The simulation results show that shear force was unable to be transferred from the upper billet on the drop die side to the bottom billet on the counter die side efficiently in the initial stage of die filling. Only when the upper billet severely deformed, did the shear force deform the bottom billet. A stiffer upper billet can enhance the efficiency of shear force transfer. The processing temperature, the relative stiffness between the upper billet and bottom billet, and frictions between dies and billets, as well as friction between billets, were important factors to control the interface outline of the bimetal parts. The experimental results are consistent with the simulation results.

  15. Die drool and die drool theory

    NASA Astrophysics Data System (ADS)

    Schmalzer, A. M.; Giacomin, A. Jeffrey

    2013-04-01

    When molten plastic is extruded from a die, it sometimes collects on the open face of the die. Known as die drool, this phenomenon costs plastics manufacturers by requiring die cleaning. This has been attributed to many causes, but none of these has led to an equation for the drool rate. In this work we provide an exact analytical solution for the drool rate, and we base this solution on a postulate of a cohesive slip layer near the die walls. We thus attribute die drool to cohesive failure within the fluid at an internal surface where the fluid slips on itself. We adimensionalize the drool rate with the production rate, and call this the build up ratio, BR. We provide an exact analytical solution for BR when the cohesive slip layer either sticks at the wall. We examine the slit geometry corresponding to sheet or film extrusion.

  16. SLIP CASTING METHOD

    DOEpatents

    Allison, A.G.

    1959-09-01

    S>A process is described for preparing a magnesium oxide slip casting slurry which when used in conjunction with standard casting techniques results in a very strong "green" slip casting and a fired piece of very close dimensional tolerance. The process involves aging an aqueous magnestum oxide slurry, having a basic pH value, until it attains a specified critical viscosity at which time a deflocculating agent is added without upsetting the basic pH value.

  17. Displaced capillary dies

    DOEpatents

    Kalejs, Juris P.; Chalmers, Bruce; Surek, Thomas

    1984-01-01

    An asymmetrical shaped capillary die made exclusively of graphite is used to grow silicon ribbon which is capable of being made into solar cells that are more efficient than cells produced from ribbon made using a symmetrically shaped die.

  18. Displaced capillary dies

    DOEpatents

    Kalejs, Juris P.; Chalmers, Bruce; Surek, Thomas

    1982-01-01

    An asymmetrical shaped capillary die made exclusively of graphite is used to grow silicon ribbon which is capable of being made into solar cells that are more efficient than cells produced from ribbon made using a symmetrically shaped die.

  19. Packaged die heater

    SciTech Connect

    Spielberger, Richard; Ohme, Bruce Walker; Jensen, Ronald J.

    2011-06-21

    A heater for heating packaged die for burn-in and heat testing is described. The heater may be a ceramic-type heater with a metal filament. The heater may be incorporated into the integrated circuit package as an additional ceramic layer of the package, or may be an external heater placed in contact with the package to heat the die. Many different types of integrated circuit packages may be accommodated. The method provides increased energy efficiency for heating the die while reducing temperature stresses on testing equipment. The method allows the use of multiple heaters to heat die to different temperatures. Faulty die may be heated to weaken die attach material to facilitate removal of the die. The heater filament or a separate temperature thermistor located in the package may be used to accurately measure die temperature.

  20. Experimental and numerical study of the effect of mold vibration on aluminum castings alloys

    NASA Astrophysics Data System (ADS)

    Abu-Dheir, Numan

    2005-07-01

    The recent advances in scientific and engineering tools have allowed researchers to integrate more science into manufacturing, leading to improved and new innovative processes. As a result, important accomplishments have been reached in the area of designing and engineering new materials for various industrial applications. This subject is of critical significance because of the impact it could have on the manufacturing industry. In the casting industry, obtaining the desired microstructure and properties during solidification may reduce or eliminate the need for costly thermo-mechanical processing prior to secondary manufacturing processes. Several techniques have been developed to alter and control the microstructure of castings during solidification including semi-solid processing, electromagnetic stirring, electromagnetic vibration, and mechanical vibration. Although it is established that mold vibration can significantly influence the structure and properties of castings, however, most of the studies are generally qualitative, limited to a small range of conditions and no attempts have been made to simulate the effect of vibration on casting microstructure. In this work, a detailed experimental and numerical investigation is carried out to advance the utilization of mold vibration as an effective tool for controlling and modifying the casting microstructure. The effects of a wide range of vibration amplitudes and frequencies on the solidification kinetics, microstructure formation and mechanical properties of Al-Si alloys are examined. Results show strong influence of mold vibration on the resulting casting. The presence of porosity was significantly reduced as a result of mold vibration. In addition, the changes in microstructure and mechanical properties can be successfully represented by the changes in solidification characteristics. Increasing the vibration amplitude tends to reduce the lamellar spacing and change the silicon morphology to become more

  1. Study of protective coatings for aluminum die casting molds

    NASA Astrophysics Data System (ADS)

    Peter, Ildiko; Rosso, Mario; Gobber, Federico Simone

    2015-12-01

    In this paper, the development and characterization of some protective coatings on steel substrate are presented. The coatings are realized by plasma spray techniques. The substrate material used is a Cr-Mo-V based hot work tool steel, initially submitted to vacuum heat treatment to achieve homogeneous hardness. The main attention is focused on the study of wear and on the characterization of the interface between the substrate material and the coating layer, because of their key role in determining the resistance of the coating layer. Simulation of friction and wear processes is performed by pin-on-disk test and the tested samples are observed by scanning electron microscopy.

  2. Casting Footprints for Eternity

    NASA Technical Reports Server (NTRS)

    1999-01-01

    Apollo 11 Astronaut Buzz Aldrin has his footprints casted during the dedication ceremony of the rocket fountain at Building 4200 at Marshall Space Flight Center. The casts of Aldrin's footprints will be placed in the newly constructed Von Braun courtyard representing the accomplishments of the Apollo 11 lunar landing.

  3. HIGH PRESSURE DIES

    DOEpatents

    Wilson, W.B.

    1960-05-31

    A press was invented for subjecting specimens of bismuth, urania, yttria, or thoria to high pressures and temperatures. The press comprises die parts enclosing a space in which is placed an electric heater thermally insulated from the die parts so as not to damage them by heat. The die parts comprise two opposed inner frustoconical parts and an outer part having a double frustoconical recess receiving the inner parts. The die space decreases in size as the inner die parts move toward one another against the outer part and the inner parts, though very hard, do not fracture because of the mode of support provided by the outer part.

  4. An Application of Trapped-Air Analysis to Large Complex High-Pressure Magnesium Casting

    SciTech Connect

    Prindiville, J; Lee, S; Gokhale, A

    2004-07-08

    The usual method for simulating die-castings consists of a solidification analysis of the casting process - a computer calculation of heat transfer between the casting and the die components. The use of cyclic simulations, coupled with the geometric accuracy of the finite element method, has advanced this procedure to the point where it is routinely used for reliable prediction of shrinkage defects in die-castings. Filling analysis is also routinely used to get a glimpse of cavity filling and ensures that overflows are at their most effective location. When coupled with heat transfer, a filling analysis is also very effective in demonstrating the effects of heat loss in the fluid and how it consequentially can negatively affect filling.

  5. Casting the Die before the Die Is Cast: The Importance of the Home Numeracy Environment for Preschool Children

    ERIC Educational Resources Information Center

    Niklas, Frank; Schneider, Wolfgang

    2014-01-01

    Mathematical competencies are important not only for academic achievement at school but also for professional success later in life. Although we know a lot about the impact of "Home Literacy Environment" on the development of early linguistic competencies, research on "Home Numeracy Environment" (HNE) and the assessment of its…

  6. Low Cost Al-Si Casting Alloy As In-Situ Composite for High Temperature Applications

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A.

    2000-01-01

    A new aluminum-silicon (Al-Si) alloy has been successfully developed at NASA- Marshall Space Flight Center (MSFC) that has significant improvement in tensile and fatigue strength at elevated temperatures (500 F-700 F). The alloy offers a number of benefits such as light weight, high hardness, low thermal expansion and high surface wear resistance. In hypereutectic form, this alloy is considered as an in-situ Al-Si composite with tensile strength of about 90% higher than the auto industry 390 alloy at 600 F. This composite is very economically produced by using either conventional permanent steel molds or die casting. The projected material cost is less than $0.90 per pound, and automotive components such as pistons can be cast for high production rate using conventional casting techniques with a low and fully accounted cost. Key Words: Metal matrix composites, In-situ composite, aluminum-silicon alloy, hypereutectic alloy, permanent mold casting, die casting.

  7. INTERIOR VIEW WITH LARGE PIPE CASTING MACHINE CASTING A 48' ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    INTERIOR VIEW WITH LARGE PIPE CASTING MACHINE CASTING A 48' PIPE OPERATOR SPRAYING A POWDER TO HELP SOLIDIFY THE PIPE BEING CENTRIFUGALLY CAST. - United States Pipe & Foundry Company Plant, Pipe Casting & Testing Area, 2023 St. Louis Avenue at I-20/59, Bessemer, Jefferson County, AL

  8. Casting in Sport

    PubMed Central

    DeCarlo, Mark; Malone, Kathy; Darmelio, John; Rettig, Arthur

    1994-01-01

    Attempts by sports medicine professionals to return high school athletes with hand and wrist injuries to competition quickly and safely have been the source of confusion and debate on many playing fields around the country. In addition to the differing views regarding the appropriateness of playing cast usage in high school football, a debate exists among sports medicine professionals as to which material is best suited for playing cast construction. Materials used in playing cast construction should be hard enough to provide sufficient stabilization to the injured area and include adequate padding to absorb blunt impact forces. The purpose of the biomechanical portion of this investigation was to attempt to determine the most appropriate materials for use in constructing playing casts for the hand and wrist by assessing different materials for: 1) hardness using a Shore durometer, and 2) ability to absorb impact using a force platform. Results revealed that RTV11 and Scotchcast were the “least hard” of the underlying casting materials and that Temper Stick foam greatly increased the ability of RTV11 to absorb impact. Assessment of the mechanical properties of playing cast materials and review of current developments in high school football rules are used to aid practitioners in choosing the most appropriate materials for playing cast construction. ImagesFig 1.Fig 2.Fig 3. PMID:16558257

  9. CASTING METHOD AND APPARATUS

    DOEpatents

    Gray, C.F.; Thompson, R.H.

    1958-10-01

    An improved apparatus for the melting and casting of uranium is described. A vacuum chamber is positioned over the casting mold and connected thereto, and a rod to pierce the oxide skin of the molten uranium is fitted into the bottom of the melting chamber. The entire apparatus is surrounded by a jacket, and operations are conducted under a vacuum. The improvement in this apparatus lies in the fact that the top of the melting chamber is fitted with a plunger which allows squeezing of the oxide skin to force out any molten uranium remaining after the skin has been broken and the molten charge has been cast.

  10. CENTRIFUGAL CASTING MACHINE

    DOEpatents

    Shuck, A.B.

    1958-04-01

    A device is described that is specifically designed to cast uraniumn fuel rods in a vacuunn, in order to obtain flawless, nonoxidized castings which subsequently require a maximum of machining or wastage of the expensive processed material. A chamber surrounded with heating elements is connected to the molds, and the entire apparatus is housed in an airtight container. A charge of uranium is placed in the chamber, heated, then is allowed to flow into the molds While being rotated. Water circulating through passages in the molds chills the casting to form a fine grained fuel rod in nearly finished form.

  11. Die singulation method

    SciTech Connect

    Swiler, Thomas P; Garcia, Ernest J; Francis, Kathryn M

    2014-01-07

    A method is disclosed for singulating die from a semiconductor substrate (e.g. a semiconductor-on-insulator substrate or a bulk silicon substrate) containing an oxide layer (e.g. silicon dioxide or a silicate glass) and one or more semiconductor layers (e.g. monocrystalline or polycrystalline silicon) located above the oxide layer. The method etches trenches through the substrate and through each semiconductor layer about the die being singulated, with the trenches being offset from each other around at least a part of the die so that the oxide layer between the trenches holds the substrate and die together. The trenches can be anisotropically etched using a Deep Reactive Ion Etching (DRIE) process. After the trenches are etched, the oxide layer between the trenches can be etched away with a HF etchant to singulate the die. A release fixture can be located near one side of the substrate to receive the singulated die.

  12. Die singulation method

    SciTech Connect

    Swiler, Thomas P.; Garcia, Ernest J.; Francis, Kathryn M.

    2013-06-11

    A method is disclosed for singulating die from a semiconductor substrate (e.g. a semiconductor-on-insulator substrate or a bulk silicon substrate) containing an oxide layer (e.g. silicon dioxide or a silicate glass) and one or more semiconductor layers (e.g. monocrystalline or polycrystalline silicon) located above the oxide layer. The method etches trenches through the substrate and through each semiconductor layer about the die being singulated, with the trenches being offset from each other around at least a part of the die so that the oxide layer between the trenches holds the substrate and die together. The trenches can be anisotropically etched using a Deep Reactive Ion Etching (DRIE) process. After the trenches are etched, the oxide layer between the trenches can be etched away with an HF etchant to singulate the die. A release fixture can be located near one side of the substrate to receive the singulated die.

  13. Extrusion die and method

    DOEpatents

    Lipp, G. Daniel

    1994-04-26

    A method and die apparatus for manufacturing a honeycomb body of rhombic cell cross-section by extrusion through an extrusion die of triangular cell discharge slot configuration, the die incorporating feedholes at selected slot intersections only, such that slot segments communicating directly with the feedholes discharge web material and slot segments not so connected do not discharge web material, whereby a rhombic cell cross-section in the extruded body is provided.

  14. The Ambiguous Dying Syndrome

    ERIC Educational Resources Information Center

    Bern-Klug, Mercedes

    2004-01-01

    More than one-half of the 2.4 million deaths that will occur in the United States in 2004 will be immediately preceded by a time in which the likelihood of dying can best be described as "ambiguous." Many people die without ever being considered "dying" or "at the end of life." These people may miss out on the opportunity to close important…

  15. Old soldiers never die ....

    PubMed Central

    2012-01-01

    An ancestral supersoldier phenotype of Pheidole ants can be recovered when selection for supersoldiers re-emerges, indicating that the developmental potential for caste pathways is retained. PMID:22356770

  16. MOLDS FOR CASTING PLUTONIUM

    DOEpatents

    Anderson, J.W.; Miley, F.; Pritchard, W.C.

    1962-02-27

    A coated mold for casting plutonium comprises a mold base portion of a material which remains solid and stable at temperatures as high as the pouring temperature of the metal to be cast and having a thin coating of the order of 0.005 inch thick on the interior thereof. The coating is composed of finely divided calcium fluoride having a particle size of about 149 microns. (AEC)

  17. Method of casting aerogels

    DOEpatents

    Poco, J.F.

    1993-09-07

    The invention describes a method for making monolithic castings of transparent silica aerogel with densities in the range from 0.001 g/cm[sup 3] to 0.6 g/cm[sup 3]. Various shapes of aerogels are cast in flexible polymer molds which facilitate removal and eliminate irregular surfaces. Mold dimensions are preselected to account for shrinkage of aerogel which occurs during the drying step of supercritical extraction of solvent. 2 figures.

  18. Method of casting aerogels

    DOEpatents

    Poco, John F.

    1993-01-01

    The invention describes a method for making monolithic castings of transparent silica aerogel with densities in the range from 0.001 g/cm.sup.3 to 0.6 g/cm.sup.3. Various shapes of aerogels are cast in flexible polymer molds which facilitate removal and eliminate irregular surfaces. Mold dimensions are preselected to account for shrinkage of alcogel which occurs during the drying step of supercritical extraction of solvent.

  19. Viability changes: Microbiological analysis of dental casts

    PubMed Central

    Žilinskas, Juozas; Junevičius, Jonas; Ramonaitė, Agnė; Pavilonis, Alvydas; Gleiznys, Alvydas; Sakalauskienė, Jurgina

    2014-01-01

    Background This study evaluated the survival of the most prevalent oral bacteria and fungi (Staphylococcus aureus, Klebsiella pneumoniae, Escherichia coli, and Candida albicans) in dental casts, and compared changes in the amounts of these microorganisms at different time intervals to determine how long dental casts may pose threat to the health of dental personnel and patients. Material/Methods When manufacturing the casts, regular water was replaced with sterile distilled water, where suspensions of the studied bacteria or the fungus at certain concentrations were prepared. When the dental casts were fully set (solidified), plaster shavings were examined immediately after the contact of the studied microorganism with the plaster, as well as after 1, 2, 24, 48, 72, 96, and 120 hours. Following that, we measured how the amount of the studied bacteria and fungi in 1 gram of the plaster changed within the studied period of time. Results Klebsiella pneumoniae survived in plaster for up to 4 days, and the reduction in the number of these bacteria became statistically significant after 1 day (p<0.05). Staphylococcus aureus remained viable in plaster for up to 4 days, and the number of these bacteria dropped after 1 day (p<0.05). Escherichia coli disappeared after 2 days, and a reduction was already observed after 2 hours (p<0.05). Candida albicans in plaster models died within 2 days, and a reduction in their number was observed after 1 day (p<0.05). Conclusions The microorganisms did not multiply in the gypsum casts and their number significantly dropped instead of increasing. PMID:24902637

  20. A Winning Cast

    NASA Technical Reports Server (NTRS)

    2001-01-01

    Howmet Research Corporation was the first to commercialize an innovative cast metal technology developed at Auburn University, Auburn, Alabama. With funding assistance from NASA's Marshall Space Flight Center, Auburn University's Solidification Design Center (a NASA Commercial Space Center), developed accurate nickel-based superalloy data for casting molten metals. Through a contract agreement, Howmet used the data to develop computer model predictions of molten metals and molding materials in cast metal manufacturing. Howmet Metal Mold (HMM), part of Howmet Corporation Specialty Products, of Whitehall, Michigan, utilizes metal molds to manufacture net shape castings in various alloys and amorphous metal (metallic glass). By implementing the thermophysical property data from by Auburn researchers, Howmet employs its newly developed computer model predictions to offer customers high-quality, low-cost, products with significantly improved mechanical properties. Components fabricated with this new process replace components originally made from forgings or billet. Compared with products manufactured through traditional casting methods, Howmet's computer-modeled castings come out on top.

  1. (Continuous casting 1985)

    SciTech Connect

    Wilde, R.A.

    1985-06-12

    The report covers the Continuous Casting '85 Conference including informal discussions with conference attendees. In general, the papers presented at the conference concerned an overview of continuous steel casting worldwide, state-of-the-art aspects of steel continuous casting technology including caster startup problems, modifications, control system strategies, energy use profiles, quality control aspects, steel chemistry control, refractories, operational aspects of continuous casters, etc. No papers were presented in the development of thin section or thin strip casting of steel. Informal discussions were held with several conference attendees including (1) Bernard Trentini, Executive Director of the Association Technique De La Siderurgie Francaise in Paris, France (similar to the American Iron and Steel Institute); (2) Dr. Wolfgang Reichelt and Dr. Peter Voss-Spilker both of Mannesmann Demag Huttentechnik -a continuous casting and other steel making machine builder in-lieu of meeting at their plant in Duisburg, FRG on May 31; (3) Ewan C. Hewitt of Devote McKee Corp., Sheffield, England; (4) Wilfried Heinemann, head of R D Dept. at Concast Standard AG in Zurich, Switzerland; and (5) Hideo Ueno, engineer of melting section, Mitsubishi Steel Mfg. Co. Ltd, Tokyo Japan. A visit was made to the Teesside Laboratories of British Steel Corp. for discussions of their thin section casting research program in particular and R D program in general.

  2. Salvaged castings and methods of salvaging castings with defective cast cooling bumps

    DOEpatents

    Johnson, Robert Alan; Schaeffer, Jon Conrad; Lee, Ching-Pang; Abuaf, Nesim; Hasz, Wayne Charles

    2002-01-01

    Castings for gas turbine parts exposed on one side to a high-temperature fluid medium have cast-in bumps on an opposite cooling surface side to enhance heat transfer. Areas on the cooling surface having defectively cast bumps, i.e., missing or partially formed bumps during casting, are coated with a braze alloy and cooling enhancement material to salvage the part.

  3. The effect of Sr and Fe additions on the microstructure and mechanical properties of a direct squeeze cast Al-7Si-0.3Mg alloy

    SciTech Connect

    Dong, J.X.; Karnezis, P.A.; Durrant, G.; Cantor, B.

    1999-05-01

    This article describes the results of an investigation into the microstructure and mechanical properties of a gravity die cast and direct squeeze cast LM25 alloy (Al-7Si-0.3Mg-0.3Fe). The direct squeeze cast LM25 alloy has superior mechanical properties compared to the gravity die cast LM25 alloy, especially with regard to ductility, which is increased from {approximately}1.7 pct for the gravity die cast LM25 alloy to {approximately}8.0 pct for the direct squeeze cast LM25 alloy in the T6 heat-treated conditions. This increase in ductility is due to (1) the removal of porosity, (2) a decrease in Si particle size, and (3) a refinement of the Fe-Si-aluminide particles. High cooling rates in direct squeeze casting result in quench modification of the Si particles, such that chemical modification with Sr or Na may not be required. In addition, direct squeeze casting is more tolerant of Fe impurities in the alloy, due to the formation of smaller Fe-Si-aluminide particles than those in gravity die cast material. The direct squeeze cast LM25 + Fe alloy (Al-7Si-0.3Mg-1.0Fe) has a ductility of {approximately}6.5 pct, compared to that of {approximately}0.5 pct for the gravity die cast LM25 + Fe alloy in the T6 heat-treated condition. This increase in tolerance to Fe impurities can lead to a substantial reduction in manufacturing costs due to (1) reduced raw-material costs, (2) reduced die sticking, and (3) improved die life.

  4. The effect of Sr and Fe additions on the microstructure and mechanical properties of a direct squeeze cast Al-7Si-0.3Mg alloy

    NASA Astrophysics Data System (ADS)

    Dong, J. X.; Karnezis, P. A.; Durrant, G.; Cantor, B.

    1999-05-01

    This article describes the results of an investigation into the microstructure and mechanical properties of a gravity die cast and direct squeeze cast LM25 alloy (Al-7Si-0.3Mg-0.3Fe). The direct squeeze cast LM25 alloy has superior mechanical properties compared to the gravity die cast LM25 alloy, especially with regard to ductility, which is increased from ˜1.7 pct for the gravity die cast LM25 alloy to ˜8.0 pct for the direct squeeze cast LM25 alloy in the T6 heat-treated condition. This increase in ductility is due to (1) the removal of porosity, (2) a decrease in Si particle size, and (3) a refinement of the Fe-Si-aluminide particles. High cooling rates in direct squeeze casting result in quench modification of the Si particles, such that chemical modification with Sr or Na may not be required. In addition, direct squeeze casting is more tolerant of Fe impurities in the alloy, due to the formation of smaller Fe-Si-aluminide particles than those in gravity die cast material. The direct squeeze cast LM25+Fe alloy (Al-7Si-0.3Mg-1.0Fe) has a ductility of ˜6.5 pct, compared to that of ˜0.5 pct for the gravity die cast LM25 + Fe alloy in the T6 heat-treated condition. This increase in tolerance to Fe impurities can lead to a substantial reduction in manufacturing costs due to (1) reduced raw-material costs, (2) reduced die sticking, and (3) improved die life.

  5. A method for determining adequate resistance form of complete cast crown preparations.

    PubMed

    Weed, R M; Baez, R J

    1984-09-01

    A diagram with various degrees of occlusal convergence, which takes into consideration the length and diameter of complete crown preparations, was designed as a guide to assist the dentist to obtain adequate resistance form. To test the validity of the diagram, five groups of complete cast crown stainless steel dies were prepared (3.5 mm long, occlusal convergence 10, 13, 16, 19, and 22 degrees). Gold copings were cast for each of the 50 preparations. Displacement force was applied to the casting perpendicularly to a simulated 30-degree cuspal incline until the casting was displaced. Castings were deformed at margins except for the 22-degree group. Castings from this group were displaced without deformation, and it was concluded that there was a lack of adequate resistance form as predicted by the diagram. The hypothesis that the diagram could be used to predict adequate or inadequate resistance form was confirmed by this study. PMID:6384470

  6. Is Dying Young Worse than Dying Old?

    ERIC Educational Resources Information Center

    Jecker, Nancy S.; Schneiderman, Lawrence J.

    1994-01-01

    Notes that, in contemporary Western society, people feel death of small child is greater injustice than death of older adult and experience correspondingly greater sorrow, anger, regret, or bitterness when very young person dies. Contrasts these attitudes with those of ancient Greece and shows relevance that different attitudes toward death have…

  7. Extrusion die and method

    DOEpatents

    Lipp, G. Daniel

    1994-05-03

    A method and die apparatus for manufacturing a honeycomb body of triangular cell cross-section and high cell density, the die having a combination of (i) feedholes feeding slot intersections and (ii) feedholes feeding slot segments not supplied from slot intersections, whereby a reduction in feedhole count is achieved while still retaining good extrusion efficiency and extrudate uniformity.

  8. Micromechanical die attachment surcharge

    DOEpatents

    Filter, William F.; Hohimer, John P.

    2002-01-01

    An attachment structure is disclosed for attaching a die to a supporting substrate without the use of adhesives or solder. The attachment structure, which can be formed by micromachining, functions purely mechanically in utilizing a plurality of shaped pillars (e.g. round, square or polygonal and solid, hollow or slotted) that are formed on one of the die or supporting substrate and which can be urged into contact with various types of mating structures including other pillars, a deformable layer or a plurality of receptacles that are formed on the other of the die or supporting substrate, thereby forming a friction bond that holds the die to the supporting substrate. The attachment structure can further include an alignment structure for precise positioning of the die and supporting substrate to facilitate mounting the die to the supporting substrate. The attachment structure has applications for mounting semiconductor die containing a microelectromechanical (MEM) device, a microsensor or an integrated circuit (IC), and can be used to form a multichip module. The attachment structure is particularly useful for mounting die containing released MEM devices since these devices are fragile and can otherwise be damaged or degraded by adhesive or solder mounting.

  9. Steel castings by the electroslag casting technique. [CF8M

    SciTech Connect

    Sikka, V.K.; Mitchell, A.

    1984-01-01

    ELectroslag casting facilities in Canada and the United States were reviewed. Several valve body castings of 2-1/4 Cr-1 Mo, 9 Cr-1 Mo, and 18% Cr-8% Ni(Mo) steels were made at the University of British Columbia facility. These castings were examined for surface finish, chemical segregation, and macrostructure in the as-cast condition and after various heat treatments. Castings were subjected to tensile, Charpy impact, and creep testing. Results of these tests were compared with similar data on wrought material and sand castings.

  10. Die zwei Kulturen

    NASA Astrophysics Data System (ADS)

    Ankolekar, Anupriya; Krötzsch, Markus; Tran, Than; Vrandecic, Denny

    Oft werden zwei mögliche Entwicklungen des Webs diskutiert - das Web 2.0 und das Semantic Web. Wenn wir diese zwei Visionen für das zukünftige Web unter die Lupe nehmen, dann lässt sich feststellen, dass sich die Ideen in ihrem Kern und ihren Technologien gegenseitig ergänzen. Dementsprechend können und sollen beide Visionen von den Erfahrungen und Stärken der anderen profitieren. Wir glauben daran, dass zukünftige Webanwendungen den Web 2.0-Fokus auf Community und Benutzerfreundlichkeit beibehalten und, darüber hinaus, auch von Technologien des Semantic Web zur Vereinfachung der mashupähnlichen Datenintegration profitieren werden. Auf Basis eines Semantic Blog-Szenarios werden wir hier die Vorteile einer möglichen Kombination von Semantic Web und Web 2.0 illustrieren, die zeitnah realisiert werden kann. Wir werden auch auf technische Probleme eingehen, die bei der Erweiterung dieses Szenarios entstehen. Wir stellen dar, wie aktuelle Entwicklungen in der Semantic Web Forschung diese Probleme angehen können, und setzen zugleich auch Schwerpunkte für die zukünftige Forschung, die in diesem Zusammenhang relevant sind.

  11. Predicting Pattern Tooling and Casting Dimensions for Investment Casting, Phase II

    SciTech Connect

    Nick Cannell; Adrian S. Sabau

    2005-09-30

    The investment casting process allows the production of complex-shape parts and close dimensional tolerances. One of the most important phases in the investment casting process is the design of the pattern die. Pattern dies are used to create wax patterns by injecting wax into dies. The first part of the project involved preparation of reports on the state of the art at that time for all the areas under consideration (die-wax, wax-shell, and shell-alloy). The primary R&D focus during Phase I was on the wax material since the least was known about it. The main R&D accomplishments during this phase were determination of procedures for obtaining the thermal conductivity and viscoelastic properties of an unfilled wax and validating those procedures. Phase II focused on die-wax and shell-alloy systems. A wax material model was developed based on results obtained during the previous R&D phase, and a die-wax model was successfully incorporated into and used in commercial computer programs. Current computer simulation programs have complementary features. A viscoelastic module was available in ABAQUS but unavailable in ProCAST, while the mold-filling module was available in ProCAST but unavailable in ABAQUS. Thus, the numerical simulation results were only in good qualitative agreement with experimental results, the predicted shrinkage factors being approximately 2.5 times larger than those measured. Significant progress was made, and results showed that the testing and modeling of wax material had great potential for industrial applications. Additional R&D focus was placed on one shell-alloy system. The fused-silica shell mold and A356 aluminum alloy were considered. The experimental part of the program was conducted at ORNL and commercial foundries, where wax patterns were injected, molds were invested, and alloys were poured. It was very important to obtain accurate temperature data from actual castings, and significant effort was made to obtain temperature profiles in

  12. Effect of composition and processing on the thermal fatigue and toughness of high performance die steels. Year 1 report

    SciTech Connect

    Wallace, J.F.; Wang, Yumin; Schwam, D.

    1996-06-01

    The goal of this project is to extend the lifetime of dies for die casting by 20%. Since the die contributes about 10% to the cost of die cast parts, such an improvement in lifetime would result in annual savings of over $200 Million dollars. This is based on the estimated annual die production of one Billion dollars in the US. The major tasks of this two year project are: (1) Evaluate NEW DIE STEEL COMPOSITIONS that have been developed for demanding applications and compare them to Premium Grade H-13 die steel. (2) Optimize the AUSTENITIZING TREATMENT of the new composition. Assess the effects of fast, medium and slow COOLING RATES DURING HEAT TREATMENT, on the thermal fatigue resistance and toughness of the die steel. (3) Determine the effect of ELECTRO-DISCHARGE MACHINING (EDM) on the thermal fatigue resistance and impact properties of the steel. (4) Select demanding components and conduct IN-PLANT TESTING by using the new steel. Compare the performance of the new steel with identical components made of Premium Grade H-13. The immersion thermal fatigue specimen developed at CWRU is being used to determine resistance to heat checking, and the Charpy V-notch test for evaluating the toughness. The overall result of this project will be identification of the best steel available on the market and the best processing methods for aluminum die casting dies. This is an interim report for year 1 of the project.

  13. Application of Numerical Optimization to Aluminum Alloy Wheel Casting

    NASA Astrophysics Data System (ADS)

    Duan, J.; Reilly, C.; Maijer, D. M.; Cockcroft, S. L.; Phillion, A. B.

    2015-06-01

    A method of numerically optimizing the cooling conditions in a low- pressure die casting process from the standpoint of maintaining good directional solidification, high cooling rates and reduced cycle times has been developed for the production of aluminumalloy wheels. The method focuses on the optimization of cooling channel timing and utilizes an open source numerical optimization algorithm coupled with an experimentally validated, ABAQUS-based, heat transfer model of the casting process. Key features of the method include: 1) carefully designed constraint functions to ensure directional solidification along the centerlineof the wheel; and 2) carefully formulated objective functions to maximize cooling rate. The method has been implemented on a prototype production die and the results have been tested with plant trial test.

  14. CAST FLOOR WITH VIEW OF TORPEDO LADLE (BENEATH CAST FLOOR) ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    CAST FLOOR WITH VIEW OF TORPEDO LADLE (BENEATH CAST FLOOR) AND KEEPERS OF THE CAST HOUSE FLOOR, S.L. KIMBROUGH AND DAVID HOLMES. - U.S. Steel, Fairfield Works, Blast Furnace No. 8, North of Valley Road, West of Ensley-Pleasant Grove Road, Fairfield, Jefferson County, AL

  15. Die Zeitung der Zukunft

    NASA Astrophysics Data System (ADS)

    Wieser, Christoph; Schaffert, Sebastian

    Schon lange wird spekuliert, wie wir in Zukunft Zeitung lesen werden. Werden wir am Frühstückstisch wie gewohnt in einer Zeitung aus Papier schmökern oder werden wir die Zeitung als biegsame Folie beschrieben mit elektronischer Tinte in Händen halten? Wird die Zeitung mit anderen Medien wie Radio und Fernsehen verschmelzen? Viele Varianten sind denkbar. Heute lässt sich schon ein Trend ablesen: Immer mehr Leser entdecken die Online-Zeitung als Informationsmedium, eine Voraussetzung für die Nutzung neuer Technologien in der Zeitung der Zukunft. In diesem Kapitel stellen wir Entwicklungsmöglichkeiten der Online-Zeitung dar, wie sie im Social Semantic Web möglich werden.

  16. When Somebody Dies

    MedlinePlus

    ... alguien muere All living things — including bugs and fish and people — die. It's difficult, even for grownups, ... kind of death for families and friends to deal with because it happens so fast. There is ...

  17. Static and Dynamic Studies on LiNi1/3 Co1/3 Mn1/3 O2 -Based Suspensions for Semi-Solid Flow Batteries.

    PubMed

    Biendicho, Jordi Jacas; Flox, Cristina; Sanz, Laura; Morante, Joan Ramon

    2016-08-01

    LiNi1/3 Co1/3 Mn1/3 O2 (LNCM)-based suspensions for semi-solid flow batteries (SSFB) have been investigated by galvanostatic charge/discharge an electrochemical impedance spectroscopy (EIS). The resistance and electrochemical performance of half cells (vs. Li/Li(+) ) as well as the rheological properties are affected by the content of a commercially available electroconductive carbon black [KetjenBlack (KB), AkzoNobel] in the suspensions. In static conditions, a cell with 11.87 and 13.97 % by volume of KB and LNCM delivers high capacity 130 mA h g(-1) at 5 mA cm(-2) , respectively, and a coulombic efficiency of 90 % over 10 injections. The impedance of half cells is dominated by a contact resistance fitted with a resistor and a constant phase element (CPE) in parallel. In flow conditions, cell potential depends on applied current density and measured over potentials are ∼0.3 and 0.7 V for 0.33 and 1 mA cm(-2) , respectively, for a cell containing a suspension with 9.53 % in volume of KB and 13.90 % in volume of LNCM. The effect of the cell contact resistance on the electrochemical performance is discussed. PMID:27332781

  18. Method for casting polyethylene pipe

    NASA Technical Reports Server (NTRS)

    Elam, R. M., Jr.

    1973-01-01

    Short lengths of 7-cm ID polyethylene pipe are cast in a mold which has a core made of room-temperature-vulcanizable (RTV) silicone. Core expands during casting and shrinks on cooling to allow for contraction of the polyethylene.

  19. Casting Of Multilayer Ceramic Tapes

    NASA Technical Reports Server (NTRS)

    Collins, Earl R., Jr.

    1991-01-01

    Procedure for casting thin, multilayer ceramic membranes, commonly called tapes, involves centrifugal casting at accelerations of 1,800 to 2,000 times normal gravitational acceleration. Layers of tape cast one at a time on top of any previous layer or layers. Each layer cast from slurry of ground ceramic suspended in mixture of solvents, binders, and other components. Used in capacitors, fuel cells, and electrolytic separation of oxygen from air.

  20. Mix/Cast Contamination Control

    NASA Technical Reports Server (NTRS)

    Wallentine, M.

    2005-01-01

    Presented is a training handbook for Mix/Cast Contamination Control; a part of a series of training courses to qualify access to Mix/Cast facilities. Contents: List Contamination Control Requirements; Identify foreign objects debris (FOD), Control Areas and their guidelines; Describe environmental monitoring; List Contamination Control Initiatives; Describe concern for Controlled Materials; Identify FOD Controlled Areas in Mix/Cast.

  1. Casting and Angling.

    ERIC Educational Resources Information Center

    Little, Mildred J.; Bunting, Camille

    The self-contained packet contains background information, lesson plans, 15 transparency and student handout masters, drills and games, 2 objective examinations, and references for teaching a 15-day unit on casting and angling to junior high and senior high school students, either as part of a regular physical education program or as a club…

  2. Extrusion cast explosive

    DOEpatents

    Scribner, Kenneth J.

    1985-01-01

    Improved, multiphase, high performance, high energy, extrusion cast explosive compositions, comprising, a crystalline explosive material; an energetic liquid plasticizer; a urethane prepolymer, comprising a blend of polyvinyl formal, and polycaprolactone; a polyfunctional isocyanate; and a catalyst are disclosed. These new explosive compositions exhibit higher explosive content, a smooth detonation front, excellent stability over long periods of storage, and lower sensitivity to mechanical stimulants.

  3. ShakeCast Manual

    USGS Publications Warehouse

    Lin, Kuo-Wan; Wald, David J.

    2008-01-01

    ShakeCast is a freely available, post-earthquake situational awareness application that automatically retrieves earthquake shaking data from ShakeMap, compares intensity measures against users? facilities, and generates potential damage assessment notifications, facility damage maps, and other Web-based products for emergency managers and responders.

  4. Hair Casts or Pseudonits

    PubMed Central

    França, Katlein; Villa, Ricardo Tadeu; Silva, Isabella Rezende; de Carvalho, Cristine Almeida; Bedin, Valcinir

    2011-01-01

    Hair casts or pseudonits are thin, elongated, cylindrical concretions that encircle the hair shaft and can be easily dislodged. A case of pseudonits in a 9-year-old girl is reported. Though not unusual, false diagnoses are common. PMID:22223977

  5. Casting and Angling.

    ERIC Educational Resources Information Center

    Smith, Julian W.

    As part of a series of books and pamphlets on outdoor education, this manual consists of easy-to-follow instructions for fishing activities dealing with casting and angling. The manual may be used as a part of the regular physical education program in schools and colleges or as a club activity for the accomplished weekend fisherman or the…

  6. Evaluation of an improved centrifugal casting machine.

    PubMed

    Donovan, T E; White, L E

    1985-05-01

    A Type III gold alloy, a silver-palladium alloy, and a base metal alloy were cast in two different centrifugal casting machines. With the number of complete cast mesh squares as an indicator of castability, the Airspin casting machine produced superior castings with all three alloys. The base metal alloy produced the greatest number of complete squares with both casting machines. PMID:3889295

  7. Computer cast blast modelling

    SciTech Connect

    Chung, S.; McGill, M.; Preece, D.S.

    1994-07-01

    Cast blasting can be designed to utilize explosive energy effectively and economically for coal mining operations to remove overburden material. The more overburden removed by explosives, the less blasted material there is left to be transported with mechanical equipment, such as draglines and trucks. In order to optimize the percentage of rock that is cast, a higher powder factor than normal is required plus an initiation technique designed to produce a much greater degree of horizontal muck movement. This paper compares two blast models known as DMC (Distinct Motion Code) and SABREX (Scientific Approach to Breaking Rock with Explosives). DMC, applies discrete spherical elements interacted with the flow of explosive gases and the explicit time integration to track particle motion resulting from a blast. The input to this model includes multi-layer rock properties, and both loading geometry and explosives equation-of-state parameters. It enables the user to have a wide range of control over drill pattern and explosive loading design parameters. SABREX assumes that heave process is controlled by the explosive gases which determines the velocity and time of initial movement of blocks within the burden, and then tracks the motion of the blocks until they come to a rest. In order to reduce computing time, the in-flight collisions of blocks are not considered and the motion of the first row is made to limit the motion of subsequent rows. Although modelling a blast is a complex task, the DMC can perform a blast simulation in 0.5 hours on the SUN SPARCstation 10--41 while the new SABREX 3.5 produces results of a cast blast in ten seconds on a 486-PC computer. Predicted percentage of cast and face velocities from both computer codes compare well with the measured results from a full scale cast blast.

  8. Precision cast vs. wrought superalloys

    NASA Technical Reports Server (NTRS)

    Tien, J. K.; Borofka, J. C.; Casey, M. E.

    1986-01-01

    While cast polycrystalline superalloys recommend themselves in virtue of better 'buy-to-fly' ratios and higher strengthening gamma-prime volume fractions than those of wrought superalloys, the expansion of their use into such critical superalloy applications as gas turbine hot section components has been slowed by insufficient casting process opportunities for microstructural control. Attention is presently drawn, however, to casting process developments facilitating the production of defect-tolerant superalloy castings having improved fracture reliability. Integrally bladed turbine wheel and thin-walled turbine exhaust case near-net-shape castings have been produced by these means.

  9. AMCC casting development, volume 2

    NASA Technical Reports Server (NTRS)

    1995-01-01

    PCC successfully cast and performed nondestructive testing, FPI and x-ray, on seventeen AMCC castings. Destructive testing, lab analysis and chemical milling, was performed on eleven of the castings and the remaining six castings were shipped to NASA or Aerojet. Two of the six castings shipped, lots 015 and 016, were fully processed per blueprint requirements. PCC has fully developed the gating and processing parameters of this part and feels the part could be implemented into production, after four more castings have been completed to ensure the repeatability of the process. The AMCC casting has been a technically challenging part due to its size, configuration, and alloy type. The height and weight of the wax pattern assembly necessitated the development of a hollow gating system to ensure structural integrity of the shell throughout the investment process. The complexity in the jacket area of the casting required the development of an innovative casting technology that PCC has termed 'TGC' or thermal gradient control. This method of setting up thermal gradients in the casting during solidification represents a significant process improvement for PCC and has been successfully implemented on other programs. The alloy, JBK75, is a relatively new alloy in the investment casting arena and required our engineering staff to learn the gating, processing, and dimensional characteristics of the material.

  10. Effects of squeeze casting on the properties of Zn-Bi monotectic alloy

    NASA Astrophysics Data System (ADS)

    Savas, M. A.; Altintas, S.; Erturan, H.

    1997-07-01

    In composite production, the shortest route is via an in situ composite in which a melt dissociates simultaneously into two rather different solid phases. The monotectic alloys can be included in this group. The present work was aimed at extending our recent squeeze casting experience on the Zn-Bi monotectic alloy in order to increase its cast quality and mechanical properties. A squeeze casting unit was built, and its die and punch were machined. The molten monotectic alloy was squeezed in this unit under pressures up to 120 MPa in its freezing range until it solidified completely. It was found that an increase in squeeze casting pressure provided increases in density, tensile strength, and Vickers hardness, which resulted in decreases in chip length and electrical resistivity. Before the squeeze casting practice, the freezing characteristics of this monotectic were estimated using basic solidification principles.

  11. Issues with dying patients.

    PubMed

    Valent, P

    1978-04-22

    Doctors have the privilege of looking after patients from the moment of birth to the moment of death. Yet, the holistic approach to patients is interfered with by the doctor's role as a warrior against death, where death's everpresent claim on our lives, and its final victory, are ignored. This paper attempts to explore why doctors are in their current position, the mechanisms for ignoring death which are shared by doctors and patients, the nature of the fear of death, and practical implications for the treatment of dying patients. More and more patients die now in medical settings. It is incumbent on doctors to understand the dying process, if much unnecessary suffering is to be prevented. PMID:661717

  12. Melting and casting of FeAl-based cast alloy

    SciTech Connect

    Sikka, V.K.; Wilkening, D.; Liebetrau, J.; Mackey, B.

    1998-11-01

    The FeAl-based intermetallic alloys are of great interest because of their low density, low raw material cost, and excellent resistance to high-temperature oxidation, sulfidation, carburization, and molten salts. The applications based on these unique properties of FeAl require methods to melt and cast these alloys into complex-shaped castings and centrifugal cast tubes. This paper addresses the melting-related issues and the effect of chemistry on the microstructure and hardness of castings. It is concluded that the use of the Exo-Melt{trademark} process for melting and the proper selection of the aluminum melt stock can result in porosity-free castings. The FeAl alloys can be melted and cast from the virgin and revert stock. A large variation in carbon content of the alloys is possible before the precipitation of graphite flakes occurs. Titanium is a very potent addition to refine the grain size of castings. A range of complex sand castings and two different sizes of centrifugal cast tubes of the alloy have already been cast.

  13. Experiences of the dying.

    PubMed

    Schoenbeck, Susan L

    2011-01-01

    It is often a mystery to us how we have come to know and believe in certain things. Beliefs are like guests who come up to a door. They come in only if the host opens it and invites them in. Otherwise they are turned away, unable to enter. LPNs/LVNs are invited to reflect on their experiences and expand their knowledge and beliefs. There is growing recognition that bedside talks of the dying, spirit travel and near-death events are real events for the people who experience them. LPNs/ LVNs are encouraged to expand their knowledge and beliefs about dying. PMID:23252027

  14. Assisted Dying in Canada.

    PubMed

    Schuklenk, Udo

    2014-01-01

    This paper makes an affirmative ethical case in favour of the decriminalization of assisted dying in Canada. It then proceeds to defending the affirmative case against various slippery-slope arguments that are typically deployed by opponents of assisted dying. Finally, a recent case of questionable professional conduct by anti-euthanasia campaigners cum academics is flagged as a warning to all of us not to permit the quality of the professional debate to deteriorate unacceptably, despite the personal emotional investments involved on all sides of the debate. PMID:26871530

  15. Volume MLS ray casting.

    PubMed

    Ledergerber, Christian; Guennebaud, Gaël; Meyer, Miriah; Bächer, Moritz; Pfister, Hanspeter

    2008-01-01

    The method of Moving Least Squares (MLS) is a popular framework for reconstructing continuous functions from scattered data due to its rich mathematical properties and well-understood theoretical foundations. This paper applies MLS to volume rendering, providing a unified mathematical framework for ray casting of scalar data stored over regular as well as irregular grids. We use the MLS reconstruction to render smooth isosurfaces and to compute accurate derivatives for high-quality shading effects. We also present a novel, adaptive preintegration scheme to improve the efficiency of the ray casting algorithm by reducing the overall number of function evaluations, and an efficient implementation of our framework exploiting modern graphics hardware. The resulting system enables high-quality volume integration and shaded isosurface rendering for regular and irregular volume data. PMID:18988986

  16. Extrusion cast explosive

    DOEpatents

    Scribner, K.J.

    1985-11-26

    Disclosed is an improved, multiphase, high performance, high energy, extrusion cast explosive compositions, comprising, a crystalline explosive material; an energetic liquid plasticizer; a urethane prepolymer, comprising a blend of polyvinyl formal, and polycaprolactone; a polyfunctional isocyanate; and a catalyst. These new explosive compositions exhibit higher explosive content, a smooth detonation front, excellent stability over long periods of storage, and lower sensitivity to mechanical stimulants. 1 fig.

  17. Extrusion cast explosive

    DOEpatents

    Scribner, K.J.

    1985-01-29

    Improved, multiphase, high performance, high energy, extrusion cast explosive compositions, comprising, a crystalline explosive material; an energetic liquid plasticizer; a urethane prepolymer, comprising a blend of polyvinyl formal, and polycaprolactone; a polyfunctional isocyanate; and a catalyst are disclosed. These new explosive compositions exhibit higher explosive content, a smooth detonation front, excellent stability over long periods of storage, and lower sensitivity to mechanical stimulants. 1 fig.

  18. Computer cast blast modelling

    SciTech Connect

    Chung, S.; McGill, M.; Preece, D.S.

    1994-12-31

    Cast blasting can be designed to utilize explosive energy effectively and economically for coal mining operations to remove overburden material. This paper compares two blast models known as DMC (Distinct Motion Code) and SABREX (Scientific Approach to Breaking Rock with Explosives). DMC applies discrete spherical elements interacted with the flow of explosive gases and the explicit time integration to track particle motion resulting from a blast. The input to this model includes multi-layer rock properties, and both loading geometry and explosives equation-of-state parameters. It enables the user to have a wide range of control over drill pattern and explosive loading design parameters. SABREX assumes that heave process is controlled by the explosive gases which determines the velocity and time of initial movement of blocks within the burden, and then tracks the motion of the blocks until they come to a rest. In order to reduce computing time, the in-flight collisions of blocks are not considered and the motion of the first row is made to limit the motion of subsequent rows. Although modelling a blast is a complex task, the advance in computer technology has increased the computing power of small work stations as well as PC (personal computers) to permit a much shorter turn-around time for complex computations. The DMC can perform a blast simulation in 0.5 hours on the SUN SPARC station 10-41 while the new SABREX 3.5 produces results of a cast blast in ten seconds on a 486-PC. Predicted percentage of cast and face velocities from both computer codes compare well with the measured results from a full scale cast blast.

  19. USGS ShakeCast

    USGS Publications Warehouse

    Wald, David; Lin, Kuo-Wan

    2007-01-01

    Automating, Simplifying, and Improving the Use of ShakeMap for Post-Earthquake Decisionmaking and Response. ShakeCast is a freely available, post-earthquake situational awareness application that automatically retrieves earthquake shaking data from ShakeMap, compares intensity measures against users facilities, and generates potential damage assessment notifications, facility damage maps, and other Web-based products for emergency managers and responders.

  20. [Casting faults and structural studies on bonded alloys comparing centrifugal castings and vacuum pressure castings].

    PubMed

    Fuchs, P; Küfmann, W

    1978-07-01

    The casting processes in use today such as centrifugal casting and vacuum pressure casting were compared with one another. An effort was made to answer the question whether the occurrence of shrink cavities and the mean diameter of the grain of the alloy is dependent on the method of casting. 80 crowns were made by both processes from the baked alloys Degudent Universal, Degudent N and the trial alloy 4437 of the firm Degusa. Slice sections were examined for macro and micro-porosity and the structural appearance was evaluated by linear analysis. Statistical analysis showed that casting faults and casting structure is independent of the method used and their causes must be found in the conditions of casting and the composition of the alloy. PMID:352670

  1. Casting larger polycrystalline silicon ingots

    SciTech Connect

    Wohlgemuth, J.; Tomlinson, T.; Cliber, J.; Shea, S.; Narayanan, M.

    1995-08-01

    Solarex has developed and patented a directional solidification casting process specifically designed for photovoltaics. In this process, silicon feedstock is melted in a ceramic crucible and solidified into a large grained semicrystalline silicon ingot. In-house manufacture of low cost, high purity ceramics is a key to the low cost fabrication of Solarex polycrystalline wafers. The casting process is performed in Solarex designed casting stations. The casting operation is computer controlled. There are no moving parts (except for the loading and unloading) so the growth process proceeds with virtually no operator intervention Today Solarex casting stations are used to produce ingots from which 4 bricks, each 11.4 cm by 11.4 cm in cross section, are cut. The stations themselves are physically capable of holding larger ingots, that would yield either: 4 bricks, 15 cm by 15 an; or 9 bricks, 11.4 cm by 11.4 an in cross-section. One of the tasks in the Solarex Cast Polycrystalline Silicon PVMaT Program is to design and modify one of the castings stations to cast these larger ingots. If successful, this effort will increase the production capacity of Solarex`s casting stations by 73% and reduce the labor content for casting by an equivalent percentage.

  2. Poetry and the Dying.

    ERIC Educational Resources Information Center

    Kramer, Aaron

    1992-01-01

    Demonstrates roles poetry can play as people confront the death of loved ones and their own dying. Gives examples of Heinrich Heine transforming his agony into art and, from the poetry of two college students, both in advanced stages of neurological disease, which was read aloud in class, teaching all present something about how to approach their…

  3. Tool & Die Technician.

    ERIC Educational Resources Information Center

    Ohio State Univ., Columbus. Center on Education and Training for Employment.

    This document contains 23 units to consider for use in a tech prep competency profile for the occupation of tool and die technician. All the units listed will not necessarily apply to every situation or tech prep consortium, nor will all the competencies within each unit be appropriate. Several units appear within each specific occupation and…

  4. When a Baby Dies.

    ERIC Educational Resources Information Center

    Church, Martha Jo; And Others

    Written especially for grieving mothers whose babies have died, this booklet offers an overview of stages and experiences through which bereaved parents commonly pass. Specifically, the text is intended to give comfort to bereaved parents, offer insight into the grieving process, and provide thoughts on leave-taking ceremonies. The first section…

  5. Navigating "Assisted Dying".

    PubMed

    Schipper, Harvey

    2016-02-01

    Carter is a bellwether decision, an adjudication on a narrow point of law whose implications are vast across society, and whose impact may not be realized for years. Coupled with Quebec's Act Respecting End-of-life Care it has sharply changed the legal landscape with respect to actively ending a person's life. "Medically assisted dying" will be permitted under circumstances, and through processes, which have yet to be operationally defined. This decision carries with it moral assumptions, which mean that it will be difficult to reach a unifying consensus. For some, the decision and Act reflect a modern acknowledgement of individual autonomy. For others, allowing such acts is morally unspeakable. Having opened the Pandora's Box, the question becomes one of navigating a tolerable societal path. I believe it is possible to achieve a workable solution based on the core principle that "medically assisted dying" should be a very rarely employed last option, subject to transparent ongoing review, specifically as to why it was deemed necessary. My analysis is based on 1. The societal conditions in which have fostered demand for "assisted dying", 2. Actions in other jurisdictions, 3. Carter and Quebec Bill 52, 4. Political considerations, 5. Current medical practice. Leading to a series of recommendations regarding. 1. Legislation and regulation, 2. The role of professional regulatory agencies, 3. Medical professions education and practice, 4. Public education, 5. Health care delivery and palliative care. Given the burden of public opinion, and the legal steps already taken, a process for assisted-dying is required. However, those legal and regulatory steps should only be considered a necessary and defensive first step in a two stage process. The larger goal, the second step, is to drive the improvement of care, and thus minimize assisted-dying. PMID:27169205

  6. Herausforderungen durch die deutsche Wiedervereinigung

    NASA Astrophysics Data System (ADS)

    Stäglin, Reiner

    Die Wiedervereinigung stellte auch die Statistik vor große Aufgaben. Die als Organ der staatlichen Planung staatsnah orientierte Statistik der DDR musste auf das zur Neutralität und wissenschaftlichen Unabhängigkeit verpflichtete System der Bundesrepublik umgestellt werden. Ebenso verlangten die Universitäten eine Neuorientierung. Die Deutsche Statistische Gesellschaft hat sich vor allem dreier Aufgaben mit großem Engagement, aber auch mit Bedachtsamkeit angenommen: Aufnahme und Integration der Statistiker aus den neuen Bundesländern in die Gesellschaft, Begleitung der Neuausrichtung des Faches Statistik an deren Hochschulen und Sicherung sowie Nutzung von Datenbeständen der ehemaligen DDR.

  7. High density tape casting system

    NASA Technical Reports Server (NTRS)

    Collins, Earl R., Jr. (Inventor)

    1989-01-01

    A system is provided for casting thin sheets (or tapes) of particles bound together, that are used for oxygen membranes and other applications, which enables the particles to be cast at a high packing density in a tape of uniform thickness. A slurry contains the particles, a binder, and a solvent, and is cast against the inside walls of a rotating chamber. Prior to spraying the slurry against the chamber walls, a solvent is applied to a container. The solvent evaporates to saturate the chamber with solvent vapor. Only then is the slurry cast. As a result, the slurry remains fluid long enough to spread evenly over the casting surface formed by the chamber, and for the slurry particles to become densely packed. Only then is the chamber vented to remove solvent, so the slurry can dry. The major novel feature is applying solvent vapor to a rotating chamber before casting slurry against the chamber walls.

  8. Low Temperature Consolidation of Micro/Nanosilver Die-Attach Preforms

    NASA Astrophysics Data System (ADS)

    McCoppin, Jared; Reitz, Thomas L.; Miller, Ryan; Vijwani, Hema; Mukhopadhyay, Sharmila; Young, Daniel

    2014-09-01

    Organically passivated silver nanopowder paste-based sintering is considered a promising solution for die-attach in high temperature power and sensing electronic devices. However, oxygen requirements during burnout and inherently high shrinkage rates limit their use to small die sizes. This work reports an alternative fabrication method that resolves decomposition and shrinkage issues of the die-attach by utilizing a prestressed optimized tape cast mixture of micro- and nanosilver particles with a polypropylene carbonate binder. The effects of prestressing, micro/nanosilver bimodal distribution, and polymer content on resulting microstructure and shear strength were investigated. Prior to application as a die-attach, uniaxial compression of the tape was found to significantly decrease shrinkage and improve green strength. This pre-stressing strategy allows for a decoupling of the resulting die-attach materials properties from the pressure applied during assembly. Bimodal mixtures consisting of 1-3 μm spherical powders with nanosilver resulted in shear strengths comparable to those of pure nanosilver. Shear strength decreased as bimodal particle size increased above 5 μm. A polymer content of ˜10 wt.% polypropylene carbonate combined with prestressing was identified as optimal for maximizing die-attach shear strength while still maintaining pliability and formability. Tape casts that were prestressed to 212 MPa by uniaxially compression and formulated with 10 wt.% of polypropylene carbonate resulted in a die-attach material with a shear strength of 54 MPa when sintered. These materials were used to demonstrate void-free 25-mm2 die-attach assemblies, suggesting that tape cast micro/nanosilver materials may be a promising die-attach method for high temperature and large-area electronics devices.

  9. Cast dielectric composite linear accelerator

    DOEpatents

    Sanders, David M.; Sampayan, Stephen; Slenes, Kirk; Stoller, H. M.

    2009-11-10

    A linear accelerator having cast dielectric composite layers integrally formed with conductor electrodes in a solventless fabrication process, with the cast dielectric composite preferably having a nanoparticle filler in an organic polymer such as a thermosetting resin. By incorporating this cast dielectric composite the dielectric constant of critical insulating layers of the transmission lines of the accelerator are increased while simultaneously maintaining high dielectric strengths for the accelerator.

  10. Development of an Optimization Methodology for the Aluminum Alloy Wheel Casting Process

    NASA Astrophysics Data System (ADS)

    Duan, Jianglan; Reilly, Carl; Maijer, Daan M.; Cockcroft, Steve L.; Phillion, Andre B.

    2015-08-01

    An optimization methodology has been developed for the aluminum alloy wheel casting process. The methodology is focused on improving the timing of cooling processes in a die to achieve improved casting quality. This methodology utilizes (1) a casting process model, which was developed within the commercial finite element package, ABAQUS™—ABAQUS is a trademark of Dassault Systèms; (2) a Python-based results extraction procedure; and (3) a numerical optimization module from the open-source Python library, Scipy. To achieve optimal casting quality, a set of constraints have been defined to ensure directional solidification, and an objective function, based on the solidification cooling rates, has been defined to either maximize, or target a specific, cooling rate. The methodology has been applied to a series of casting and die geometries with different cooling system configurations, including a 2-D axisymmetric wheel and die assembly generated from a full-scale prototype wheel. The results show that, with properly defined constraint and objective functions, solidification conditions can be improved and optimal cooling conditions can be achieved leading to process productivity and product quality improvements.

  11. Replacing London's cast iron mains

    SciTech Connect

    Thorne, A. ); Mathews, P. )

    1992-07-01

    This paper discusses the cast iron gas distribution systems that exist in many cities and contains considerable amounts of pipe that vary in age from 20 to 150 years. In many ways, cast iron is an excellent material. It is inherently corrosion resistant, easy to install and cheap. However, it is also brittle and smaller diameter cast iron pipe has a relatively low beam strength. This can lead, under some circumstances, to failure without external warning, with typically a full-circumferential failure. In congested areas this can lead to serious consequences. As a result, cast iron replacement programs are a common feature in such urban gas distribution systems.

  12. First Results of Energy Saving at Process Redesign of Die Forging Al-Alloys

    SciTech Connect

    Pepelnjak, Tomaz; Kuzman, Karl; Kokol, Anton

    2011-05-04

    The contribution deals with eco-friendly solutions for shortened production chains of forging light alloys. During the die forging operations a remarkable amount of material goes into the flash and later on into chips during finish machining. These low value side products are rich with embedded energy therefore recycling or reprocessing could be very energy saving procedure.In cooperation with a die forging company a shortened reprocessing cycle has been studied starting from re-melting the forging flash and without additional heating to cast preforms for subsequent die forging. As such preforms have not as good formability characteristics as those done from extruded billets the isothermal forging process has been adopted. First results showed that without cracks and other defects the formability is sufficient for a broad spectrum of forgings.To improve the formability a homogenization process of cast preforms has been implemented. As the process started immediately after casting, amount of additional energy for heating was minimized. To reduce voids forging process was redesigned in a way to assure greater hydrostatic pressures in parts during forging. First results were promising therefore research is going towards improving processes without adding significantly more energy as it is needed for casting with homogenization and die forging.

  13. Melting, casting, and alpha-phase extrusion of the uranium-2. 4 weight percent niobium alloy

    SciTech Connect

    Anderson, R C; Beck, D E; Kollie, T G; Zorinsky, E J; Jones, J M

    1981-10-01

    The experimental details of the melting, casting, homogenization, and alpha-phase extrusion process used to fabricate the uranium-2.4 wt % niobium alloy into 46-mm-diameter rods is described. Extrusion defects that were detected by an ultrasonic technique were eliminated by proper choice of extrusion parameters; namely, reduction ratio, ram speed, die angle, and billet preheat temperature.

  14. Heated die facilitates tungsten forming

    NASA Technical Reports Server (NTRS)

    Chattin, J. H.; Haystrick, J. E.; Laughlin, J. C.; Leidy, R. A.

    1966-01-01

    Tungsten forming in a press brake employs a bottom die assembly with a heating manifold between two water-cooled die sections. The manifold has hydrogen-oxygen burners spaced along its length for even heat during forming.

  15. Casting Equipment. Casting and Angling Skills Series. Instructor Manual.

    ERIC Educational Resources Information Center

    Staton, Robert D., Jr.

    Part of a series of self-contained instructional units designed by the Missouri Department of Conservation to teach Missourians how to use outdoor resources wisely and skillfully, the instructor manual, the first in the casting and angling series, is intended both as a reference book on casting equipment and as an introduction to the sport.…

  16. Psychotherapy with Older Dying Persons.

    ERIC Educational Resources Information Center

    Dye, Carol J.

    Psychotherapy with older dying patients can lead to problems of countertransference for the clinician. Working with dying patients requires flexibility to adapt basic therapeutics to the institutional setting. Goals of psychotherapy must be reconceptualized for dying clients. The problems of countertransference arise because clinicians themselves…

  17. When Your Child Needs a Cast

    MedlinePlus

    ... hard bandage that's usually made of material like fiberglass or plaster. Casts keep bones in place while ... water. Plaster of Paris casts are heavier than fiberglass casts and don't hold up as well ...

  18. Lost-Soap Aluminum Casting.

    ERIC Educational Resources Information Center

    Mihalow, Paula

    1980-01-01

    Lost-wax casting in sterling silver is a costly experience for the average high school student. However, this jewelry process can be learned at no cost if scrap aluminum is used instead of silver, and soap bars are used instead of wax. This lost-soap aluminum casting process is described. (Author/KC)

  19. Electroslag component casting. [Nickel aluminide

    SciTech Connect

    Sikka, V.K.

    1986-01-01

    This project is directed toward the development of electroslag-casting (ESC) technology for use in coal conversion components such as valve bodies, pump housings, and pipe fittings. The aim is also to develop a sufficient data base to permit electroslag casting to become an ASME Code-accepted process. It is also intended to transfer the ESC process technology to private industry. A total of 32 electroslag castings of 2.25Cr-1Mo, 9Cr-1Mo, type 316, and nickel aluminide were procured from four facilities for evaluation (Table 1). The most complex castings procured during this program were the valve bodies shown in Figure 2. The castings were subjected to various heat treatments (Table 2), checked for chemical composition uniformity from top to bottom, and subjected to macrostructural evaluation and mechanical properties testing. Results are discussed. 10 refs., 7 figs., 3 tabs.

  20. Machinability Study of Stir Cast Hypoeutectic Aluminum-Silicon Alloys During Turning

    NASA Astrophysics Data System (ADS)

    Sood, P. K.; Sehgal, Rakesh; Dwivedi, D. K.

    2013-02-01

    The influence of Be and Cd (iron correctors) on mechanical properties and machining behavior of hypoeutectic Al-Si alloy (Al-7Si-0.5Mg-1.2Fe) processed by conventional and semi-solid metal (SSM) processing (stir casting) techniques is investigated. The alloys under investigation were prepared by controlling melt in an induction melting furnace. The stirring of SSM was carried out at a constant stirring speed of 400 rpm under constant cooling conditions from liquidus temperature. The turning operations were carried out under dry conditions on a CNC turning center using coated-carbide insert by varying cutting speed, feed rate, depth of cut, and approaching angle. An orthogonal array, the signal-to-noise ratio, and analysis of variance were employed to study the machining performance characteristics. The results indicate that Be/Cd modification of the alloy and selected cutting parameters significantly affect the machining characteristics. The feed rate, cutting speed, and Cd as an iron corrector have more effect on the machining behavior of the alloys under study.

  1. Laser-Ultrasonic Inspection of MG/AL Castings

    SciTech Connect

    Blouin, Alain; Levesque, Daniel; Monchalin, Jean-Pierre; Baril, Eric; Fischersworring-Bunk, Andreas

    2005-04-09

    Laser-ultrasonics is used to assess the metallurgical bond between Mg/Al materials in die-cast Magnesium/Aluminum composite. The acoustic impedances of Mg, Al and air are such that the amplitude of ultrasonic echoes reflected back from a void is many times larger than the amplitude of those reflected back from a well-bonded interface. In addition, the polarity of echoes from a void is inverted compared to that from a well-bonded interface. Laser-ultrasonic F-SAFT is also used for imaging tilted Mg/Al interfaces. Experimental setup, signal processing and results for detecting voids in the Mg/Al interface of cast parts are presented.

  2. Nitriding of Aluminum Extrusion Die: Effect of Die Geometry

    NASA Astrophysics Data System (ADS)

    Akhtar, S. S.; Arif, A. F. M.; Yilbas, B. S.

    2010-04-01

    Nitriding of complex-shaped extrusion dies may result in non-uniform nitride layers and hence a required hardness may not be achieved in some regions of the bearing area. The present study is carried out to assess the effect of extrusion die profile on the characteristics and growth behavior of nitride layers so that the critical die design feature can be identified to enhance the uniformity of the nitride layer. For this purpose, AISI H13 steel samples have been manufactured with profiles similar to those of hot extrusion dies. The samples were then gas nitrided under controlled nitriding potential. The uniformity and depth of nitride layers have been investigated in terms of compound layer and total nitride case depth for selected die features. The results of this study indicated the need to include the effect of profile on the nitride layer for the optimal die design with improved service life.

  3. Accurate defect die placement and nuisance defect reduction for reticle die-to-die inspections

    NASA Astrophysics Data System (ADS)

    Wen, Vincent; Huang, L. R.; Lin, C. J.; Tseng, Y. N.; Huang, W. H.; Tuo, Laurent C.; Wylie, Mark; Chen, Ellison; Wang, Elvik; Glasser, Joshua; Kelkar, Amrish; Wu, David

    2015-10-01

    Die-to-die reticle inspections are among the simplest and most sensitive reticle inspections because of the use of an identical-design neighboring-die for the reference image. However, this inspection mode can have two key disadvantages: (1) The location of the defect is indeterminate because it is unclear to the inspector whether the test or reference image is defective; and (2) nuisance and false defects from mask manufacturing noise and tool optical variation can limit the usable sensitivity. The use of a new sequencing approach for a die-to-die inspection can resolve these issues without any additional scan time, without sacrifice in sensitivity requirement, and with a manageable increase in computation load. In this paper we explore another approach for die-to-die inspections using a new method of defect processing and sequencing. Utilizing die-to-die double arbitration during defect detection has been proven through extensive testing to generate accurate placement of the defect in the correct die to ensure efficient defect disposition at the AIMS step. The use of this method maintained the required inspection sensitivity for mask quality as verified with programmed-defectmask qualification and then further validated with production masks comparing the current inspection approach to the new method. Furthermore, this approach can significantly reduce the total number of defects that need to be reviewed by essentially eliminating the nuisance and false defects that can result from a die-to-die inspection. This "double-win" will significantly reduce the effort in classifying a die-to-die inspection result and will lead to improved cycle times.

  4. Sixty Years of Casting Research

    NASA Astrophysics Data System (ADS)

    Campbell, John

    2015-11-01

    The 60 years of solidification research since the publication of Chalmer's constitutional undercooling in 1953 has been a dramatic advance of understanding which has and continues to be an inspiration. In contrast, 60 years of casting research has seen mixed fortunes. One of its success stories relates to improvements in inoculation of gray irons, and another to the discovery of spheroidal graphite iron, although both of these can be classified as metallurgical rather than casting advances. It is suggested that true casting advances have dated from the author's lab in 1992 when a critical surface turbulence condition was defined for the first time. These last 20 years have seen the surface entrainment issues of castings developed to a sufficient sophistication to revolutionize the performance of light alloy and steel foundries. However, there is still a long way to go, with large sections of the steel and Ni-base casting industries still in denial that casting defects are important or even exist. The result has been that special ingots are still cast poorly, and shaped casting operations have suffered massive losses. For secondary melted and cast materials, electro-slag remelting has the potential to be much superior to expensive vacuum arc remelting, which has cost our aerospace and defense industries dearly over the years. This failure to address and upgrade our processing of liquid metals is a serious concern, since the principle entrainment defect, the bifilm, is seen as the principle initiator of cracks in metals; in general, bifilms are the Griffith cracks that initiate failures by cracking. A new generation of crack resistant metals and engineering structures can now be envisaged.

  5. Strip casting with fluxing agent applied to casting roll

    DOEpatents

    Williams, Robert S.; O'Malley, Ronald J.; Sussman, Richard C.

    1997-01-01

    A strip caster (10) for producing a continuous strip (24) includes a tundish (12) for containing a melt (14), a pair of horizontally disposed water cooled casting rolls (22) and devices (29) for electrostatically coating the outer peripheral chill surfaces (44) of the casting rolls with a powder flux material (56). The casting rolls are juxtaposed relative to one another for forming a pouting basin (18) for receiving the melt through a teeming tube (16) thereby establishing a meniscus (20) between the rolls for forming the strip. The melt is protected from the outside air by a non-oxidizing gas passed through a supply line (28) to a sealing chamber (26). A preferred flux is boron oxide having a melting point of about 550.degree. C. The flux coating enhances wetting of the steel melt to the casting roll and dissolves any metal oxide formed on the roll.

  6. Strip casting with fluxing agent applied to casting roll

    DOEpatents

    Williams, R.S.; O`Malley, R.J.; Sussman, R.C.

    1997-07-29

    A strip caster for producing a continuous strip includes a tundish for containing a melt, a pair of horizontally disposed water cooled casting rolls and devices for electrostatically coating the outer peripheral chill surfaces of the casting rolls with a powder flux material. The casting rolls are juxtaposed relative to one another for forming a pouting basin for receiving the melt through a teeming tube thereby establishing a meniscus between the rolls for forming the strip. The melt is protected from the outside air by a non-oxidizing gas passed through a supply line to a sealing chamber. A preferred flux is boron oxide having a melting point of about 550 C. The flux coating enhances wetting of the steel melt to the casting roll and dissolves any metal oxide formed on the roll. 3 figs.

  7. Strip casting apparatus and method

    DOEpatents

    Williams, R.S.; Baker, D.F.

    1988-09-20

    Strip casting apparatus including a molten-metal-holding container and a nozzle to deposit molten metal onto a moving chill drum to directly cast continuous metallic strip. The nozzle body includes a slot bounded between a back and a front lip. The slot width exceeds about 20 times the gap distance between the nozzle and the chill drum surface. Preferably, the slot width exceeds 0.5 inch. This method of strip casting minimizes pressure drop, insuring better metal-to-chill-drum contact which promotes heat transfer and results in a better quality metallic strip. 6 figs.

  8. Biomimetic Materials by Freeze Casting

    NASA Astrophysics Data System (ADS)

    Porter, Michael M.; Mckittrick, Joanna; Meyers, Marc A.

    2013-06-01

    Natural materials, such as bone and abalone nacre, exhibit exceptional mechanical properties, a product of their intricate microstructural organization. Freeze casting is a relatively simple, inexpensive, and adaptable materials processing method to form porous ceramic scaffolds with controllable microstructural features. After infiltration of a second polymeric phase, hybrid ceramic-polymer composites can be fabricated that closely resemble the architecture and mechanical performance of natural bone and nacre. Inspired by the narwhal tusk, magnetic fields applied during freeze casting can be used to further control architectural alignment, resulting in freeze-cast materials with enhanced mechanical properties.

  9. Slip-Cast Superconductive Parts

    NASA Technical Reports Server (NTRS)

    Wise, Stephanie A.; Buckley, John D.; Vasquez, Peter; Buck, Gregory M.; Hicks, Lana P.; Hooker, Matthew W.; Taylor, Theodore D.

    1993-01-01

    Complex shapes fabricated without machining. Nonaqueous slip-casting technique used to form complexly shaped parts from high-temperature superconductive materials like YBa(2)Cu(3)O(7-delta). Such parts useful in motors, vibration dampers, and bearings. In process, organic solvent used as liquid medium. Ceramic molds made by lost-wax process used instead of plaster-of-paris molds, used in aqueous slip-casting but impervious to organic solvents and cannot drain away liquid medium. Organic-solvent-based castings do not stick to ceramic molds as they do to plaster molds.

  10. Strip casting apparatus and method

    DOEpatents

    Williams, Robert S.; Baker, Donald F.

    1988-01-01

    Strip casting apparatus including a molten-metal-holding container and a nozzle to deposit molten metal onto a moving chill drum to directly cast continuous metallic strip. The nozzle body includes a slot bounded between a back and a front lip. The slot width exceeds about 20 times the gap distance between the nozzle and the chill drum surface. Preferably, the slot width exceeds 0.5 inch. This method of strip casting minimizes pressure drop, insuring better metal-to-chill-drum contact which promotes heat transfer and results in a better quality metallic strip.

  11. MACHINING ELIMINATION THROUGH APPLICATION OF THREAD FORMING FASTENERS IN NET SHAPED CAST HOLES

    SciTech Connect

    Cleaver, Ryan J; Cleaver, Todd H; Talbott, Richard

    2012-05-02

    The ultimate objective of this work was to eliminate approximately 30% of the machining performed in typical automotive engine and transmission plants by using thread forming fasteners in as-cast holes of aluminum and magnesium cast components. The primary issues at the source of engineers reluctance to implementing thread forming fasteners in lightweight castings are: * Little proof of consistency of clamp load vs. input torque in either aluminum or magnesium castings. * No known data to understand the effect on consistency of clamp load as casting dies wear. The clamp load consistency concern is founded in the fact that a portion of the input torque used to create clamp load is also used to create threads. The torque used for thread forming may not be consistent due to variations in casting material, hole size and shape due to tooling wear and process variation (thermal and mechanical). There is little data available to understand the magnitude of this concern or to form the basis of potential solutions if the range of clamp load variation is very high (> +/- 30%). The range of variation that can be expected in as-cast hole size and shape over the full life cycle of a high pressure die casting die was established in previous work completed by Pacific Northwest National Laboratory, (PNNL). This established range of variation was captured in a set of 12 cast bosses by designing core pins at the size and draft angles identified in the sited previous work. The cast bosses were cut into nuts that could be used in the Ford Fastener Laboratory test-cell to measure clamp load when a thread forming fastener was driven into a cast nut. There were two sets of experiments run. First, a series of cast aluminum nuts were made reflecting the range of shape and size variations to be expected over the life cycle of a die casting die. Taptite thread forming fasteners, (a widely used thread forming fastener suitable for aluminum applications), were driven into the various cored, as-cast

  12. 14 CFR 23.621 - Casting factors.

    Code of Federal Regulations, 2014 CFR

    2014-01-01

    ... structural castings except castings that are pressure tested as parts of hydraulic or other fluid systems and do not support structural loads. (b) Bearing stresses and surfaces. The casting factors specified in... of § 23.305 at an ultimate load corresponding to a casting factor of 1.25; and (ii) The...

  13. 14 CFR 23.621 - Casting factors.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... structural castings except castings that are pressure tested as parts of hydraulic or other fluid systems and do not support structural loads. (b) Bearing stresses and surfaces. The casting factors specified in... of § 23.305 at an ultimate load corresponding to a casting factor of 1.25; and (ii) The...

  14. 14 CFR 23.621 - Casting factors.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... structural castings except castings that are pressure tested as parts of hydraulic or other fluid systems and do not support structural loads. (b) Bearing stresses and surfaces. The casting factors specified in... of § 23.305 at an ultimate load corresponding to a casting factor of 1.25; and (ii) The...

  15. 14 CFR 23.621 - Casting factors.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... structural castings except castings that are pressure tested as parts of hydraulic or other fluid systems and do not support structural loads. (b) Bearing stresses and surfaces. The casting factors specified in... of § 23.305 at an ultimate load corresponding to a casting factor of 1.25; and (ii) The...

  16. Heat transfer at the mold-metal interface in permanent mold casting of aluminum alloys project. Annual project status report for the period October 1, 1997 to September 30, 1998

    SciTech Connect

    Pehlke, R.D.; Hao, S.W.

    1998-09-30

    In the first year of this three-year project, substantial progress has been achieved. This project on heat transfer coefficients in metal permanent mold casting is being conducted in three areas. They are the theoretical study at the University of Michigan, the experimental investigations of squeeze casting and semi-solid casting at CMI-Tech Center, and the experimental investigation of low pressure permanent mold casting at Amcast Automotive. U-M did an initial geometry which was defined for ProCAST to solve, and then a geometry half the size was defined and solved using the same boundary conditions. A conceptual mold geometry was examined and is represented as an axisymmetric element.Furthermore, the influences of the localized heat transfer coefficients on the casting process were carefully studied. The HTC Evaluator has been proposed and initially developed by the U-M team. The Reference and the Database Modules of the HTC Evaluator have been developed, and extensively tested. A series of technical barriers have been cited and potential solutions have been surveyed. At the CMI-Tech Center, the Kistler direct cavity pressure measurement system has been purchased and tested. The calibrations has been evaluated. The probe is capable of sensing a light finger pressure. The experimental mold has been designed and modified. The experimental mold has been designed and modified. The first experiment is scheduled for October 14, 1998. The geometry of the experimental hockey-puck casting has been given to the U-M team for numerical analysis.

  17. Graphite/Thermoplastic-Pultrusion Die

    NASA Technical Reports Server (NTRS)

    Wilson, Maywood L.; Frye, Mark W.; Johnson, Gary S.; Stanfield, Clarence E.

    1990-01-01

    Attachment to extruder produces thermoplastic-impregnated graphite tape. Consists of profile die, fiber/resin collimator, and crosshead die body. Die designed to be attached to commercially available extrusion machine capable of extruding high-performance thermoplastics. Simple attachment to commercial extruder enables developers of composites to begin experimenting with large numbers of proprietary resins, fibers, and hybrid composite structures. With device, almost any possible fiber/resin combination fabricated.

  18. Investment casting design of experiment. Final report

    SciTech Connect

    Owens, R.

    1997-10-01

    Specific steps in the investment casting process were analyzed in a designed experiment. The casting`s sensitivity to changes in these process steps was experimentally determined Dimensional and radiographic inspection were used to judge the sensitivity of the casting. Thirty-six castings of different pedigrees were poured and measured. Some of the dimensional inspection was conducted during the processing. It was confirmed that wax fixturing, number of gates, gate location, pour and mold temperature, pour speed, and cooling profile all affected the radiographic quality of the casting. Gate and runner assembly techniques, number of gates, and mold temperature affect the dimensional quality of the casting.

  19. Foreigners dying in Istanbul.

    PubMed

    Uzun, Ibrahim; Celbis, Osman; Baydar, Cetin Lutfi; Alkan, Nevzat; Arslan, Murat Nihat

    2009-09-01

    The study included 411 deaths selected from 14,647 medicolegal deaths autopsied in the Morgue Department of Forensic Medicine Institute Directorate, affiliated with the Ministry of Justice, between 1998 and 2002. Data were collected from court documents, coroner's investigation reports, and autopsy reports. The parameters of age, gender, nationality and origin, cause and place of death in foreigners dying in Istanbul were evaluated in the study. Out of 14,647 medicolegal deaths, 3.5% were foreigners from 34 different nationalities. The nationality with the highest rate of foreigner deaths (34%) was Romanian. Out of 411 deaths, 74.3% were male and 25.7% were female. Of all cases, 64.4% were tourists visiting Istanbul and 35.6% had a job in Istanbul. Of 146 foreigners employed in Istanbul, 94.5% did not have a work permit, while only 5.5% had a work permit. PMID:19674242

  20. The nature of urinary casts

    PubMed Central

    McQueen, E. G.

    1962-01-01

    The composition of hyaline casts has been investigated. The major constituent appears to be the urinary mucoprotein described by Tamm and Horsfall. Small amounts only of serum proteins are present. Neither the amounts excreted nor the concentration of Tamm-Horsfall protein appeared to determine the rate of cast formation. The only invariable association of hyaline cast formation was with the presence of significant amounts of serum proteins in the urine. In vitro it was found that aqueous solutions of serum albumin were particularly effective in producing precipitation of Tamm-Horsfall protein. This interaction was inhibited in normal urine but occurred to a greater extent in nephrotic urine and is suggested as the possible mechanism of hyaline cast formation. Images PMID:16810981

  1. Advanced casting: Today and tomorrow

    NASA Astrophysics Data System (ADS)

    Mietrach, D.

    The state of aluminum casting technology in terms of processes, component sizes, design and material-scientific data as well as mechanical characteristics was established during visits to foundries in the USA, Canada, France, Italy, Great Britain and the Federal Republic of Germany. Components of the primary structure of Tornado and ALPHA aircraft, (pylon, intake floor) classified according to the degree of difficulty during casting, were used to compare existing designs (riveted sheet metal and machined parts) and cast versions with regard to cost reduction and technical reliability. Visual inspection, dimensional checks, chemical composition analysis, penetrant tests, X-ray tests, metallographic investigations, and tensile tests were carried out. Cost savings of 25% and weight savings of 20% can be achieved by using castings.

  2. Casting Using A Polystyrene Pattern

    NASA Technical Reports Server (NTRS)

    Vasquez, Peter; Guenther, Bengamin; Vranas, Thomas; Veneris, Peter; Joyner, Michael

    1993-01-01

    New technique for making metal aircraft models saves significant amount of time and effort in comparison with conventional lost-wax method. Produces inexpensive, effective wind-tunnel models. Metal wind-tunnel model cast by use of polystyrene pattern.

  3. Moldless casting by laser

    NASA Astrophysics Data System (ADS)

    McLean, Marc A.; Shannon, G. J.; Steen, William M.

    1997-09-01

    The principle of laser cladding involves the use of high power carbon-dioxide lasers and powder deposition technology to provide wear and corrosion resistant surface coatings to engineering components. By injecting metal powder into a laser generated melt pool on a moving substrate a solidified metal track can be produced. Deposition of successive tracks produces a multi-layer build. Laser direct casting (LDC) utilizes a coaxial nozzle enabling consistent omnidirectional deposition to produce 3D components from a selection of metal powders. The influence of the principal process parameters over the process features namely, powder catchment efficiency, beam shape and build rates are presented with several successfully generated 3D components. Nickel, stainless steel and satellite powders were deposited at laser powders of 0.4 to 1.4 kW and speeds of 500 to 1000 mm/min achieving build rates of 3 to 9 mm3/s. Fully dense metallurgical structures have been produced with no cracking or porosity and powder catchment efficiencies up to 85% have been achieved.

  4. A Membrane Process for Recycling Die Lube from Wastewater Solutions

    SciTech Connect

    Eric S. Peterson; Jessica Trudeau; Bill Cleary; Michael Hackett; William A. Greene

    2003-04-01

    An active-surface membrane technology was used to separate a die lube manufacturing wastewater stream consisting of various oils, hydrocarbons, heavy metals, and silicones. The ultrafiltration membranes reduced organics from initial oil and grease contents by 20–25X, carbon oxygen demand (COD) by 1.5 to 2X, and total organic carbon (TOC) by 0.6, while the biological oxygen demand (BOD) remained constant. The active-surface membranes were not fouled as badly as non-active-surface systems and the active-surface membrane flux levels were consistently higher and more stable than those of the non-active-surface membranes tested. Field testing demonstrated that the rotary microfilter can concentrate the die lube, i.e. remove the glycerin component, and produce a die lube suitable for recycling. The recycling system operated for six weeks with only seven cleaning cycles and no mechanical or electrical failures. Test data and quality records indicate that the die casting scrap was reduced from 8.4 to 7.8%. There is no doubt that this test yielded tremendous results. This separation process presents significant opportunities that can be evaluated further.

  5. A Membrane Process for Recycling Die Lube from Wastewater Solutions

    SciTech Connect

    Peterson, E. S.; Trudeau, J.; Cleary, B.; Hackett, M.; Greene, W. A.

    2003-04-30

    An active-surface membrane technology was used to separate a die lube manufacturing wastewater stream consisting of various oils, hydrocarbons, heavy metals, and silicones. The ultrafiltration membranes reduced organics from initial oil and grease contents by 20-25X, carbon oxygen demand (COD) by 1.5 to 2X, and total organic carbon (TOC) by 0.6, while the biological oxygen demand (BOD) remained constant. The active-surface membranes were not fouled as badly as non-active-surface systems and the active-surface membrane flux levels were consistently higher and more stable than those of the non-active-surface membranes tested. Field testing demonstrated that the rotary microfilter can concentrate the die lube, i.e. remove the glycerin component, and produce a die lube suitable for recycling. The recycling system operated for six weeks with only seven cleaning cycles and no mechanical or electrical failures. Test data and quality records indicate that the die casting scrap was reduced from 8.4 to 7.8%. There is no doubt that this test yielded tremendous results. This separation process presents significant opportunities that can be evaluated further.

  6. Two Piece Compaction Die Design

    SciTech Connect

    Coffey, Ethan N

    2010-03-01

    Compaction dies used to create europium oxide and tantalum control plates were modeled using ANSYS 11.0. Two-piece designs were considered in order to make the dies easier to assemble than the five-piece dies that were previously used. The two areas of concern were the stresses at the interior corner of the die cavity and the distortion of the cavity wall due to the interference fit between the two pieces and the pressure exerted on the die during the compaction process. A successful die design would have stresses less than the yield stress of the material and a maximum wall distortion on the order of 0.0001 in. Design factors that were investigated include the inner corner radius, the value of the interference fit, the compaction force, the size of the cavity, and the outer radius and geometry of the outer ring. The results show that for the europium oxide die, a 0.01 in. diameter wire can be used to create the cavity, leading to a 0.0055 in. radius corner, if the radial interference fit is 0.003 in. For the tantalum die, the same wire can be used with a radial interference fit of 0.001 in. Also, for the europium oxide die with a 0.003 in. interference fit, it is possible to use a wire with a diameter of 0.006 in. for the wire burning process. Adding a 10% safety factor to the compaction force tends to lead to conservative estimates of the stresses but not for the wall distortion. However, when the 10% safety factor is removed, the wall distortion is not affected enough to discard the design. Finally, regarding the europium oxide die, when the cavity walls are increased by 0.002 in. per side or the outer ring is made to the same geometry as the tantalum die, all the stresses and wall distortions are within the desired range. Thus, the recommendation is to use a 0.006 in. diameter wire and a 0.003 in. interference fit for the europium oxide die and a 0.01 in. diameter wire and a 0.001 in. interference fit for the tantalum die. The dies can also be made to have the

  7. Energy Saving Melting and Revert Reduction Technology (E-SMARRT): Mechanical Performance of Dies

    SciTech Connect

    R. Allen Miller, Principal Investigator; Kabiri-Bamoradian, Contributors: Khalil; Delgado-Garza, Abelardo; Murugesan, Karthik; Ragab, Adham

    2011-09-13

    As a net shape process, die casting is intrinsically efficient and improvements in energy efficiency are strongly dependent on design and process improvements that reduce scrap rates so that more of the total consumed energy goes into acceptable, usable castings. A casting that is distorted and fails to meet specified dimensional requirements is typically remelted but this still results in a decrease in process yield, lost productivity, and increased energy consumption. This work focuses on developing, and expanding the use of, computer modeling methods that can be used to improve the dimensional accuracy of die castings and produce die designs and machine/die setups that reduce rejection rates due to dimensional issues. A major factor contributing to the dimensional inaccuracy of the casting is the elastic deformations of the die cavity caused by the thermo mechanical loads the dies are subjected to during normal operation. Although thermal and die cavity filling simulation are widely used in the industry, structural modeling of the die, particularly for managing part distortion, is not yet widely practiced. This may be due in part to the need to have a thorough understanding of the physical phenomenon involved in die distortion and the mathematical theory employed in the numerical models to efficiently model the die distortion phenomenon. Therefore, two of the goals of this work are to assist in efforts to expand the use of structural modeling and related technologies in the die casting industry by 1) providing a detailed modeling guideline and tutorial for those interested in developing the necessary skills and capability and 2) by developing simple meta-models that capture the results and experience gained from several years of die distortion research and can be used to predict key distortion phenomena of relevance to a die caster with a minimum of background and without the need for simulations. These objectives were met. A detailed modeling tutorial was

  8. Titan Casts Revealing Shadow

    NASA Astrophysics Data System (ADS)

    2004-05-01

    A rare celestial event was captured by NASA's Chandra X-ray Observatory as Titan -- Saturn's largest moon and the only moon in the Solar System with a thick atmosphere -- crossed in front of the X-ray bright Crab Nebula. The X-ray shadow cast by Titan allowed astronomers to make the first X-ray measurement of the extent of its atmosphere. On January 5, 2003, Titan transited the Crab Nebula, the remnant of a supernova explosion that was observed to occur in the year 1054. Although Saturn and Titan pass within a few degrees of the Crab Nebula every 30 years, they rarely pass directly in front of it. "This may have been the first transit of the Crab Nebula by Titan since the birth of the Crab Nebula," said Koji Mori of Pennsylvania State University in University Park, and lead author on an Astrophysical Journal paper describing these results. "The next similar conjunction will take place in the year 2267, so this was truly a once in a lifetime event." Animation of Titan's Shadow on Crab Nebula Animation of Titan's Shadow on Crab Nebula Chandra's observation revealed that the diameter of the X-ray shadow cast by Titan was larger than the diameter of its solid surface. The difference in diameters gives a measurement of about 550 miles (880 kilometers) for the height of the X-ray absorbing region of Titan's atmosphere. The extent of the upper atmosphere is consistent with, or slightly (10-15%) larger, than that implied by Voyager I observations made at radio, infrared, and ultraviolet wavelengths in 1980. "Saturn was about 5% closer to the Sun in 2003, so increased solar heating of Titan may account for some of this atmospheric expansion," said Hiroshi Tsunemi of Osaka University in Japan, one of the coauthors on the paper. The X-ray brightness and extent of the Crab Nebula made it possible to study the tiny X-ray shadow cast by Titan during its transit. By using Chandra to precisely track Titan's position, astronomers were able to measure a shadow one arcsecond in

  9. Study of Thermal Fatigue of H13 Die Steel with Various Surface Treatments

    NASA Astrophysics Data System (ADS)

    Ivanov, V. V.; Ferguson, W. G.; Paine, I. R.

    Surfaces of die-casting dies are subjected to very severe conditions of cyclical thermal and mechanical load, and chemical and mechanical wear. Dies mostly fail due to a combination of heat checking, erosion, corrosion and soldering. It is conceivable that appropriate surface treatments and coatings have a favourable influence on the temperature dependant performance of the surface of the die. The objective of this study was to examine various surface treatments and coatings. including shot peening, nitriding, nitro-carburizing, laser hardening and remelting, electro-spark alloying (deposition) and plasma spraying, under thermal fatigue conditions. Thermal cycling tests were conducted by alternate dipping of treated samples in an LM24 melt and in water. Results and interpretation are presented in this paper. The best thermal fatigue resistance was shown for a double surface treatment of laser hardening plus electro-spark deposition.

  10. Adapt or die?

    PubMed

    Visser, S S; Nel, A H

    1996-12-01

    The worldwide economic recession and the concomitant limited stock of finances have had an influence on the available money of every household and have also inhibited the improvement of socio-economic conditions and medicine. The Reconstruction and Development Programme (RDP) has the objective of improving the living conditions of the people with regard to housing, education, training and health care. The latter seems to be a major problem which has to be addressed with the emphasis on the preventive and promotional aspects of health care. A comprehensive health care system did not come into being property in the past because of the maldistribution of health care services, personnel and differences in culture and health care beliefs and values. The question that now arises, is how to render a quality health care service within the constraints of inadequate financing and resources. A comprehensive literature study has been done with reference to quality health care and financing followed by a survey of existing health services and finances. Recommendations are made about minimum requirements to be accepted if one were to adapt rather than die in terms of the provision of healthcare: the decentralization and rationalization of the administration of health care, the stress on and realization of effective and efficient primary health care, the acceptance of participative management in health providing organizations, the provision of financial management training for health care managers and the application of management accounting principles for the improvement of the efficiency and effectiveness of management. PMID:9283343

  11. Dying and multiplying life.

    PubMed

    Rodríguez-Arias, David

    2014-09-01

    It was only after James P. Lovette's death, in 2006, that I discovered that the twenty-four-year-old colleague and friend with whom I had spent so many afternoons debating issues in organ transplantation had been the first successful child heart transplantee in the world and one of the longest-living survivors of a second transplant. During the years we met, he never even hinted at the fact that three different hearts had beaten in his chest. The revelation that his life had been an almost uninterrupted chain of medical challenges suddenly made me appreciate his quirkiness in a whole new light. Organ transplantation crudely exemplifies a traditional moral dilemma between means and ends: in order to save a life, someone else has to die. Bioethicists involved in this field have the role of identifying the ethical issues surrounding organ donation and helping others to argue in an intelligible and convincing way. In my view, bioethicists have the obligation to foster a discussion as open and transparent as possible on these matters. Still, I sometimes fear that I may be helping to cause unnecessary harms to potential recipients who are desperately waiting for a vital organ. Scholars would be chillingly cold if their quest for truth systematically came at the cost of lives lost. Every life can be meaningful and provide meaning to many others. This is true even with organ recipients, who often have short lives full of considerable suffering. PMID:25231665

  12. Fillability of Thin-Wall Steel Castings

    SciTech Connect

    Robert C. Voigt; Joseph Bertoletti; Andrew Kaley; Sandi Ricotta; Travis Sunday

    2002-07-30

    The use of steel components is being challenged by lighter nonferrous or cast iron components. The development of techniques for enhancing and ensuring the filability of thin-wall mold cavities is most critical for thinner wall cast steel production. The purpose of this research was to develop thin-wall casting techniques that can be used to reliably produce thin-wall castings from traditional gravity poured sand casting processes. The focus of the research was to enhance the filling behavior to prevent misrunds. Experiments were conducted to investigate the influence of various foundry variables on the filling of thin section steel castings. These variables include casting design, heat transfer, gating design, and metal fluidity. Wall thickness and pouring temperature have the greatest effect on casting fill. As wall thickness increases the volume to surface area of the casting increases, which increases the solidification time, allowing the metal to flow further in thicker sect ions. Pouring time is another significant variable affecting casting fill. Increases or decreases of 20% in the pouring time were found to have a significant effect on the filling of thin-wall production castings. Gating variables, including venting, pouring head height, and mold tilting also significantly affected thin-wall casting fill. Filters offer less turbulent, steadier flow, which is appropriate for thicker castings, but they do not enhance thin-wall casting fill.

  13. Cast adrift: Gortex cast liners allow greater patient activity.

    PubMed

    Dubowitz, Gerald; Miller, Deborah M

    2003-01-01

    Extremity fractures are a common injury, with nearly 1.5 million cases reported in the United States in 1998. Treatment often involves lengthy periods of immobilization. This report outlines the use of a Gortex cast liner by a subject who was able to engage in swimming and scuba diving during the healing process. We report that a Gortex cast liner may be considered for an active patient who is keen to return to limited activities during fracture healing. Apparently because of a lack of knowledge of their existence, physicians currently are underutilizing this method of casting in active patients. The use of Gortex liners elsewhere has been reported to have higher patient and physician satisfaction in both use and performance, with no reported detrimental effects on outcome. PMID:14518627

  14. Instant Casting Movie Theater: The Future Cast System

    NASA Astrophysics Data System (ADS)

    Maejima, Akinobu; Wemler, Shuhei; Machida, Tamotsu; Takebayashi, Masao; Morishima, Shigeo

    We have developed a visual entertainment system called “Future Cast” which enables anyone to easily participate in a pre-recorded or pre-created film as an instant CG movie star. This system provides audiences with the amazing opportunity to join the cast of a movie in real-time. The Future Cast System can automatically perform all the processes required to make this possible, from capturing participants' facial characteristics to rendering them into the movie. Our system can also be applied to any movie created using the same production process. We conducted our first experimental trial demonstration of the Future Cast System at the Mitsui-Toshiba pavilion at the 2005 World Exposition in Aichi Japan.

  15. Magnesium-lithium casting alloys

    NASA Technical Reports Server (NTRS)

    Latenko, V. P.; Silchenko, T. V.; Tikhonov, V. A.; Maltsev, V. P.; Korablin, V. P.

    1974-01-01

    The strength properties of magnesium-lithium alloys at room, low, and high temperatures are investigated. It is found that the alloys may have practical application at ambient temperatures up to 100 C, that negative temperatures have a favorable influence on the alloy strength, and that cyclic temperature variations have practically no effect on the strength characteristics. The influence of chemical coatings on corrosion resistance of the MgLi alloys is examined. Several facilities based on pressure casting machines, low-pressure casting machines, and magnetodynamic pumps were designed for producing MgLi alloy castings. Results were obtained for MgLi alloys reinforced with fibers having a volumetric content of 15%.

  16. Casting propellant in rocket engine

    NASA Technical Reports Server (NTRS)

    Roach, J. E.; Froehling, S. C. (Inventor)

    1976-01-01

    A method is described for casting a solid propellant in the casing of a rocket engine having a continuous wall with a single opening which is formed by leaves of a material which melt at a temperature of the propellant and with curved edges concentric to the curvature of the spherical casing. The leaves are inserted into the spherical casing through the opening forming a core having a greater width than the width of the single opening and with curved peripheral edges. The cast propellant forms a solid mass and then heated to melt the leaves and provide a central opening with radial projecting flutes.

  17. Cementite Solidification in Cast Iron

    NASA Astrophysics Data System (ADS)

    Coronado, J. J.; Sinatora, A.; Albertin, E.

    2014-06-01

    Two hypereutectic cast irons (5.01 pct Cr and 5.19 pct V) were cast and the polished surfaces of test pieces were deep-etched and analyzed via scanning electron microscopy. The results show that graphite lamellae intersect the cementite and a thin austenite film nucleates and grows on the cementite plates. For both compositions, graphite and cementite can coexist as equilibrium phases, with the former always nucleating and growing first. The eutectic carbides grow from the austenite dendrites in a direction perpendicular to the primary plates.

  18. Casting behavior of titanium alloys in a centrifugal casting machine.

    PubMed

    Watanabe, K; Miyakawa, O; Takada, Y; Okuno, O; Okabe, T

    2003-05-01

    Since dental casting requires replication of complex shapes with great accuracy, this study examined how well some commercial titanium alloys and experimental titanium-copper alloys filled a mold cavity. The metals examined were three types of commercial dental titanium [commercially pure titanium (hereinafter noted as CP-Ti), Ti-6Al-4V (T64) and Ti-6Al-7Nb (T67)], and experimental titanium-copper alloys [3%, 5% and 10% Cu (mass %)]. The volume percentage filling the cavity was evaluated in castings prepared in a very thin perforated sheet pattern and cast in a centrifugal casting machine. The flow behavior of the molten metal was also examined using a so-called "tracer element technique." The amounts of CP-Ti and all the Ti-Cu alloys filling the cavity were similar; less T64 and T67 filled the cavity. However, the Ti-Cu alloys failed to reach the end of the cavities due to a lower fluidity compared to the other metals. A mold prepared with specially designed perforated sheets was effective at differentiating the flow behavior of the metals tested. The present technique also revealed that the more viscous Ti-Cu alloys with a wide freezing range failed to sequentially flow to the end of the cavity. PMID:12593955

  19. What Happens When Someone Dies?

    MedlinePlus

    ... and sleepiness Mental confusion Constipation or incontinence Nausea Refusal to eat or drink Each of these symptoms, ... having a "non-hospital DNR" (see Understanding Health Care Decisions ) if the person is dying at home. ...

  20. INTERIOR VIEW WITH CASTING MACHINE AND A 4" DUCTILE IRON ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    INTERIOR VIEW WITH CASTING MACHINE AND A 4" DUCTILE IRON PIPE BEING EXTRACTED FROM CASTING MACHINE - McWane Cast Iron Pipe Company, Pipe Casting Area, 1201 Vanderbilt Road, Birmingham, Jefferson County, AL

  1. INTERIOR VIEW OF CASTING MACHINE WITH 4' DUCTILE IRON PIPE ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    INTERIOR VIEW OF CASTING MACHINE WITH 4' DUCTILE IRON PIPE BEING WEIGHED ON SCALES AT CASTING MACHINE. - McWane Cast Iron Pipe Company, Pipe Casting Area, 1201 Vanderbilt Road, Birmingham, Jefferson County, AL

  2. INTERIOR VIEW WITH CASTING MACHINE AND A 4' DUCTILE IRON ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    INTERIOR VIEW WITH CASTING MACHINE AND A 4' DUCTILE IRON PIPE BEING CENTRIFUGALLY CAST, AS OPERATOR WATCHES TO ENSURE QUALITY. - McWane Cast Iron Pipe Company, Pipe Casting Area, 1201 Vanderbilt Road, Birmingham, Jefferson County, AL

  3. INTERIOR VIEW WITH CASTING MACHINE COOLING A 20' IRON PIPE ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    INTERIOR VIEW WITH CASTING MACHINE COOLING A 20' IRON PIPE PRIOR TO EXTRACTION FROM CASTING MACHINE. - McWane Cast Iron Pipe Company, Pipe Casting Area, 1201 Vanderbilt Road, Birmingham, Jefferson County, AL

  4. CIR Casting System for making transtibial sockets.

    PubMed

    Wu, Yeongchi; Casanova, Hector R; Reisinger, Kim D; Smith, William K; Childress, Dudley S

    2009-03-01

    This paper describes a new casting system for transtibial socket fabrication. Like the earlier CIR Sand Casting System, the CIR Casting System is based on the 'dilatancy' principle that is similar to the packaging process for coffee beans by which loose beans become a solid mass when a vacuum is applied. The main difference from the CIR Sand Casting System is that the CIR Casting System uses light-weight, polystyrene beads in place of silica sand as the primary material for casting the negative mold. The formed negative mold can be converted into a positive sand model for modification and socket formation. With the new plaster-less casting system, the prosthetist can fabricate a transtibial prosthesis in about one hour. It reduces the set-up cost, overall weight and size of the casting system, and increases portability for service in remote areas. The System also creates minimal waste and is energy-conserving and environmentally-friendly. PMID:19235060

  5. Properties of electroslag castings: Part 1

    SciTech Connect

    Sikka, V.K.

    1984-11-01

    This part of several reports to be published on the properties of electroslag castings of 2 1/4 Cr-1 Mo, 9 Cr-1 Mo, and type 316 stainless steel describes the properties of three electroslag-cast valve bodies of type 316 stainless steel. These castings were electroslag cast at the University of British Columbia in Canada from ORNL-supplied electrodes. The castings have been characterized for surface finish, cracking, solidification structure, chemical analysis, hardness, ferrite distribution, tensile properties, Charpy impact properties, and creep properties. Tensile data on these castings were compared with the American Society of Mechanical Engineers (ASME) code minimum values for sand castings. The creep data were compared with the data on sand castings and the ASME code minimum curve for wrought material. 29 figures, 7 tables.

  6. REFRACTORY DIE FOR EXTRUDING URANIUM

    DOEpatents

    Creutz, E.C.

    1959-08-11

    A die is presented for the extrusion of metals, said die being formed of a refractory complex oxide having the composition M/sub n/O/sub m/R/sub x/O/sub y/ where M is magnesium, zinc, manganese, or iron, R is aluminum, chromic chromium, ferric iron, or manganic manganese, and m, n, x, and y are whole numbers. Specific examples are spinel, magnesium aluminate, magnetite, magnesioferrite, chromite, and franklinite.

  7. Improving care of dying children.

    PubMed Central

    Martinson, I M

    1995-01-01

    Every year about 5,000 children aged 0 to 14 years need hospice care in the United States. Children seem to know that they are dying, although this is difficult for parents to accept. Clear, empathic understanding is needed. Communication with clarity and understanding is imperative with the changes in goals from cure to palliation to comfort. The ideal place for most dying children is at home, where symptoms can be managed as effectively as in a hospital. PMID:7571589

  8. Development and Demonstration of Adanced Tooling Alloys for Molds and Dies

    SciTech Connect

    Kevin M. McHugh; Enrique J. Lavernia

    2006-01-01

    This report summarizes research results in the project Development and Demonstration of Advanced Tooling Alloys for Molds and Dies. Molds, dies and related tooling are used to manufacture most of the plastic and metal products we use every day. Conventional fabrication of molds and dies involves a multiplicity of machining, benching and heat treatment unit operations. This approach is very expensive and time consuming. Rapid Solidifcation Process (RSP) Tooling is a spray-forming technology tailored for producing molds and dies. The appraoch combines rapid solidifcation processing and net-shape materials processing in a single step. An atomized spray of a tool-forming alloy, typically a tool steel, is deposited onto an easy-to-form tool pattern to replicate the pattern's shape and surface features. By so doing, the approach eliminates many machining operations in conventional mold making, significantly reducing cost, lead time and energy. Moreover, rapid solidification creates unique microstructural features by suppressing carbide precipitation and growth, and creating metastable phases. This can result in unique material properties following heat treatment. Spray-formed and aged tool steel dies have exhibited extended life compared to conventional dies in many forming operations such as forging, extrusion and die casting. RSP Tooling technolocy was commercialized with the formation of RSP Tooling, LLC in Solon, Oh.

  9. Integrally cored ceramic investment casting mold fabricated by ceramic stereolithography

    NASA Astrophysics Data System (ADS)

    Bae, Chang-Jun

    Superalloy airfoils are produced by investment casting (IC), which uses ceramic cores and wax patterns with ceramic shell molds. Hollow cored superalloy airfoils in a gas turbine engine are an example of complex IC parts. The complex internal hollow cavities of the airfoil are designed to conduct cooling air through one or more passageways. These complex internal passageways have been fabricated by a lost wax process requiring several processing steps; core preparation, injection molding for wax pattern, and dipping process for ceramic shell molds. Several steps generate problems such as high cost and decreased accuracy of the ceramic mold. For example, costly tooling and production delay are required to produce mold dies for complex cores and wax patterns used in injection molding, resulting in a big obstacle for prototypes and smaller production runs. Rather than using separate cores, patterns, and shell molds, it would be advantageous to directly produce a mold that has the casting cavity and the ceramic core by one process. Ceramic stereolithography (CerSLA) can be used to directly fabricate the integrally cored ceramic casting mold (ICCM). CerSLA builds ceramic green objects from CAD files from many thin liquid layers of powder in monomer, which are solidified by polymerization with a UV laser, thereby "writing" the design for each slice. This dissertation addresses the integrally cored casting ceramic mold (ICCM), the ceramic core with a ceramic mold shell in a single patternless construction, fabricated by ceramic stereolithography (CerSLA). CerSLA is considered as an alternative method to replace lost wax processes, for small production runs or designs too complex for conventional cores and patterns. The main topic is the development of methods to successfully fabricate an ICCM by CerSLA from refractory silica, as well as related issues. The related issues are the segregation of coarse fused silica powders in a layer, the degree of segregation parameter to

  10. Effect of ferrite on cast stainless steels

    SciTech Connect

    Nadezhdin, A.; Cooper, K. ); Timbers, G. . Kraft Pulp Division)

    1994-09-01

    Premature failure of stainless steel castings in bleach washing service is attributed to poor casting quality high porosity and to a high ferrite content, which makes the castings susceptible to corrosion by hot acid chloride solutions. A survey of the chemical compositions and ferrite contents of corrosion-resistant castings in bleach plants at three pulp mills found high [delta]-ferrite levels in the austenitic matrix due to the improper balance between austenite and ferrite stabilizers.

  11. 14 CFR 27.621 - Casting factors.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings except... structural loads. (b) Bearing stresses and surfaces. The casting factors specified in paragraphs (c) and (d... at an ultimate load corresponding to a casting factor of 1.25; and (ii) The deformation...

  12. 14 CFR 27.621 - Casting factors.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings except... structural loads. (b) Bearing stresses and surfaces. The casting factors specified in paragraphs (c) and (d... at an ultimate load corresponding to a casting factor of 1.25; and (ii) The deformation...

  13. 14 CFR 29.621 - Casting factors.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings except... structural loads. (b) Bearing stresses and surfaces. The casting factors specified in paragraphs (c) and (d... at an ultimate load corresponding to a casting factor of 1.25; and (ii) The deformation...

  14. 14 CFR 29.621 - Casting factors.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings except... structural loads. (b) Bearing stresses and surfaces. The casting factors specified in paragraphs (c) and (d... at an ultimate load corresponding to a casting factor of 1.25; and (ii) The deformation...

  15. 14 CFR 27.621 - Casting factors.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings except... structural loads. (b) Bearing stresses and surfaces. The casting factors specified in paragraphs (c) and (d... at an ultimate load corresponding to a casting factor of 1.25; and (ii) The deformation...

  16. 14 CFR 29.621 - Casting factors.

    Code of Federal Regulations, 2014 CFR

    2014-01-01

    ... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings except... structural loads. (b) Bearing stresses and surfaces. The casting factors specified in paragraphs (c) and (d... at an ultimate load corresponding to a casting factor of 1.25; and (ii) The deformation...

  17. 14 CFR 29.621 - Casting factors.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings except... structural loads. (b) Bearing stresses and surfaces. The casting factors specified in paragraphs (c) and (d... at an ultimate load corresponding to a casting factor of 1.25; and (ii) The deformation...

  18. 14 CFR 27.621 - Casting factors.

    Code of Federal Regulations, 2014 CFR

    2014-01-01

    ... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings except... structural loads. (b) Bearing stresses and surfaces. The casting factors specified in paragraphs (c) and (d... at an ultimate load corresponding to a casting factor of 1.25; and (ii) The deformation...

  19. Chimerical categories: caste, race, and genetics.

    PubMed

    Sabir, Sharjeel

    2003-12-01

    Is discrimination based on caste equivalent to racism? This paper explores the complex relationship between genetic, race and caste. It also discusses the debate over the exclusion of a discussion of caste-based discrimination at the 2001 World Conference against Racism, Racial Discrimination, Xenophobia and Related Intolerance held in Durban, South Africa. PMID:14768649

  20. Pressure distribution in centrifugal dental casting.

    PubMed

    Nielsen, J P

    1978-02-01

    Equations are developed for liquid metal pressure in centrifugal dental casting, given the instantaneous rotational velocity, density, and certain dimensions of the casting machine and casting pattern. A "reference parabola" is introduced making the fluid pressure concept more understandable. A specially designed specimen demonstrates experimentally the reference parabola at freezing. PMID:355283

  1. Prediction of Microporosity in Shrouded Impeller Castings

    SciTech Connect

    Viswanathan, S. Nelson, C.D.

    1998-09-01

    The purpose of this Cooperative Research and Development Agreement (CRADA) between the Oak Ridge National Laboratory (ORNL) and Morris Bean and Company was to link computer models of heat and fluid flow with previously developed quality criteria for the prediction of microporosity in a Al-4.5% Cu alloy shrouded impeller casting. The results may be used to analyze the casting process design for the commercial production of 206 o alloy shrouded impeller castings. Test impeller castings were poured in the laboratory for the purpose of obtaining thermal data and porosity distributions. Also, a simulation of the test impeller casting was conducted and the results validated with porosity measurements on the test castings. A comparison of the predicted and measured microporosity distributions indicated an excellent correlation between experiments and prediction. The results of the experimental and modeling studies undertaken in this project indicate that the quality criteria developed for the prediction of microporosity in Al-4.5% Cu alloy castings can accurately predict regions of elevated microporosity even in complex castings such as the shrouded impeller casting. Accordingly, it should be possible to use quality criteria for porosity prediction in conjunction with computer models of heat and fluid flow to optimize the casting process for the production of shrouded impeller castings. Since high levels of microporosity may be expected to result in poor fatigue properties, casting designs that are optimized for low levels of microporosity should exhibit superior fatigue life.

  2. Casting Freedom, 1860-1862

    ERIC Educational Resources Information Center

    Social Education, 2005

    2005-01-01

    Thomas Crawford, an American Sculptor, created the full-size figure of Freedom in clay. Molds were made, from which a full-size positive plaster model was cast in five main sections. This model is on view today in the basement rotunda of the Russell Senate Office Building. Clark Mills was a self-taught American sculptor with experience in casting…

  3. Tape casting of magnesium oxide.

    SciTech Connect

    Ayala, Alicia; Corral, Erica L.; Loehman, Ronald E.; Bencoe, Denise Nora; Reiterer, Markus; Shah, Raja A.

    2008-02-01

    A tape casting procedure for fabricating ceramic magnesium oxide tapes has been developed as a method to produce flat sheets of sintered MgO that are thin and porous. Thickness of single layer tapes is in the range of 200-400 {micro}m with corresponding surface roughness values in the range of 10-20 {micro}m as measured by laser profilometry. Development of the tape casting technique required optimization of pretreatment for the starting magnesium oxide (MgO) powder as well as a detailed study of the casting slurry preparation and subsequent heat treatments for sintering and final tape flattening. Milling time of the ceramic powder, plasticizer, and binder mixture was identified as a primary factor affecting surface morphology of the tapes. In general, longer milling times resulted in green tapes with a noticeably smoother surface. This work demonstrates that meticulous control of the entire tape casting operation is necessary to obtain high-quality MgO tapes.

  4. Graphite Formation in Cast Iron

    NASA Technical Reports Server (NTRS)

    Stefanescu, D. M.

    1985-01-01

    In the first phase of the project it was proven that by changing the ratio between the thermal gradient and the growth rate for commercial cast iron samples solidifying in a Bridgman type furnace, it is possible to produce all types of graphite structures, from flake to spheroidal, and all types of matrices, from ferritic to white at a certain given level of cerium. KC-135 flight experiments have shown that in a low-gravity environment, no flotation occurs even in spheroidal graphite cast irons with carbon equivalent as high as 5%, while extensive graphite flotation occurred in both flake and spheroidal graphite cast irons, in high carbon samples solidified in a high gravity environment. This opens the way for production of iron-carbon composite materials, with high carbon content (e.g., 10%) in a low gravity environment. By using KC-135 flights, the influence of some basic elements on the solidification of cast iron will be studied. The mechanism of flake to spheroidal graphite transition will be studied, by using quenching experiments at both low and one gravity for different G/R ratios.

  5. ENVIRONMENTAL ASSESSMENT OF IRON CASTING

    EPA Science Inventory

    Sampling of ductile iron casting in green sand molds with phenolic isocyanate cores and in phenol-formaldehyde bound shell molds did not provide definitive proof that environmentally hazardous organic emission occur. Both molding systems produced the same type of major emissions,...

  6. Advanced Lost Foam Casting Technology

    SciTech Connect

    Charles E. Bates; Harry E. Littleton; Don Askeland; Taras Molibog; Jason Hopper; Ben Vatankhah

    2000-11-30

    This report describes the research done under the six tasks to improve the process and make it more functional in an industrial environment. Task 1: Pattern Pyrolysis Products and Pattern Properties Task 2: Coating Quality Control Task 3: Fill and Solidification Code Task 4: Alternate Pattern Materials Task 5: Casting Distortion Task 6: Technology Transfer

  7. Diabetic Neuropathy: What is a Total Contact Cast?

    MedlinePlus

    ... Web version Diabetic Neuropathy | What is a Total Contact Cast? What is a total contact cast? A total contact cast is a cast used to treat ulcers ( ... foot--that's why it is called a total contact cast. The cast helps to protect the skin ...

  8. Mechanical evaluation of a soft cast material.

    PubMed

    Zmurko, M G; Belkoff, S M; Herzenberg, J E

    1997-08-01

    In this study, the structural and material properties of a new semi-rigid material, Scotchcast SoftCast (SCS), were compared to the properties of two rigid materials, plaster of paris (POP) and Scotchcast Plus (SCP). Cylinders and flat beams made from 4, 6, 8, and 10 layers of each casting material were tested in three-point bending and diametrical compression. Initial stiffness and yield force values of SCS casts were significantly lower than for casts of SCP and POP made of the same number of layers. Casts made from SCS may be indicated for non-rigid applications, but not where rigid immobilization is required. PMID:9263288

  9. Process development of thin strip steel casting

    SciTech Connect

    Sussman, R.C.; Williams, R.S.

    1990-12-01

    An important new frontier is being opened in steel processing with the emergence of thin strip casting. Casting steel directly to thin strip has enormous benefits in energy savings by potentially eliminating the need for hot reduction in a hot strip mill. This has been the driving force for numerous current research efforts into the direct strip casting of steel. The US Department of Energy initiated a program to evaluate the development of thin strip casting in the steel industry. In earlier phases of this program, planar flow casting on an experimental caster was studied by a team of engineers from Westinghouse Electric corporation and Armco Inc. A subsequent research program was designed as a fundamental and developmental study of both planar and melt overflow casting processes. This study was arranged as several separate and distinct tasks which were often completed by different teams of researchers. An early task was to design and build a water model to study fluid flow through different designs of planar flow casting nozzles. Another important task was mathematically modeling of melt overflow casting process. A mathematical solidification model for the formation of the strip in the melt overflow process was written. A study of the material and conditioning of casting substrates was made on the small wheel caster using the melt overflow casting process. This report discusses work on the development of thin steel casting.

  10. Emulsion based cast booster - a priming system

    SciTech Connect

    Gupta, R.N.; Mishra, A.K.

    2005-07-01

    This paper explores the potential of emulsion based cast booster to be used as primer to initiate bulk delivered emulsion explosives used in mines. An attempt has been made for comparative study between conventional cast booster and emulsion based cast booster in terms of the initiation process developed and their capability to develop and maintain the stable detonation process in the column explosives. The study has been conducted using a continuous velocity of detonation (VOD) measuring instrument. During this study three blasts have been monitored. In each blast two holes have been selected for study, the first hole being initiated with conventional cast booster while the other one with emulsion based cast booster. The findings of the study advocates that emulsion based cast booster is capable of efficient priming of bulk delivered column explosive with stable detonation process in the column. Further, the booster had advantages over the conventional PETN/TNT based cast booster. 5 refs., 2 figs., 1 tab., 1 photo.

  11. Acting to let someone die.

    PubMed

    McGee, Andrew

    2015-02-01

    This paper examines the recent prominent view in medical ethics that withdrawing life-sustaining treatment (LST) is an act of killing. I trace this view to the rejection of the traditional claim that withdrawing LST is an omission rather than an act. Although that traditional claim is not as problematic as this recent prominent view suggests, my main claim is that even if we accepted that withdrawing LST should be classified as an act rather than as an omission, it could still be classified as letting die rather than killing. Even though omissions are contrasted with acts, letting die need not be, for one can let die by means of acts. The remainder of the paper is devoted to establishing this claim and addresses certain objections to it. PMID:24320715

  12. Clinical management of dying patients.

    PubMed Central

    Gavrin, J; Chapman, C R

    1995-01-01

    Dying is universal, and death should be a peaceful time. Myriad comfort measures are available in the last weeks before life ends. Discussions about end-of-life issues often suffer from lack of informed opinion. Palliative care experts have identified specific somatic and psychological sources of distress for dying patients and their loved ones. Pain, shortness of breath, nausea and vomiting, and fear of abandonment contribute substantially to both physical and psychological discomfort toward the end of life. Simple, effective methods exist for relieving those symptoms. Knowledge about the natural events associated with dying and an informed approach to medical and psychological interventions contribute to systematic and successful comfort care. We describe the origin of physical and psychological distress at the end of life and provide strategies for alleviating many of the discomforts. PMID:7571591

  13. Titanium casting: the surface reaction layer of castings obtained using ultra-low-temperature molds.

    PubMed

    Kikuchi, H; Onouchi, M; Hsu, H C; Kurotani, T; Nishiyama, M

    2001-03-01

    To examine whether the surface reaction layer of titanium castings can be reduced by lowering the mold temperature during casting, we cast titanium at three mold temperatures, including an ultra-low temperature produced by cooling the mold with liquid nitrogen, then measured the tensile strength and elongation of the castings. The titanium was cast using a centrifugal casting machine, and the molds were incinerated according to the manufacturers' instructions. Castings were then made with the molds at 200 degrees C, 600 degrees C, and an ultra-low temperature (-196 degrees C). The castability of titanium cast in the mold at the ultra-low temperature was good. The Vickers hardness near the surface layer of castings decreased as the mold temperature decreased. PMID:11383633

  14. Inner surface roughness of complete cast crowns made by centrifugal casting machines.

    PubMed

    Ogura, H; Raptis, C N; Asgar, K

    1981-05-01

    Six variables that could affect the surface roughness of a casting were investigated. The variables were (1) type of alloy, (2) mold temperature, (3) metal casting temperature, (4) casting machine, (5) sandblasting, and (6) location of each section. It was determined that the training portion of a complete cast crown had rougher surfaces than the leading portion. Higher mold and casting temperatures produced rougher castings, and this effect was more pronounced in the case of the base metal alloy. Sandblasting reduced the roughness, but produced scratched surfaces. Sandblasting had a more pronounced affect on the surface roughness of the base metal alloy cast either at a higher mold temperature or metal casting temperature. The morphology and the roughness profile of the original cast surface differed considerably with the type of alloy used. PMID:7012322

  15. Superplastic Response of Continuously Cast AZ31B Magnesium Sheet Alloys

    NASA Astrophysics Data System (ADS)

    Boileau, J. M.; Friedman, P. A.; Houston, D. Q.; Luckey, S. G.

    2010-06-01

    Magnesium sheet is typically produced for commercial applications with the traditional DC-ingot casting method. As a result of the hexagonal close-packed crystallographic structure in magnesium, multiple rolling passes and annealing steps are required to reduce the thickness of the ingots. Thus, high fabrication costs characterize the creation of magnesium sheet suitable for common forming operations. Recently, continuous casting (CC) technology, where molten metal is solidified directly into sheet form, has been applied to magnesium alloys; this method has shown the potential to significantly reduce the cost of fabricating magnesium sheet alloys. In order to understand the viability of the CC process, a study was conducted to investigate the superplastic potential of alloys produced by this method. This study focused on AZ31B Mg that was continuously-cast on twin-roll casters from three different suppliers. These three materials were compared with a production DC-cast AZ31B alloy in terms of microstructure, elevated-temperature tensile properties, and superplastic forming response. The data from this study found that microstructural features such as grain size and segregation can significantly affect the forming response. Additionally, the CC alloys can have equivalent or superior SPF response compared to DC-cast alloys, as demonstrated in both elevated temperature tensile tests and superplastic forming trials using a rectangular pan die.

  16. 'Die Zeit' im Konversationsunterricht ('Die Zeit' in a Conversation Class)

    ERIC Educational Resources Information Center

    Becker-Cantarino, Barbel

    1975-01-01

    The German weekly newspaper "Die Zeit" contains a very rich variety of topics and is therefore an inexhaustable source for an exciting conversation class. This article outlines and lists the advantages of a German conversation course organized around this newspaper. (Text is in German.) (TL)

  17. Portable punch and die jig

    DOEpatents

    Lewandowski, Edward F.; Anderson, Petrus A.

    1978-01-01

    A portable punch and die jig includes a U-shaped jig of predetermined width having a slot of predetermined width in the base thereof extending completely across the width of the jig adapted to fit over the walls of rectangular tubes and a punch and die assembly disposed in a hole extending through the base of the jig communicating with the slot in the base of the jig for punching a hole in the walls of the rectangular tubes at precisely determined locations.

  18. Dying radio galaxies in clusters

    NASA Astrophysics Data System (ADS)

    Murgia, M.; Parma, P.; Mack, K.-H.; de Ruiter, H. R.; Fanti, R.; Govoni, F.; Tarchi, A.; Giacintucci, S.; Markevitch, M.

    2011-02-01

    Aims: We present a study of five "dying" nearby (z ≤ 0.2) radio galaxies belonging to both the WENSS minisurvey and the B2 bright catalogs WNB1734+6407, WNB1829+6911, WNB1851+5707, B2 0120+33, and B2 1610+29. Methods: These sources have been selected on the basis of their extremely steep broad-band radio spectra, which strongly indicates that either these objects belong to the rare class of dying radio galaxies or we are observing "fossil" radio plasma remaining from a previous instance of nuclear activity. We derive the relative duration of the dying phase from the fit of a synchrotron radiative model to the radio spectra of the sources. Results: The modeling of the integrated spectra and the deep spectral index images obtained with the VLA confirmed that in these sources the central engine has ceased to be active for a significant fraction of their lifetime, although their extended lobes have not yet completely faded away. We found that WNB1851+5707 is in reality composed of two distinct dying galaxies, which appear blended together as a single source in the WENSS. In the cases of WNB1829+6911 and B2 0120+33, the fossil radio lobes are seen in conjunction with a currently active core. A very faint core is also detected in a MERLIN image of WNB1851+5707a, one of the two dying sources composing WNB1851+5707. We found that all sources in our sample are located (at least in projection) at the center of an X-ray emitting cluster. Conclusions: Our results suggest that the duration of the dying phase for a radio source in a cluster can be significantly higher than that of a radio galaxy in the field, although no firm conclusions can be drawn because of the small number statistics involved. The simplest interpretation of the tendency for dying galaxies to be found in clusters is that the low-frequency radio emission from the fading radio lobes lasts longer if their expansion is somewhat reduced or even stopped. Another possibility is that the occurrence of dying

  19. Die Herz-Lungen-Maschine

    NASA Astrophysics Data System (ADS)

    Krane, Markus; Bauernschmitt, Robert; Lange, Rüdiger

    Das Kapitel der modernen Herzchirurgie mit Einsatz der Herz-Lungen-Maschine am Menschen beginnt am 6. Mai 1953, als J. Gibbon bei einer 18-jährigen Patientin einen angeborenen Defekt in der Vorhofscheidewand verschließt [1]. Mit ersten experimentellen Versuchen zur extrakorporalen Zirkulation begann Gibbon bereits in den 30er Jahren des 20. Jahrhunderts. Die Grundlage für die heute gebräuchliche Rollerpumpe schufen Porter und Bradley mit ihrer "rotary pump“, welche sie 1855 zum Patent anmeldeten. Diese Pumpe wurde von DeBakey und Schmidt modifiziert und entspricht im Wesentlichen noch der heute sich im Routinebetrieb befindlichen Rollerpumpe [2].

  20. Pressure rig for repetitive casting

    NASA Technical Reports Server (NTRS)

    Vasquez, Peter (Inventor); Hutto, William R. (Inventor); Philips, Albert R. (Inventor)

    1989-01-01

    The invention is a pressure rig for repetitive casting of metal. The pressure rig performs like a piston for feeding molten metal into a mold. Pressure is applied to an expandable rubber diaphragm which expands like a balloon to force the metal into the mold. A ceramic cavity which holds molten metal is lined with blanket-type insulating material, necessitating only a relining for subsequent use and eliminating the lengthy cavity preparation inherent in previous rigs. In addition, the expandable rubber diaphragm is protected by the insulating material thereby decreasing its vulnerability to heat damage. As a result of the improved design the life expectancy of the pressure rig contemplated by the present invention is more than doubled. Moreover, the improved heat protection has allowed the casting of brass and other alloys with higher melting temperatures than possible in the conventional pressure rigs.

  1. MHD technology in aluminum casting

    SciTech Connect

    Kalinichenko, I.

    1984-08-01

    The use of MHD technology in aluminum casting is discussed. Associates of the Latvian Academy of Sciences Institute of Physics developed magnetohydrodynamic units for the Siberian plant. A MHD unit made it possible to free five persons from heavy work at the plant. Labor productivity doubled in this section. With the aid of the magnetic field, the alloy silumin is obtained in only three hours. Specialists of the Irkutsk affiliate of the All-Union Scientific Research and Design Institute of the Aluminum, Magnesium and Electrode Industry are convinced that MHD technology has a bright future. However, this will necessitate the development of new MHD technology for different types of casting facilities, with their specific features taken into account.

  2. FEM stress analysis of the cooling hole of an HPDC die

    NASA Astrophysics Data System (ADS)

    Kimura, T.; Yamagata, H.; Tanikawa, S.

    2015-06-01

    Cracking at a cooling hole is a typical die failure mode in a high-pressure die-casting (HPDC) die. We simulated the thermal distortion of a die considering the HPDC machine deflection and revealed a stress concentration at the cooling hole. The stress concentration at the cooling hole changes after injection or after spraying and blowing air. The cooling hole top remains in a compression stress state 5, 10, and 20 mm deep from the die surface, but the stress amplitudes are higher when the depths are shallower. It was suggested that cracking takes place due to the high compressive stress and that the shear stress assists the propagation of the initiated crack. On the other hand, the stress condition at the R portion of the cooling hole is always a tensile state, but the mean stress and stress amplitude values were not found to be in the range that causes fatigue fracture. It was demonstrated that the developed analysis is valuable in designing the cooling hole of an HPDC die.

  3. Comparing the Accuracy of Three Different Impression Materials in Making Duplicate Dies

    PubMed Central

    Bajoghli, Farshad; Sabouhi, Mahmoud; Nosouhian, Saeid; Davoudi, Amin; Behnamnia, Zeynab

    2015-01-01

    Background: Marginal adaptation is very important in cast restorations. Maladaptation leads to plaque retention, reduction of mechanical and esthetic properties. The aim of this study was to evaluate the precision of three different impression materials (including: Additional silicone [AS] and condensational silicone [CS] and polyether [PE]) for duplicating master dies. Materials and Methods: Three master dies from an acrylic tooth model-with supragingival and shoulder finishing line was made by using PE: Impergum, CS: Speedex, and AS: Panasil separately. The Ni-Cr copings were prepared from master dies separately. They were placed on the acrylic model and the mean marginal difference was recorded by using a stereomicroscope. Then 30 duplicate test dies were made by using the same impression materials and the marginal gaps were recorded. The comparison was done by one-way ANOVA and SPSS software (Version 13) at a significant level of 0.05. Results: The mean marginal difference of four walls from Impergum (38.56 um) was the lowest than Speedex (38.92 um) and Panasil (38.24 um). The Impergum had the highest capability in making duplicate dies (P > 0.05). Conclusion: The Impergum impression material manifested the highest capability in making a better marginal adaptation of duplicate dies but further studies are needed to make a precise decision. PMID:26229364

  4. Effects of molten aluminum on H13 dies and coatings

    NASA Astrophysics Data System (ADS)

    Yu, M.; Shivpuri, R.; Rapp, R. A.

    1995-04-01

    The effects of molten aluminum casting alloy A390 on a commercially heat treated H13 die steel and two wear-resistant coatings, Cr23C6 and TiN, were investigated by an accelerated corrosion test. The H13 steel suffered severe corrosion due to the rapid formation of intermetallic compounds. The formation of multilayer intermetallic compounds and the simultaneous dissociation of the intermetallic compound τ6 (Al4FeSi) were attributed to the fast dissolution of H13 steels into the melt. This dissolution of the H13 steel was accelerated dramatically by turbulence and an increase in melt temperature. Significant improvement in corrosion resistance was achieved for the H13 steel coated by Cr23C6 via a pack cementation process.

  5. Extrusion strains produced in cast and in powder aluminum billets

    SciTech Connect

    Peacock, H B; Berghaus, D G

    1986-01-01

    A full-field solution for strains produced during axisymmetric extrusion may be obtained through a study of laminar flowlines which are produced as the material flows through the die. A flow function is mathematically constructed, using the flowlines, to determine the material flow rate along the given path. Velocities and strain-rates are determined along the flowlines. Flowline curves are determined experimentally from the stamped rectangular grid which was originally placed on an axial plane in a pre-extruded billet. For the powder metal billet, density values must also be determined experimentally. The method has been applied to the axisymmetric extrusion of cast and powder aluminum billets. Material deformation was studied for the powdered metal billet using the Scanning Electron Microscope.

  6. Robert Merton Dies at 92

    ERIC Educational Resources Information Center

    Snell, Joel C.

    2006-01-01

    This article features Robert Merton, who died recently at age 92. Merton came into this world as a Jewish baby named Meyer Schkolnick. He lived in South Philly where his parents wrenched a living as blue-collar workers. Merton chose an Anglicized name to move into the Yankee dominated America of the 20's and 30's. At Harvard, he studied under…

  7. Attitudes on Death and Dying.

    ERIC Educational Resources Information Center

    Andrus, Charles E.

    This paper explored attitudes toward death and dying revealed through interviews with members of the clergy, the medical profession, funeral directors, nursing home residents, and selected others. The sampling was small and results are not intended to be representative of the groups to which these people belong. Rather, the study may be used as a…

  8. Integrated Forming Simulations and Die Structural Analysis for Optimal Die Designs

    NASA Astrophysics Data System (ADS)

    Aitharaju, Venkat; Liu, Malcolm; Dong, Jennifer; Zhang, Jimmy; Wang, Chuan-tao

    2005-08-01

    After gaining a huge success in applying stamping simulations and formability analysis to validate die face developments, GM moves forward to winning total manufacturability in stamping process. Of which, ensuring die structure integrity and minimizing weight is one of the important initiatives. Stamping die design (or solid modeling of stamping dies) was traditionally conducted by following the die design manuals and standards. For any design changes beyond the standards, however, there are no math-based tools available to die designers to verify the outcome of the changes. Die structural analysis (DSA) provides a math-tool to validate the design changes and quantify the safety factors. Several years ago, GM Manufacturing Engineering — Die Center started die structural analysis to meet the increasing demands of customer needs in various areas: (1) to validate design changes; (2) to identify root cause of die breakage during the tryout and stamping operations and propose repair schemes; (3) to optimize the die design for weight reduction; (4) to improve press throughput via optimizing the scrap chute openings, and (5) to provide a math-based tool to validate revisions to the current die design standards. In the integrated forming and die structural analysis, after successful line die surface developments, the forming loads (binder force, pad force, and forming tonnages) are extracted from forming simulations and applied to solid die members for structural analyses of stress, strains, and deflections. In the past few years, Die Center conducted static, dynamic and fatigue analysis for many dies that covers the die design changes requested by die design, die construction and stamping plants. This paper presents some fundamentals and issues of integrated forming and die structural analysis and illustrates the significant impact of die structural analysis on die design, die construction and production stamping.

  9. Cast Metals Coalition Technology Transfer and Program Management Final Report

    SciTech Connect

    Gwyn, Mike

    2009-03-31

    The Cast Metals Coalition (CMC) partnership program was funded to ensure that the results of the Department of Energy's (DOE) metalcasting research and development (R&D) projects are successfully deployed into industry. Specifically, the CMC program coordinated the transfer and deployment of energy saving technologies and process improvements developed under separately funded DOE programs and projects into industry. The transition of these technologies and process improvements is a critical step in the path to realizing actual energy savings. At full deployment, DOE funded metalcasting R&D results are projected to save 55% of the energy used by the industry in 1998. This closely aligns with DOE's current goal of driving a 25% reduction in industrial energy intensity by 2017. In addition to benefiting DOE, these energy savings provide metalcasters with a significant economic advantage. Deployment of already completed R&D project results and those still underway is estimated to return over 500% of the original DOE and industry investment. Energy savings estimates through December 2008 from the Energy-Saving Melting and Revert Reduction Technology (E-SMARRT) portfolio of projects alone are 12 x 1012 BTUs, with a projection of over 50 x 1012 BTUs ten years after program completion. These energy savings and process improvements have been made possible through the unique collaborative structure of the CMC partnership. The CMC team consists of DOE's Office of Industrial Technology, the three leading metalcasting technical societies in the U.S: the American Foundry Society; the North American Die Casting Association; and the Steel Founders Society of America; and the Advanced Technology Institute (ATI), a recognized leader in distributed technology management. CMC provides collaborative leadership to a complex industry composed of approximately 2,100 companies, 80% of which employ less than 100 people, and only 4% of which employ more than 250 people. Without collaboration

  10. Marginal accuracy of nickel chromium copings fabricated by conventional and accelerated casting procedures, produced with ringless and metal ring investment procedures: A comparative in vitro study

    PubMed Central

    Alex, Deepa; Shetty, Y. Bharath; Miranda, Glynis Anita; Prabhu, M. Bharath; Karkera, Reshma

    2015-01-01

    Background: Conventional investing and casting techniques are time-consuming and usually requires 2–4 h for completion. Accelerated nonstandard, casting techniques have been reported to achieve similar quality results in significantly less time, namely, in 30–40 min. During casting, it is essential to achieve compensation for the shrinkage of solidifying alloy by investment expansion. The metal casting ring restricts the thermal expansion of investment because the thermal expansion of the ring is lesser than that of the investment. The use of casting ring was challenged with the introduction of the ringless technique. Materials and Methods: A total of 40 test samples of nickel chromium (Ni-Cr) cast copings were obtained from the patterns fabricated using inlay casting wax. The 20 wax patterns were invested using metal ring and 20 wax patterns were invested using the ringless investment system. Of both the groups, 10 samples underwent conventional casting, and the other 10 underwent accelerated casting. The patterns were casted using the induction casting technique. All the test samples of cast copings were evaluated for vertical marginal gaps at four points on the die employing a stereo optical microscope. Results: The vertical marginal discrepancy data obtained were tabulated. Mean and standard deviations were obtained. Vertical discrepancies were analyzed using analysis of variance and Tukey honestly significantly different. The data obtained were found to be very highly significant (P < 0.001). Mean vertical gap was the maximum for Group II (53.64 μm) followed by Group IV (47.62 μm), Group I (44.83 μm) and Group III (35.35 μm). Conclusion: The Ni-Cr cast copings fabricated with the conventional casting using ringless investment system showed significantly better marginal fit than that of cast copings fabricated from conventional and accelerated casting with metal ring investment and accelerated casting using ringless investment since those copings had

  11. Method for casting thin metal objects

    DOEpatents

    Pehrson, Brandon P; Moore, Alan F

    2015-04-14

    Provided herein are various embodiments of systems for casting thin metal plates and sheets. Typical embodiments include layers of mold cavities that are oriented vertically for casting the metal plates. In some embodiments, the mold cavities include a beveled edge such that the plates that are cast have a beveled edge. In some embodiments, the mold cavities are filled with a molten metal through an open horizontal edge of the cavity. In some embodiments, the mold cavities are filled through one or more vertical feed orifices. Further disclosed are methods for forming a thin cast metal plate or sheet where the thickness of the cast part is in a range from 0.005 inches to 0.2 inches, and the surface area of the cast part is in a range from 16 square inches to 144 square inches.

  12. Clean Cast Steel Technology, Phase IV

    SciTech Connect

    Charles E. Bates

    2003-02-24

    The objective of the Clean Cast Steel Technology Program was to improve casting product quality by removing or minimizing oxide defects and to allow the production of higher integrity castings for high speed machining lines. Previous research has concentrated on macro-inclusions that break, chip, or crack machine tool cutters and drills and cause immediate shutdown of the machining lines. The overall goal of the project is to reduce the amount of surface macro-inclusions and improve the machinability of steel castings. Macro-inclusions and improve the machinability of steel castings. Macro-inclusions have been identified by industrial sponsors as a major barrier to improving the quality and marketability of steel castings.

  13. Gating of Permanent Molds for ALuminum Casting

    SciTech Connect

    David Schwam; John F. Wallace; Tom Engle; Qingming Chang

    2004-03-30

    This report summarizes a two-year project, DE-FC07-01ID13983 that concerns the gating of aluminum castings in permanent molds. The main goal of the project is to improve the quality of aluminum castings produced in permanent molds. The approach taken was determine how the vertical type gating systems used for permanent mold castings can be designed to fill the mold cavity with a minimum of damage to the quality of the resulting casting. It is evident that somewhat different systems are preferred for different shapes and sizes of aluminum castings. The main problems caused by improper gating are entrained aluminum oxide films and entrapped gas. The project highlights the characteristic features of gating systems used in permanent mold aluminum foundries and recommends gating procedures designed to avoid common defects. The study also provides direct evidence on the filling pattern and heat flow behavior in permanent mold castings.

  14. Properties of electroslag castings. Part 2

    SciTech Connect

    Sikka, V.K.

    1985-08-01

    The quality, response to heat treatment, and mechanical properties of electroslag-cast step blocks from Cameron Iron Works and from Selectrotech, Inc., are described. The mechanical properties include Charpy impact, tensile, and creep. Properties of the electroslag castings were compared to determine the differences between casters, between wrought and electroslag cast properties, and between sand and electroslag castings. Results are presented to show that the electroslag casting process has a potential for producing properties similar to those of wrought material for 2 1/4 Cr-1 Mo and 9 Cr-1 Mo steel and similar to those of sand-cast material for type 316 stainless steel. 5 refs., 46 figs., 4 tabs.

  15. Energy-Saving Melting and Revert Reduction Technology (E-SMARRT): Use of Laser Engineered Net Shaping for Rapid Manufacturing of Dies with Protective Coatings and Improved Thermal Management

    SciTech Connect

    Brevick, Jerald R.

    2014-06-13

    In the high pressure die casting process, molten metal is introduced into a die cavity at high pressure and velocity, enabling castings of thin wall section and complex geometry to be obtained. Traditional die materials have been hot work die steels, commonly H13. Manufacture of the dies involves machining the desired geometry from monolithic blocks of annealed tool steel, heat treating to desired hardness and toughness, and final machining, grinding and polishing. The die is fabricated with internal water cooling passages created by drilling. These materials and fabrication methods have been used for many years, however, there are limitations. Tool steels have relatively low thermal conductivity, and as a result, it takes time to remove the heat from the tool steel via the drilled internal water cooling passages. Furthermore, the low thermal conductivity generates large thermal gradients at the die cavity surfaces, which ultimately leads to thermal fatigue cracking on the surfaces of the die steel. The high die surface temperatures also promote the metallurgical bonding of the aluminum casting alloy to the surface of the die steel (soldering). In terms of process efficiency, these tooling limitations reduce the number of die castings that can be made per unit time by increasing cycle time required for cooling, and increasing downtime and cost to replace tooling which has failed either by soldering or by thermal fatigue cracking (heat checking). The objective of this research was to evaluate the feasibility of designing, fabricating, and testing high pressure die casting tooling having properties equivalent to H13 on the surface in contact with molten casting alloy - for high temperature and high velocity molten metal erosion resistance – but with the ability to conduct heat rapidly to interior water cooling passages. A layered bimetallic tool design was selected, and the design evaluated for thermal and mechanical performance via finite element analysis. H13 was

  16. Directional Solidification of Nodular Cast Iron

    NASA Technical Reports Server (NTRS)

    Curreri, P. A.; Stefanescu, D. M.; Hendrix, J. C.

    1987-01-01

    Cerium enhances formation of graphite nodules. Preliminary experiments in directional solidification of cast iron shows quantitative correlation of graphite microstructure with growth rate and thermal gradient, with sufficient spheroidizing element to form spheroidal graphite under proper thermal conditions. Experimental approach enables use of directional solidification to study solidification of spheriodal-graphite cast iron in low gravity. Possible to form new structural materials from nodular cast iron.

  17. A Benchmark Study on Casting Residual Stress

    SciTech Connect

    Johnson, Eric M.; Watkins, Thomas R; Schmidlin, Joshua E; Dutler, S. A.

    2012-01-01

    Stringent regulatory requirements, such as Tier IV norms, have pushed the cast iron for automotive applications to its limit. The castings need to be designed with closer tolerances by incorporating hitherto unknowns, such as residual stresses arising due to thermal gradients, phase and microstructural changes during solidification phenomenon. Residual stresses were earlier neglected in the casting designs by incorporating large factors of safety. Experimental measurement of residual stress in a casting through neutron or X-ray diffraction, sectioning or hole drilling, magnetic, electric or photoelastic measurements is very difficult and time consuming exercise. A detailed multi-physics model, incorporating thermo-mechanical and phase transformation phenomenon, provides an attractive alternative to assess the residual stresses generated during casting. However, before relying on the simulation methodology, it is important to rigorously validate the prediction capability by comparing it to experimental measurements. In the present work, a benchmark study was undertaken for casting residual stress measurements through neutron diffraction, which was subsequently used to validate the accuracy of simulation prediction. The stress lattice specimen geometry was designed such that subsequent castings would generate adequate residual stresses during solidification and cooling, without any cracks. The residual stresses in the cast specimen were measured using neutron diffraction. Considering the difficulty in accessing the neutron diffraction facility, these measurements can be considered as benchmark for casting simulation validations. Simulations were performed using the identical specimen geometry and casting conditions for predictions of residual stresses. The simulation predictions were found to agree well with the experimentally measured residual stresses. The experimentally validated model can be subsequently used to predict residual stresses in different cast

  18. Cast Process Simulation for the Rapid Tooling.

    NASA Astrophysics Data System (ADS)

    Zhang, Renji; Jiang, Rui; Liu, Yuan; Yan, Yongnian

    1997-03-01

    A major use for RP (Rapid Prototyping) now is in the foundry industry. It is so called RT (Rapid Tooling). Models are used as patterns for sand and plaster casting or used as sacrificial models in investment casting in the RT. In order to improve casting quality, a cast process simulation program for the RT has been made. This simulation depends on analysis of size accuracy parameters. The result could be came back into the CAD forming program. After that a new CAD data have been adopted in RT process. Then the RT technology could have sufficient accuracy in fabrication. Work supported by the Natural Science Foundation of China (NSFC).

  19. High-Density-Tape Casting System

    NASA Technical Reports Server (NTRS)

    Collins, Earl R., Jr.

    1987-01-01

    Centrifuge packs solids from slurry into uniform, dense layer. New system produces tapes of nearly theoretical packing density. Centrifugal system used to cast thin tapes for capacitors, fuel cells, and filters. Cylindrical rotary casting chamber mounted on high-speed bearings and connected to motor. Liquid for vapor-pressure control and casting slurry introduced from syringes through rotary seal. During drying step, liquid and vapor vented through feed tubes or other openings. Laminated tapes produced by adding more syringes to cast additional layers of different materials.

  20. Spray casting project final report

    SciTech Connect

    Churnetski, S.R.; Thompson, J.E.

    1996-08-01

    Lockheed Martin Energy Systems, Inc. (Energy Systems), along with other participating organizations, has been exploring the feasibility of spray casting depleted uranium (DU) to near-net shape as a waste minimization effort. Although this technology would be useful in a variety of applications where DU was the material of choice, this effort was aimed primarily at gamma-shielding components for use in storage and transportation canisters for high-level radioactive waste, particularly in the Multipurpose Canister (MPC) application. In addition to the waste-minimization benefits, spray casting would simplify the manufacturing process by allowing the shielding components for MPC to be produced as a single component, as opposed to multiple components with many fabrication and assembly steps. In earlier experiments, surrogate materials were used to simulate the properties (specifically reactivity and density) of DU. Based on the positive results from those studies, the project participants decided that further evaluation of the issues and concerns that would accompany spraying DU was warranted. That evaluation occupied substantially all of Fiscal Year 1995, yielding conceptual designs for both an intermediate facility and a production facility and their associated engineering estimates. An intermediate facility was included in this study to allow further technology development in spraying DU. Although spraying DU to near-net shape seems to be feasible, a number of technical, engineering, and safety issues would need to be evaluated before proceeding with a production facility. This report is intended to document the results from the spray-casting project and to provide information needed by anyone interested in proceeding to the next step.

  1. Release of ToxCastDB and ExpoCastDB databases

    EPA Science Inventory

    EPA has released two databases - the Toxicity Forecaster database (ToxCastDB) and a database of chemical exposure studies (ExpoCastDB) - that scientists and the public can use to access chemical toxicity and exposure data. ToxCastDB users can search and download data from over 50...

  2. Guide for extrusion dies eliminates straightening operation

    NASA Technical Reports Server (NTRS)

    Gyorgak, C. A.; Hoover, R. J.

    1964-01-01

    To prevent distortion of extruded metal, a guidance assembly is aligned with the die. As the metal emerges from the extrusion dies, it passes directly into the receiver and straightening tube system, and the completed extrusion is withdrawn.

  3. Control of Cast Iron Microstructure

    NASA Technical Reports Server (NTRS)

    Graham, J.; Lillybeck, N.; Franco, N.; Stefanescu, D. M.

    1985-01-01

    The use of microgravity for industrial research in the processing of cast iron was investigated. Solidification experiments were conducted using the KC-135 and F-104 aircraft, and an experiment plan was developed for follow-on experiments using the Shuttle. Three areas of interest are identified: (1) measurement of thermophysical properties in the melt; (2) understanding of the relative roles of homogeneous nucleation, grain multiplication, and innocultants in forming the microstructure; and (3) exploring the possibility of obtaining an aligned graphite structure in hypereutectic Fe, Ni, and Co.

  4. Microdefects in cast multicrystalline silicon

    SciTech Connect

    Wolf, E.; Klinger, D.; Bergmann, S.

    1995-08-01

    The microdefect etching behavior of cast multicrystalline BAYSIX and SILSO samples is mainly the same as that of EFG silicon, in spite of the very different growth parameters applied to these two techniques and the different carbon contents of the investigated materials. Intentional decorating of mc silicon with copper, iron and gold did not influence the results of etching and with help of infrared transmission microscopy no metal precipitates at the assumed microdefects could be established. There are many open questions concerning the origin of the assumed, not yet doubtless proved microdefects.

  5. [Dying with cancer: Hollywood lessons].

    PubMed

    Niemeyer, Fernanda; Kruse, Maria Henriqueta Luce

    2013-12-01

    The study attempts to understand how dying from cancer is portrayed by five movies produced in Hollywood between 1993 and 2006. Based on the cultural studies and their post-structuralism version and supported by the notions of discourse and subjectivity, as proposed by philosopher Michel Foucault, we suggest one of the possible readings of the movie picture corpus. We assess how the movie picture discourse acts as a cultural pedagogy that produces ways of seeing dying with cancer: immortalizing the healthy body image, silencing death, taking care of the dead body and, finally, accepting death. Our proposal is intended to stimulate reflections that may contribute to care and education in nursing. PMID:25080714

  6. RSP Tooling - A Revolutionary New Process to Manufacture Die Cast Production Tooling in Prototype Timing

    SciTech Connect

    Mc Hugh, Kevin Matthew; Knirsch, James; Folkestad, James

    2002-10-01

    RSP Tooling, LLC (Solon, OH) has signed an exclusive license with the Idaho National Engineered and Environmental Laboratory - INEEL (Idaho Falls, ID) - for the development and commercialization of the rapid solidification process within the field of tooling (RSP tooling), which is a recent revolution in the moldmaking industry. The first production machine is scheduled for delivery this year. This machine will be able to produce a 6 x 6 x 4 inch tool with finished cavities in two hours. Such a production rate is revolutionary, and will likely change the tooling industry dramatically.

  7. Killing, letting die and euthanasia.

    PubMed

    Husak, D N

    1979-12-01

    Medical ethicists debate whether or not the moral assessment of cases of euthanasia should depend on whether the patient is 'killed' or 'allowed to die'. The usual presupposition is that a clear distinction between killing and letting die can be drawn so that this substantive question is not begged. I contend that the categorisation of cases of instances of killing rather than as instances of letting die depends in part on a prior moral assessment of the case. Hence is it trivially rather than substantively true that the distinction has moral significance. But even if a morally neutral (ie non-question begging) distinction could be drawn, its application to the euthanasia controversy is problematic. I illustrate the difficulties of employing this distinction to reach moral conclusions by critically discussing Philippa Foot's recent treatment of euthanasia. I conclude that even if an act of euthanasia is an instance of killing, and there exists a prima facie moral duty not to kill, and no more stringent duty overrides this duty, one still cannot determine such an act to be morally impermissible. PMID:541821

  8. Adolescents’ Perceived Risk of Dying

    PubMed Central

    Fischhoff, Baruch; de Bruin, Wändi Bruine; Parker, Andrew M.; Millstein, Susan G.; Halpern-Felsher, Bonnie L.

    2009-01-01

    Purpose Although adolescents’ expectations are accurate or moderately optimistic for many significant life events, they greatly overestimate their chances of dying soon. We examine here whether adolescents’ mortality judgments are correlated with their perceptions of direct threats to their survival. Such sensitivity would indicate the importance of ensuring that adolescents have accurate information about those threats, as well as the psychological support needed to deal with them. Methods Data from two separate studies were used: a national study of 3,436 14–18 year old adolescents and a regional sample of 124 7th graders and 132 9th graders, 12–16 years old. Participants were asked about their chance of dying in the next year and before age 20, and about the extent of various threats to their physical well being. Results Adolescents in both samples greatly overestimated their chance of dying. Those mortality estimates were higher for adolescents who reported direct threats (e.g., an unsafe neighborhood). Thus, adolescents were sensitive to the relative size of threats to their survival, but not to the implications for absolute risk levels. Conclusions Contrary to the folk wisdom that adolescents have a unique sense of invulnerability, those studied here reported an exaggerated sense of mortality, which was highest among those reporting greater threats in their lives. Such fears could affect adolescents’ short-term well being and future planning. PMID:20159504

  9. Yield Improvement in Steel Casting (Yield II)

    SciTech Connect

    Richard A. Hardin; Christoph Beckermann; Tim Hays

    2002-02-18

    This report presents work conducted on the following main projects tasks undertaken in the Yield Improvement in Steel Casting research program: Improvement of Conventional Feeding and Risering Methods, Use of Unconventional Yield Improvement Techniques, and Case Studies in Yield Improvement. Casting trials were conducted and then simulated using the precise casting conditions as recorded by the participating SFSA foundries. These results present a statistically meaningful set of experimental data on soundness versus feeding length. Comparisons between these casting trials and casting trials performed more than forty years ago by Pellini and the SFSA are quite good and appear reasonable. Comparisons between the current SFSA feeding rules and feeding rules based on the minimum Niyama criterion reveal that the Niyama-based rules are generally less conservative. The niyama-based rules also agree better with both the trials presented here, and the casting trails performed by Pellini an d the SFSA years ago. Furthermore, the use of the Niyama criterion to predict centerline shrinkage for horizontally fed plate sections has a theoretical basis according to the casting literature reviewed here. These results strongly support the use of improved feeding rules for horizontal plate sections based on the Niyama criterion, which can be tailored to the casting conditions for a given alloy and to a desired level of soundness. The reliability and repeatability of ASTM shrinkage x-ray ratings was investigated in a statistical study performed on 128 x-rays, each of which were rated seven different times. A manual ''Feeding and Risering Guidelines for Steel Castings' is given in this final report. Results of casting trials performed to test unconventional techniques for improving casting yield are presented. These use a stacked arrangement of castings and riser pressurization to increase the casting yield. Riser pressurization was demonstrated to feed a casting up to four time s the

  10. Clean cast steel technology. Final report

    SciTech Connect

    Bates, C.E.; Griffin, J.A.

    1998-06-01

    This report documents the results obtained from the Clean Cast Steel Technology Program financially supported by the DOE Metal Casting Competitiveness Research Program and industry. The primary objective of this program is to develop technology for delivering steel free of oxide macroinclusions to mold cavities. The overall objective is to improve the quality of cast steel by developing and demonstrating the technology for substantially reducing surface and sub-surface oxide inclusions. Two approaches are discussed here. A total of 23 castings were produced by submerge pouring along with sixty conventionally poured castings. The submerged poured castings contained, on average, 96% fewer observable surface inclusions (11.9 vs 0.4) compared to the conventionally poured cast parts. The variation in the population of surface inclusions also decreased by 88% from 5.5 to 0.7. The machinability of the casting was also improved by submerged pouring. The submerge poured castings required fewer cutting tool changes and less operator intervention during machining. Subsequent to these trials, the foundry has decided to purchase more shrouds for continued experimentation on other problem castings where submerge pouring is possible. An examination of melting and pouring practices in four foundries has been carried out. Three of the four foundries showed significant improvement in casting quality by manipulating the melting practice. These melting practice variables can be grouped into two separate categories. The first category is the pouring and filling practice. The second category concerns the concentration of oxidizable elements contained in the steel. Silicon, manganese, and aluminum concentrations were important factors in all four foundries. Clean heats can consistently be produced through improved melting practice and reducing exposure of the steel to atmospheric oxygen during pouring and filling.

  11. Contoured Orifice for Silicon-Ribbon Die

    NASA Technical Reports Server (NTRS)

    Mackintosh, B. H.

    1985-01-01

    Die configuration encourages purity and stable growth. Contour of die orifice changes near ribbon edges. As result, silicon ribbon has nearly constant width and little carbon contamination. Die part of furnace being developed to produce high-quality, low-cost material for solar cells.

  12. Jewish tradition in death and dying.

    PubMed

    Ross, H M

    1998-10-01

    Death is often a spiritually difficult time for the dying and their families. Judaism approaches dying with some unique views that can differ from other religious traditions. Through an understanding of Jewish tradition, nurses can ease the dying process for Jewish patients and their families. PMID:10036429

  13. INTERIOR VIEW WITH CASTING MACHINE AND A 20' DUCTILE IRON ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    INTERIOR VIEW WITH CASTING MACHINE AND A 20' DUCTILE IRON PIPE BEING EXTRACTED USING PIPE PULLERS. - McWane Cast Iron Pipe Company, Pipe Casting Area, 1201 Vanderbilt Road, Birmingham, Jefferson County, AL

  14. Energy use in selected metal casting facilities - 2003

    SciTech Connect

    Eppich, Robert E.

    2004-05-01

    This report represents an energy benchmark for various metal casting processes. It describes process flows and energy use by fuel type and processes for selected casting operations. It also provides recommendations for improving energy efficiency in casting.

  15. Impact of Simulation Technology on Die and Stamping Business

    NASA Astrophysics Data System (ADS)

    Stevens, Mark W.

    2005-08-01

    Over the last ten years, we have seen an explosion in the use of simulation-based techniques to improve the engineering, construction, and operation of GM production tools. The impact has been as profound as the overall switch to CAD/CAM from the old manual design and construction methods. The changeover to N/C machining from duplicating milling machines brought advances in accuracy and speed to our construction activity. It also brought significant reductions in fitting sculptured surfaces. Changing over to CAD design brought similar advances in accuracy, and today's use of solid modeling has enhanced that accuracy gain while finally leading to the reduction in lead time and cost through the development of parametric techniques. Elimination of paper drawings for die design, along with the process of blueprinting and distribution, provided the savings required to install high capacity computer servers, high-speed data transmission lines and integrated networks. These historic changes in the application of CAE technology in manufacturing engineering paved the way for the implementation of simulation to all aspects of our business. The benefits are being realized now, and the future holds even greater promise as the simulation techniques mature and expand. Every new line of dies is verified prior to casting for interference free operation. Sheet metal forming simulation validates the material flow, eliminating the high costs of physical experimentation dependent on trial and error methods of the past. Integrated forming simulation and die structural analysis and optimization has led to a reduction in die size and weight on the order of 30% or more. The latest techniques in factory simulation enable analysis of automated press lines, including all stamping operations with corresponding automation. This leads to manufacturing lines capable of running at higher levels of throughput, with actual results providing the capability of two or more additional strokes per

  16. Computer simulation applied to jewellery casting: challenges, results and future possibilities

    NASA Astrophysics Data System (ADS)

    Tiberto, Dario; Klotz, Ulrich E.

    2012-07-01

    Computer simulation has been successfully applied in the past to several industrial processes (such as lost foam and die casting) by larger foundries and direct automotive suppliers, while for the jewelry sector it is a procedure which is not widespread, and which has been tested mainly in the context of research projects. On the basis of a recently concluded EU project, the authors here present the simulation of investment casting, using two different softwares: one for the filling step (Flow-3D®), the other one for the solidification (PoligonSoft®). A work on material characterization was conducted to obtain the necessary physical parameters for the investment (used for the mold) and for the gold alloys (through thermal analysis). A series of 18k and 14k gold alloys were cast in standard set-ups to have a series of benchmark trials with embedded thermocouples for temperature measurement, in order to compare and validate the software output in terms of the cooling curves for definite test parts. Results obtained with the simulation included the reduction of micro-porosity through an optimization of the feeding channels for a controlled solidification of the metal: examples of the predicted porosity in the cast parts (with metallographic comparison) will be shown. Considerations on the feasibility of applying the casting simulation in the jewelry sector will be reached, underlining the importance of the software parametrization necessary to obtain reliable results, and the discrepancies found with the experimental comparison. In addition an overview on further possibilities of application for the CFD in jewellery casting, such as the modeling of the centrifugal and tilting processes, will be presented.

  17. Casting fine grained, fully dense, strong inorganic materials

    SciTech Connect

    Brown, Sam W.; Spencer, Larry S.; Phillips, Michael R.

    2015-11-24

    Methods and apparatuses for casting inorganic materials are provided. The inorganic materials include metals, metal alloys, metal hydrides and other materials. Thermal control zones may be established to control the propagation of a freeze front through the casting. Agitation from a mechanical blade or ultrasonic energy may be used to reduce porosity and shrinkage in the casting. After solidification of the casting, the casting apparatus may be used to anneal the cast part.

  18. 21 CFR 880.6185 - Cast cover.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 21 Food and Drugs 8 2010-04-01 2010-04-01 false Cast cover. 880.6185 Section 880.6185 Food and Drugs FOOD AND DRUG ADMINISTRATION, DEPARTMENT OF HEALTH AND HUMAN SERVICES (CONTINUED) MEDICAL DEVICES GENERAL HOSPITAL AND PERSONAL USE DEVICES General Hospital and Personal Use Miscellaneous Devices § 880.6185 Cast cover. (a) Identification. A...

  19. 14 CFR 29.621 - Casting factors.

    Code of Federal Regulations, 2013 CFR

    2013-01-01

    ... 14 Aeronautics and Space 1 2013-01-01 2013-01-01 false Casting factors. 29.621 Section 29.621 Aeronautics and Space FEDERAL AVIATION ADMINISTRATION, DEPARTMENT OF TRANSPORTATION AIRCRAFT AIRWORTHINESS STANDARDS: TRANSPORT CATEGORY ROTORCRAFT Design and Construction General § 29.621 Casting factors. (a) General. The factors, tests, and...

  20. 14 CFR 25.621 - Casting factors.

    Code of Federal Regulations, 2014 CFR

    2014-01-01

    ... meet approved specifications. Paragraphs (c) and (d) of this section apply to any structural castings... structural loads. (b) Bearing stresses and surfaces. The casting factors specified in paragraphs (c) and (d... of 1.25; and (ii) The deformation requirements of § 25.305 at a load of 1.15 times the limit load....

  1. 14 CFR 25.621 - Casting factors.

    Code of Federal Regulations, 2013 CFR

    2013-01-01

    ... 14 Aeronautics and Space 1 2013-01-01 2013-01-01 false Casting factors. 25.621 Section 25.621 Aeronautics and Space FEDERAL AVIATION ADMINISTRATION, DEPARTMENT OF TRANSPORTATION AIRCRAFT AIRWORTHINESS STANDARDS: TRANSPORT CATEGORY AIRPLANES Design and Construction General § 25.621 Casting factors. (a) General. The factors, tests, and...

  2. 14 CFR 25.621 - Casting factors.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... meet approved specifications. Paragraphs (c) and (d) of this section apply to any structural castings... structural loads. (b) Bearing stresses and surfaces. The casting factors specified in paragraphs (c) and (d... of 1.25; and (ii) The deformation requirements of § 25.305 at a load of 1.15 times the limit load....

  3. 14 CFR 23.621 - Casting factors.

    Code of Federal Regulations, 2013 CFR

    2013-01-01

    ... 14 Aeronautics and Space 1 2013-01-01 2013-01-01 false Casting factors. 23.621 Section 23.621 Aeronautics and Space FEDERAL AVIATION ADMINISTRATION, DEPARTMENT OF TRANSPORTATION AIRCRAFT AIRWORTHINESS STANDARDS: NORMAL, UTILITY, ACROBATIC, AND COMMUTER CATEGORY AIRPLANES Design and Construction § 23.621 Casting factors. (a) General. The...

  4. 14 CFR 25.621 - Casting factors.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... meet approved specifications. Paragraphs (c) and (d) of this section apply to any structural castings... structural loads. (b) Bearing stresses and surfaces. The casting factors specified in paragraphs (c) and (d... of 1.25; and (ii) The deformation requirements of § 25.305 at a load of 1.15 times the limit load....

  5. 14 CFR 27.621 - Casting factors.

    Code of Federal Regulations, 2013 CFR

    2013-01-01

    ... 14 Aeronautics and Space 1 2013-01-01 2013-01-01 false Casting factors. 27.621 Section 27.621 Aeronautics and Space FEDERAL AVIATION ADMINISTRATION, DEPARTMENT OF TRANSPORTATION AIRCRAFT AIRWORTHINESS STANDARDS: NORMAL CATEGORY ROTORCRAFT Design and Construction General § 27.621 Casting factors. (a) General. The factors, tests, and...

  6. 14 CFR 25.621 - Casting factors.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... meet approved specifications. Paragraphs (c) and (d) of this section apply to any structural castings... structural loads. (b) Bearing stresses and surfaces. The casting factors specified in paragraphs (c) and (d... of 1.25; and (ii) The deformation requirements of § 25.305 at a load of 1.15 times the limit load....

  7. The CAST (Childhood Asperger Syndrome Test)

    ERIC Educational Resources Information Center

    Williams, Jo; Scott, Fiona; Stott, Carol; Allison, Carrie; Bolton, Patrick; Baron-Cohen, Simon; Brayne, Carol

    2005-01-01

    The Childhood Asperger Syndrome Test (CAST) is a parental questionnaire to screen for autism spectrum conditions. In this validation study, the CAST was distributed to 1925 children aged 5-11 in mainstream Cambridgeshire schools. A sample of participants received a full diagnostic assessment, conducted blind to screen status. The sensitivity of…

  8. Iron/Phosphorus Alloys for Continuous Casting

    NASA Technical Reports Server (NTRS)

    Dufresne, E. R.

    1986-01-01

    Continuous casting becomes practicable because of reduced eutectic temperature. Experimental ferrous alloy has melting point about 350 degrees C lower than conventional steels, making possible to cast structural members and eliminating need for hot rolling. Product has normal metal structure and good physical properties. Process used to make rails, beams, slabs, channels, and pipes.

  9. PRODUCTION OF SLIP CAST CALCIA HOLLOWWARE

    DOEpatents

    Stoddard, S.D.; Nuckolls, D.E.; Cowan, R.E.

    1963-12-31

    A method for producing slip cast calcia hollow ware in which a dense calcia grain is suspended in isobutyl acetate or a mixture of tertiary amyl alcohol and o-xylene is presented. A minor amount of triethanolamine and oleic acid is added to the suspension vehicle as viscosity adjusting agents and the suspension is cast in a plaster mold, dried, and fired. (AEC)

  10. Casting Shadows in the Science Classroom.

    ERIC Educational Resources Information Center

    Nolan, Kathleen

    2003-01-01

    Uses the metaphor of shadows in a critical exploration of what it means to know and how the cultures of classrooms have shaped these images of knowing. Directs attention to objects that cast shadows on the learning and knowing of mathematics and science through the voices of preservice teachers. Discusses shadow casting toward textbooks, teachers,…

  11. Slip casting and nitridation of silicon powder

    NASA Astrophysics Data System (ADS)

    Seiko, Y.

    1985-03-01

    Powdered Silicon was slip-cast with a CaSO4 x 0.5H2O mold and nitrided in a N atm. containing 0 or 5 vol. % H at 1000 to 1420 deg. To remove the castings, the modeling faces were coated successively with an aq. salt soap and powdered cellulose containing Na alginate, and thus prevented the sticking problem.

  12. Slip casting and nitridation of silicon powder

    NASA Technical Reports Server (NTRS)

    Seiko, Y.

    1985-01-01

    Powdered Silicon was slip-cast with a CaSO4 x 0.5H2O mold and nitrided in a N atm. containing 0 or 5 vol. % H at 1000 to 1420 deg. To remove the castings, the modeling faces were coated successively with an aq. salt soap and powdered cellulose containing Na alginate, and thus prevented the sticking problem.

  13. Processing of IN-718 Lattice Block Castings

    NASA Technical Reports Server (NTRS)

    Hebsur, Mohan G.

    2002-01-01

    Recently a low cost casting method known as lattice block casting has been developed by JAM Corporation, Wilmington, Massachusetts for engineering materials such as aluminum and stainless steels that has shown to provide very high stiffness and strength with only a fraction of density of the alloy. NASA Glenn Research Center has initiated research to investigate lattice block castings of high temperature Ni-base superalloys such as the model system Inconel-718 (IN-718) for lightweight nozzle applications. Although difficulties were encountered throughout the manufacturing process , a successful investment casting procedure was eventually developed. Wax formulation and pattern assembly, shell mold processing, and counter gravity casting techniques were developed. Ten IN-718 lattice block castings (each measuring 15-cm wide by 30-cm long by 1.2-cm thick) have been successfully produced by Hitchiner Gas Turbine Division, Milford, New Hampshire, using their patented counter gravity casting techniques. Details of the processing and resulting microstructures are discussed in this paper. Post casting processing and evaluation of system specific mechanical properties of these specimens are in progress.

  14. The present status of dental titanium casting

    NASA Astrophysics Data System (ADS)

    Okabe, Toru; Ohkubo, Chikahiro; Watanabe, Ikuya; Okuno, Osamu; Takada, Yukyo

    1998-09-01

    Experimentation in all aspects of titanium casting at universities and industries throughout the world for the last 20 years has made titanium and titanium-alloy casting nearly feasible for fabricating sound cast dental prostheses, including crowns, inlays, and partial and complete dentures. Titanium casting in dentistry has now almost reached the stage where it can seriously be considered as a new method to compete with dental casting using conventional noble and base-metal alloys. More than anything else, the strength of titanium’s appeal lies in its excellent biocompatibility, coupled with its comparatively low price and abundant supply. Research efforts to overcome some problems associated with this method, including studies on the development of new titanium alloys suitable for dental use, will continue at many research sites internationally.

  15. Possible segregation caused by centrifugal titanium casting.

    PubMed

    Watanabe, K; Okawa, S; Kanatani, M; Nakano, S; Miyakawa, O; Kobayashi, M

    1996-12-01

    The possibility of the segregation under solidification process using a centrifugal casting machine was investigated using an electron probe microanalyzer with elemental distribution map, line analysis and quantitative analysis. When a very small quantity of platinum was added to local molten titanium during the casting process, macroscopic segregation was observed under conditions of density difference of 0.1 g/cm3 at the most, confirming that the centrifugal force of the casting machine is extremely strong. When a Ti-6Al-4V alloy was cast, however, no macroscopic segregation was observed. The centrifugal force of the casting machine examined in the present study hardly results in the body-force segregation in this titanium alloy. PMID:9550020

  16. Final report on Expendable Pattern Casting Technology

    SciTech Connect

    Not Available

    1990-07-01

    The Expendable Pattern Casting (EPC) process is a potential casting process breakthrough which could dramatically improve the competitiveness of the US foundry industry. Cooperatively supported by US Industry and the Department of Energy and managed by the American Foundrymen's Society, a project was started in May 1989 to develop and optimize expendable pattern casting technology. Four major tasks were conducted in the first phase of the project. Those tasks involved: (1) reviewing published literature to determine the major problems in the EPC process, (2) evaluating factors influencing sand flow and compaction, (3) evaluating and comparing factors influencing sand flow and compaction, (3) evaluating and comparing casting precision obtained in the EPC process with that obtained in other processes, and (4) identifying critical parameters that control dimensional precision and defect formation in EP castings. 26 refs., 27 figs., 11 tabs.

  17. The role of water in slip casting

    NASA Technical Reports Server (NTRS)

    Mccauley, R. A.; Phelps, G. W.

    1984-01-01

    Slips and casting are considered in terms of physical and colloidal chemistry. Casting slips are polydisperse suspensions of lyophobic particles in water, whose degree of coagulation is controlled by interaction of flocculating and deflocculating agents. Slip casting rate and viscosity are functions of temperature. Slip rheology and response to deflocculating agents varies significantly as the kinds and amounts of colloid modifiers change. Water is considered as a raw material. Various concepts of water/clay interactions and structures are discussed. Casting is a de-watering operation in which water moves from slip to cast to mold in response to a potential energy termed moisture stress. Drying is an evaporative process from a free water surface.

  18. BMM SHAKEOUT AND VIBRATING CONVEYOR TRANSPORT SAND AND CASTINGS TO ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    BMM SHAKEOUT AND VIBRATING CONVEYOR TRANSPORT SAND AND CASTINGS TO SEPARATIONS SCREENS. - Southern Ductile Casting Company, Shaking, Degating & Sand Systems, 2217 Carolina Avenue, Bessemer, Jefferson County, AL

  19. 27 CFR 447.22 - Forgings, castings, and machined bodies.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ..., castings, extrusions, and machined bodies) which have reached a stage in manufacture where they are clearly... components, accessories, attachments and parts) then the particular forging, casting, extrusion,...

  20. Investigation on Tool Wear Rate for Modified and Unmodified Aluminium-Silicon Casting Alloy

    NASA Astrophysics Data System (ADS)

    Haque, M. M.; Khan, A. A.; Ismail, Ahmad F.

    This study demonstrates and explains the effect of strontium modification on machinability of aluminium-silicon eutectic (LM-6 type) alloy. This alloy is known to have many favourable features including weight to strength ratio, high corrosion resistance and excellent castability. However, normal unmodified LM-6 alloy has poor machinability, which reduces its applications range. In this work, various samples of LM-6 alloy were cast using sand and metallic chill mould with and without strontium addition. Machining on each cast product, was carried out using recommended cutting parameters for Al-Si alloys. Strontium modified samples have recorded a reduction in average flank wear, an increase in shear plane angles and a reduction in chip thickness. The main reason for this improvement is the refining effect of strontium, which reduces the size of the hard silicon particles. As a result, their abrasive action on the tool face has reduced a lot. Dramatic reductions in tool wear rate were recorded when the microstructures were refined. On the other hand, when no refinement of microstructure occurs, tool wear rate becomes high. Chip analysis showed that strontium modified sample produced a thinner chip thickness with a larger shear plane angle, requiring less cutting forces. The tool wear depends not only on the phases present in the work material, but also on their sizes and distribution over entire structure. Thus, strontium modification has better effect on machinability of die cast alloy compared to that of the sand cast LM-6 alloy.

  1. Experimental Study and Numerical Verification of Heat Transfer in Squeeze Casting of Aluminum Alloy A443

    NASA Astrophysics Data System (ADS)

    Sun, Zhizhong; Hu, Henry; Niu, Xiaoping

    2012-12-01

    As an effective tool, simulation helps do the analysis and optimization in advance and undertake preventive action. A critical portion of casting simulation is the heat transfer at the metal/mold interface. However, it is difficult to determine the values of interfacial heat-transfer coefficients (IHTCs) in squeeze casting of aluminum alloys due to many influence factors. In this work, IHTCs were determined by using the inverse algorithm based on measured temperature histories and finite-difference analysis in a five-step squeeze casting of aluminum alloy A443. The results showed the IHTCs initially reached a maximum peak value followed by a gradually decline to a lower level. Similar characteristics of IHTC peak values were also observed at 30, 60, and 90 MPa applied pressures. With the applied pressure of 60 MPa, the peak IHTC values of aluminum alloy A443 from steps 1 to 5 varied from 5629 W/m2K to 9419 W/m2K. The comparison of the predicted cooling curves with the experimental measurement manifested the cooling temperatures calculated by the IHTC values determined in the current study were in the best agreement with experimental ones. The verification of the determined IHTC values demonstrates that the inverse algorithm is an effective tool for determination of the IHTC at the squeeze casting-die interface.

  2. Die Welt des Herrn Kuhn

    NASA Astrophysics Data System (ADS)

    Kern, Daniela

    Eines Morgens erwachte Herr Kuhn fröstelnd und staunte darüber, dass es in seinerWohnung eiskalt war. Dennoch quälte er sich aus seiner kuscheligen Bettdecke heraus und schlurfte ins Bad. "Hoffentlich wird wenigstens das Wasser warm", dachte er sich, als er den Wasserhahn betätigte - aber es kam nicht nur kein warmesWasser, außer einem unheilvollen Gluckser kam gar nichts aus der Leitung. "Dann werde ich wohl mal den Klempner anrufen", sprach er sich leise in den Bart und griff zu seinem Handy - doch das Netz war tot! Herr Kuhn begann nun, sich ernsthaft Sorgen zu machen, "Oje, was ist denn heute nur los? Ist irgendetwas Schlimmes passiert?" Um einen besseren Überblick über die Lage zu bekommen und sich austauschen zu können, brannte er nun förmlich darauf, rauszugehen und zur Arbeit zu fahren. An anderen Tagen, die er frisch geduscht und mit Kaffee und Marmeladen-Brot begann, war er selten so motiviert. So ging er also nun mit leerem Magen aus dem Haus. Hätte er den Versuch unternommen, sein tägliches Marmeladenbrot zuzubereiten, und dafür den Kühlschrank geöffnet, um das Marmeladenglas herauszunehmen, wäre ihm aufgefallen, dass auch die Stromversorgung Störungen unterworfen war, unschön zu erkennen an den ersten grünen, felligen Inseln auf seinem Lieblingskäse.

  3. The effect of four sprue shapes on the quality of cobalt-chromium cast removable partial denture frame-works

    PubMed Central

    Viswambaran, M.; Agarwal, S. K.

    2013-01-01

    Statement of Problem: Sprue design is a factor that controls the velocity and adequate supply of metal to the mould. Currently various manufacturers recommend different shapes of sprue, which have not been advocated in textbooks and literature is lacking for their routine applications. Purpose: This in vitro study was carried out to determine the efficacy of four sprue shapes in producing complete, void free cobalt-chrome removable partial denture frameworks. Materials and Methods: A brass metal die with a Kennedy class III, modification 1, partially edentulous arch was used and four sprue shapes (Group A-Ribbon, Group B-Square, Group C-Round and Group D- Round with reservoir) were evaluated. 40 refractory casts were made, 10 wax patterns for each sprue design were waxed up, invested with phosphate bonded investment material and castings done with induction casting machine by the same operator under standardized protocols. The cast frameworks were evaluated for 1. The defects observed visually before finishing and polishing procedures, 2. Fit on the master die as seen with naked eye and 3. Defects on radiographic evaluation. Data were tabulated and statistically analyzed with 1-way ANOVA followed by Student ‘t’ test. Results: The results differed significantly (P < 0.0001) between the Groups with maximum defects in the castings of Group A followed in decreasing order by Group B, Group C and Group D. When comparing between the Groups (P < 0.05), the defects in Groups C and D was significantly lower than Group A and Group B. Conclusions: Round sprues with reservoir produced most satisfactory fit of castings with minimum number of internal and external defects. PMID:24014998

  4. Bioinspired Design: Magnetic Freeze Casting

    NASA Astrophysics Data System (ADS)

    Porter, Michael Martin

    Nature is the ultimate experimental scientist, having billions of years of evolution to design, test, and adapt a variety of multifunctional systems for a plethora of diverse applications. Next-generation materials that draw inspiration from the structure-property-function relationships of natural biological materials have led to many high-performance structural materials with hybrid, hierarchical architectures that fit form to function. In this dissertation, a novel materials processing method, magnetic freeze casting, is introduced to develop porous scaffolds and hybrid composites with micro-architectures that emulate bone, abalone nacre, and other hard biological materials. This method uses ice as a template to form ceramic-based materials with continuously, interconnected microstructures and magnetic fields to control the alignment of these structures in multiple directions. The resulting materials have anisotropic properties with enhanced mechanical performance that have potential applications as bone implants or lightweight structural composites, among others.

  5. Fatigue Properties of Cast Magnesium Wheels

    NASA Astrophysics Data System (ADS)

    Li, Zhenming; Luo, Alan A.; Wang, Qigui; Peng, Liming; Zhang, Peng

    2016-05-01

    This paper investigates the fatigue properties and deformation behavior of a newly developed Mg-2.96Nd-0.21Zn-0.39Zr magnesium alloy wheel in both as-cast and T6 conditions. Compared with the as-cast alloy, the T6-treated alloy shows a significant increase in fatigue strength and cyclic stress amplitude. This is believed to be attributed to the change of defect type from porosity to oxides and the increased matrix strength in the T6 (peak-aged) condition. For the as-cast alloy wheel, fatigue failure mainly originated from the cast defects including porosity, oxide film, and inclusion at or near the sample surface. In the T6-treated alloy, however, oxides and inclusions or slip bands initiate the fatigue cracks. Solution treatment appears to reduce or eliminate the shrinkage porosity because of grain growth and dissolution of as-cast eutectic phases in the grain boundaries. The cyclic stress amplitude of the as-cast alloy increases with increasing the number of cycles, while the T6-treated alloy shows cyclic softening after the stress reaches a maximum value. The Coffin-Manson law and Basquin equation can be used to evaluate the life of low cycle fatigue. The developed long crack model and multi-scale fatigue (MSF) models can be used to predict high-cycle fatigue life of the Mg-2.96Nd-0.21Zn-0.39Zr alloys with or without casting defects.

  6. Characterization of Technetium Speciation in Cast Stone

    SciTech Connect

    Um, Wooyong; Jung, Hun Bok; Wang, Guohui; Westsik, Joseph H.; Peterson, Reid A.

    2013-11-11

    This report describes the results from laboratory tests performed at Pacific Northwest National Laboratory (PNNL) for the U.S. Department of Energy (DOE) EM-31 Support Program (EMSP) subtask, “Production and Long-Term Performance of Low Temperature Waste Forms” to provide additional information on technetium (Tc) speciation characterization in the Cast Stone waste form. To support the use of Cast Stone as an alternative to vitrification for solidifying low-activity waste (LAW) and as the current baseline waste form for secondary waste streams at the Hanford Site, additional understanding of Tc speciation in Cast Stone is needed to predict the long-term Tc leachability from Cast Stone and to meet the regulatory disposal-facility performance requirements for the Integrated Disposal Facility (IDF). Characterizations of the Tc speciation within the Cast Stone after leaching under various conditions provide insights into how the Tc is retained and released. The data generated by the laboratory tests described in this report provide both empirical and more scientific information to increase our understanding of Tc speciation in Cast Stone and its release mechanism under relevant leaching processes for the purpose of filling data gaps and to support the long-term risk and performance assessments of Cast Stone in the IDF at the Hanford Site.

  7. Fatigue Properties of Cast Magnesium Wheels

    NASA Astrophysics Data System (ADS)

    Li, Zhenming; Luo, Alan A.; Wang, Qigui; Peng, Liming; Zhang, Peng

    2016-08-01

    This paper investigates the fatigue properties and deformation behavior of a newly developed Mg-2.96Nd-0.21Zn-0.39Zr magnesium alloy wheel in both as-cast and T6 conditions. Compared with the as-cast alloy, the T6-treated alloy shows a significant increase in fatigue strength and cyclic stress amplitude. This is believed to be attributed to the change of defect type from porosity to oxides and the increased matrix strength in the T6 (peak-aged) condition. For the as-cast alloy wheel, fatigue failure mainly originated from the cast defects including porosity, oxide film, and inclusion at or near the sample surface. In the T6-treated alloy, however, oxides and inclusions or slip bands initiate the fatigue cracks. Solution treatment appears to reduce or eliminate the shrinkage porosity because of grain growth and dissolution of as-cast eutectic phases in the grain boundaries. The cyclic stress amplitude of the as-cast alloy increases with increasing the number of cycles, while the T6-treated alloy shows cyclic softening after the stress reaches a maximum value. The Coffin-Manson law and Basquin equation can be used to evaluate the life of low cycle fatigue. The developed long crack model and multi-scale fatigue (MSF) models can be used to predict high-cycle fatigue life of the Mg-2.96Nd-0.21Zn-0.39Zr alloys with or without casting defects.

  8. AMCC casting development. Volume 1: Executive Summary

    NASA Astrophysics Data System (ADS)

    1995-03-01

    The Advanced Combustion Chamber Casting (AMCC) has been a technically challenging part due to its size, configuration, and alloy type. The height and weight of the wax pattern assembly necessitated the development of a hollow gating system to ensure structural integrity of the shell throughout the investment process. The complexity in the jacket area of the casting required the development of an innovative casting technology that PCC has termed 'TGC' or Thermal Gradient Control. This method, of setting up thermal gradients in the casting during solidification, represents a significant process improvement for PCC and has been successfully implemented on other programs. Metallurgical integrity of the final four castings was very good. Only the areas of the parts that utilized 'TGC Shape & Location System #2' showed any significant areas of microshrinkage when evaluated by non-destructive tests. Alumina oxides detected by FPI on the 'float' surfaces (top sid surfaces of the casting during solidification) of the part were almost entirely less than the acceptance criteria of .032 inches in diameter. Destructive chem mill of the castings was required to determine the effect of the process variables used during the processing of these last four parts (with the exception of the 'Shape & Location of TGC' variable).

  9. AMCC casting development. Volume 1: Executive Summary

    NASA Technical Reports Server (NTRS)

    1995-01-01

    The Advanced Combustion Chamber Casting (AMCC) has been a technically challenging part due to its size, configuration, and alloy type. The height and weight of the wax pattern assembly necessitated the development of a hollow gating system to ensure structural integrity of the shell throughout the investment process. The complexity in the jacket area of the casting required the development of an innovative casting technology that PCC has termed 'TGC' or Thermal Gradient Control. This method, of setting up thermal gradients in the casting during solidification, represents a significant process improvement for PCC and has been successfully implemented on other programs. Metallurgical integrity of the final four castings was very good. Only the areas of the parts that utilized 'TGC Shape & Location System #2' showed any significant areas of microshrinkage when evaluated by non-destructive tests. Alumina oxides detected by FPI on the 'float' surfaces (top sid surfaces of the casting during solidification) of the part were almost entirely less than the acceptance criteria of .032 inches in diameter. Destructive chem mill of the castings was required to determine the effect of the process variables used during the processing of these last four parts (with the exception of the 'Shape & Location of TGC' variable).

  10. NWIS MEASUREMENTS FOR URANIUM METAL ANNULAR CASTINGS

    SciTech Connect

    MATTINGLY, J.K.; VALENTINE, T.E.; MIHALCZO, J.T.

    1998-03-13

    This report describes measurements performed with annular uranium metal castings of different enrichments to investigate the use of {sup 252}Cf-source-driven noise analysis measurements as a means to quantify the amount of special nuclear material (SNM) in the casting. This work in FY 97 was sponsored by the Oak Ridge Y-12 Plant and the DOE Office of Technology Development Programs. Previous measurements and calculational studies have shown that many of the signatures obtained from the source-driven measurement are very sensitive to fissile mass. Measurements were performed to assess the applicability of this method to standard annular uranium metal castings at the Oak Ridge Y-12 plant under verification by the International Atomic Energy Agency (IAEA) using the Nuclear Weapons Identification System (NWIS) processor. Before the measurements with different enrichments, a limited study of source-detector-casting moderator configurations was performed to enhance the correlated information. These configurations consisted of a casting with no reflector and with various thicknesses of polyethylene reflectors up to 10.16 cm in 2.54 cm steps. The polyethylene moderator thickness of 7.62 cm was used for measurements with castings of different enrichments reported here. The sensitivity of the measured parameters to fissile mass was investigated using four castings each with a different enrichment. The high sensitivity of this measurement method to fissile mass and to other material and configurations provides some advantages over existing safeguards methods.

  11. Subcritical Measurements Multiple HEU Metal Castings

    SciTech Connect

    Mihalczo, John T; Archer, Daniel E; Wright, Michael C

    2008-01-01

    Experiments with the standard annular highly enriched uranium (HEU) metal castings at Y-12 were performed in which up to 5 castings ({approx}90kg) were assembled in a tightly packed array with minimal spacing between castings. The fission chain multiplication process was initiated by a time tagged {sup 253}Cf spontaneously fissioning neutron source or time and directionally tagged neutrons from a small portable DT neutron generator and the prompt neutron time behavior measured with plastic scintillation detectors sensitive the fast neutron (>1 MeV) and gamma ray without distinction. These experiments were performed to provide data to benchmark methods for the calculation of the prompt neutron time behavior. Previous measurements with a single casting have been reported. This paper presents the experimental results for multiple castings. The prompt time decay was obtained by time coincidence correlation measurements between the detectors and the time tagged neutron source emission (equivalent to randomly pulsed neutron measurements) and between pairs of plastic scintillation detectors (equivalent to a 2-detector Rossi-alpha measurement). These standard HEU storage castings at the Y-12 plant had 5.000-in-OD, 3.500-in-ID, masses between 17,636 and 17,996 g, impurity content of 992 ppm, density of 18.75 g/cm{sup 3} and average enrichment of 93.16 wt % {sup 235}U. The castings were in tight fitting 025-in.-thick, 8.0-in-high stainless steel (SS-304) cylindrical cans for contamination control which were 8.0 in high. One can had an inside diameter of 3.0 in so that the Cf source could be located on the axes of this casting. Four 1 x 1 x 6 in plastic scintillators with the long dimension perpendicular to axes of the castings and adjacent to the outer surface of the casting cans were used. The detectors were enclosed in 1/4.-in.-thick lead shields on four 1 x 6 surfaces and on the 1 x 1 surface. The small surface of the lead shield was adjacent to the steel table. The

  12. Methods for Casting Subterranean Ant Nests

    PubMed Central

    Tschinkel, Walter R.

    2010-01-01

    The study of subterranean ant nests has been impeded by the difficulty of rendering their structures in visible form. Here, several different casting materials are shown to make perfect casts of the underground nests of ants. Each material (dental plaster, paraffin wax, aluminum, zinc) has advantages and limitations, which are discussed. Some of the materials allow the recovery of the ants entombed in the casts, allowing a census of the ants to be connected with features of their nest architecture. The necessary equipment and procedures are described in the hope that more researchers will study this very important aspect of ant natural history. PMID:20673073

  13. Vacuum die attach for integrated circuits

    DOEpatents

    Schmitt, Edward H.; Tuckerman, David B.

    1991-01-01

    A thin film eutectic bond for attaching an integrated circuit die to a circuit substrate is formed by coating at least one bonding surface on the die and substrate with an alloying metal, assembling the die and substrate under compression loading, and heating the assembly to an alloying temperature in a vacuum. A very thin bond, 10 microns or less, which is substantially void free, is produced. These bonds have high reliability, good heat and electrical conduction, and high temperature tolerance. The bonds are formed in a vacuum chamber, using a positioning and loading fixture to compression load the die, and an IR lamp or other heat source. For bonding a silicon die to a silicon substrate, a gold silicon alloy bond is used. Multiple dies can be bonded simultaneously. No scrubbing is required.

  14. Die singulation method and package formed thereby

    SciTech Connect

    Anderson, Robert C.; Shul, Randy J.; Clews, Peggy J.; Baker, Michael S.; De Boer, Maarten P.

    2012-08-07

    A method is disclosed for singulating die from a substrate having a sacrificial layer and one or more device layers, with a retainer being formed in the device layer(s) and anchored to the substrate. Deep Reactive Ion Etching (DRIE) etching of a trench through the substrate from the bottom side defines a shape for each die. A handle wafer is then attached to the bottom side of the substrate, and the sacrificial layer is etched to singulate the die and to form a frame from the retainer and the substrate. The frame and handle wafer, which retain the singulated die in place, can be attached together with a clamp or a clip and to form a package for the singulated die. One or more stops can be formed from the device layer(s) to limit a sliding motion of the singulated die.

  15. Reinraumtechnik für die Medizintechnik

    NASA Astrophysics Data System (ADS)

    Petek, Max; Jungbluth, Martin; Krampe, Erhard

    Die Reinraumtechnik ist heute ein unverzichtbarer Bestandteil bei der Fertigung von Produkten der Life Sciences, den Bereichen Pharma, Lebensmittel, Kosmetik und Medizintechnik. In Anbetracht der langen Historie der Medizintechnik ist sie jedoch eine sehr junge Disziplin. Die Bedeutung von Keimen und die richtige Einschätzung ihrer Größe wurden zwar sehr früh bereits durch Paracelsus erkannt, jedoch wurden daraus noch keine speziellen oder kontinuierlich umgesetzten Hygienevorschriften abgeleitet. Die erste bekannte technische Umsetzung von Hygieneempfehlungen geht auf den Franzosen François Nicolas Appert zurück, der eine aseptische Abfüllmethode für Lebensmittel entwickelte und diese 1810 veröffentlichte [1]. Die erste dokumentierte medizinische Umsetzung stellten Hygienevorschriften für Ärzte dar, die Ignaz Philipp Semmelweis nach 1847 in der Wiener Klinik für Geburtshilfe einführte [2].

  16. Vacuum die attach for integrated circuits

    DOEpatents

    Schmitt, E.H.; Tuckerman, D.B.

    1991-09-10

    A thin film eutectic bond for attaching an integrated circuit die to a circuit substrate is formed by coating at least one bonding surface on the die and substrate with an alloying metal, assembling the die and substrate under compression loading, and heating the assembly to an alloying temperature in a vacuum. A very thin bond, 10 microns or less, which is substantially void free, is produced. These bonds have high reliability, good heat and electrical conduction, and high temperature tolerance. The bonds are formed in a vacuum chamber, using a positioning and loading fixture to compression load the die, and an IR lamp or other heat source. For bonding a silicon die to a silicon substrate, a gold silicon alloy bond is used. Multiple dies can be bonded simultaneously. No scrubbing is required. 1 figure.

  17. The cast aluminum denture base. Part II: Technique.

    PubMed

    Halperin, A R; Halperin, G C

    1980-07-01

    A technique to wax-up and cast an aluminum base and a method to incorporate the base into the final denture base has been discussed. This technique does not use induction casting, rather it uses two casting ovens and a centrifugal casting machine. PMID:6991680

  18. Basic Casting from A to Z. Student's Instruction Booklet.

    ERIC Educational Resources Information Center

    Zebco, Tulsa, OK.

    A profusely illustrated student instruction booklet contains step-by-step directions and diagrams for learning four basic casting techniques. Separate sections cover basic spin-casting, spinning, bait-casting, and fly-casting. Each section details recommended equipment (reel, rod, line, plug, tackle, lures, leaders, flies), describes specific…

  19. GRINDING ROOM AT SOUTHERN DUCTILE CASTING COMPANY, BESSEMER FOUNDRY SHOWING ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    GRINDING ROOM AT SOUTHERN DUCTILE CASTING COMPANY, BESSEMER FOUNDRY SHOWING WHEELABORATOR THAT IMPALE SHOT AT TUMBLING CASTINGS TO REMOVE EXCESS SURFACE METALS AND SAND; ANNEALING OVENS TO HEAT CERTAIN CASTINGS TO ACHIEVE A DESIRED CHARACTERISTIC; AND GRINDING WHEELS USED TO REMOVE GATES. - Southern Ductile Casting Company, Grinding & Shipping, 2217 Carolina Avenue, Bessemer, Jefferson County, AL

  20. Cross-Validation of the Computerized Adaptive Screening Test (CAST).

    ERIC Educational Resources Information Center

    Pliske, Rebecca M.; And Others

    The Computerized Adaptive Screening Test (CAST) was developed to provide an estimate at recruiting stations of prospects' Armed Forces Qualification Test (AFQT) scores. The CAST was designed to replace the paper-and-pencil Enlistment Screening Test (EST). The initial validation study of CAST indicated that CAST predicts AFQT at least as accurately…

  1. 49 CFR 192.275 - Cast iron pipe.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 49 Transportation 3 2013-10-01 2013-10-01 false Cast iron pipe. 192.275 Section 192.275... Cast iron pipe. (a) Each caulked bell and spigot joint in cast iron pipe must be sealed with mechanical leak clamps. (b) Each mechanical joint in cast iron pipe must have a gasket made of a...

  2. 49 CFR 192.275 - Cast iron pipe.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 49 Transportation 3 2014-10-01 2014-10-01 false Cast iron pipe. 192.275 Section 192.275... Cast iron pipe. (a) Each caulked bell and spigot joint in cast iron pipe must be sealed with mechanical leak clamps. (b) Each mechanical joint in cast iron pipe must have a gasket made of a...

  3. 49 CFR 192.275 - Cast iron pipe.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 49 Transportation 3 2012-10-01 2012-10-01 false Cast iron pipe. 192.275 Section 192.275... Cast iron pipe. (a) Each caulked bell and spigot joint in cast iron pipe must be sealed with mechanical leak clamps. (b) Each mechanical joint in cast iron pipe must have a gasket made of a...

  4. Solidification Conditions and Microstructure in Continuously Cast Aluminum

    NASA Astrophysics Data System (ADS)

    Buxmann, K.; Gold, E.

    1982-04-01

    The well-known relationship between cell size or dendrite spacing and local solidification time gives the possibility of calculating the thermal parameters of solidification from the microstructure of the as-cast product. As a basis for such calculations, the dendrite spacing of different aluminum castings (DC cast ingots of different diameters, cast in conventional and electromagnetic molds; cast strip from roll casters, belt casters, and block casters; and Properzi cast rod) has been measured through their cross sections. Based on these measurements, a qualitative discussion of the thermal conditions during the solidification of these products is given, and the influence of a variation in the casting conditions discussed.

  5. Machinability of Austempered Ductile Iron (ADI) Produced by Integrated Green Technology of Continuous Casting-Heat Treatment Processes

    SciTech Connect

    Meena, A.; El Mansori, M.; Ghidossi, P.

    2011-01-17

    This study presents the novel processing technique known as continuous casting-heat treatment processes to produce Austempered Ductile Iron (ADI) which is a new class of ductile iron. ADI is characterized by improved mechanical properties but has low machinability as compared to other cast irons and steel of similar strength. The novel technique is developed by the integration of casting (in die casting) and heat treatment processes in foundry to save cost energy and time. Specimens just after casting were austenitized at 930 deg. C for 90 min and then austempered in fluidized bed at 380 deg. C for 90 and 120 min. Hence, the effect of austempering time on the morphology of retained austenite and mechanical properties of the material were examined and compared with conventionally produced ADI. Drilling tests were then carried out to evaluate the machinability of ADI in terms of cutting forces, chip micro-hardness, chip morphology and surface roughness. The mechanical properties of ADI austempered for 120 min have found to be better as compare to the ADI austempered for 90 min.

  6. Machinability of Austempered Ductile Iron (ADI) Produced by Integrated Green Technology of Continuous Casting-Heat Treatment Processes

    NASA Astrophysics Data System (ADS)

    Meena, A.; El Mansori, M.; Ghidossi, P.

    2011-01-01

    This study presents the novel processing technique known as continuous casting-heat treatment processes to produce Austempered Ductile Iron (ADI) which is a new class of ductile iron. ADI is characterized by improved mechanical properties but has low machinability as compared to other cast irons and steel of similar strength. The novel technique is developed by the integration of casting (in die casting) and heat treatment processes in foundry to save cost energy and time. Specimens just after casting were austenitized at 930° C for 90 min and then austempered in fluidized bed at 380° C for 90 and 120 min. Hence, the effect of austempering time on the morphology of retained austenite and mechanical properties of the material were examined and compared with conventionally produced ADI. Drilling tests were then carried out to evaluate the machinability of ADI in terms of cutting forces, chip micro-hardness, chip morphology and surface roughness. The mechanical properties of ADI austempered for 120 min have found to be better as compare to the ADI austempered for 90 min.

  7. Should assisted dying be legalised?

    PubMed Central

    2014-01-01

    When an individual facing intractable pain is given an estimate of a few months to live, does hastening death become a viable and legitimate alternative for willing patients? Has the time come for physicians to do away with the traditional notion of healthcare as maintaining or improving physical and mental health, and instead accept their own limitations by facilitating death when requested? The Universities of Oxford and Cambridge held the 2013 Varsity Medical Debate on the motion “This House Would Legalise Assisted Dying”. This article summarises the key arguments developed over the course of the debate. We will explore how assisted dying can affect both the patient and doctor; the nature of consent and limits of autonomy; the effects on society; the viability of a proposed model; and, perhaps most importantly, the potential need for the practice within our current medico-legal framework. PMID:24423249

  8. Advanced lost foam from casting technology

    SciTech Connect

    Bates, C. E.; Littleton, H. E.; Askeland, D.; Griffin, J.; Miller, B. A.; Sheldon, D. S.

    1996-05-01

    Previous research made significant advances in understanding the Lost Foam Casting (LFC) Process and clearly identified areas where additional research was needed to improve the process and make it more functional in an industrial environment. The current project focused on five areas listed as follows: Task 1: Precision Pattern Production Task 2: Pattern Coating Consistency Task 3: Sand Fill and Compaction Effects Task 4: Pattern Gating Task 5: Mechanical Properties of Castings. This report summarizes the work done under the current contract in all five areas in the period of October 1, 1994 through December 31, 1995. Twenty-eight (28) companies jointly participate in the project. These companies represent a variety of disciplines, including pattern designers, pattern producers, coating manufacturers, plant design companies, compaction equipment manufacturers, casting producers, and casting buyers.

  9. Thermal transport properties of grey cast irons

    SciTech Connect

    Hecht, R.L.; Dinwiddie, R.B.; Porter, W.D.; Wang, Hsin

    1996-10-01

    Thermal diffusivity and thermal conductivity of grey cast iron have been measured as a function of graphite flake morphology, chemical composition, and position in a finished brake rotor. Cast iron samples used for this investigation were cut from ``step block`` castings designed to produce iron with different graphite flake morphologies resulting from different cooling rates. Samples were also machined from prototype alloys and from production brake rotors representing a variation in foundry practice. Thermal diffusivity was measured at room and elevated temperatures via the flash technique. Heat capacity of selected samples was measured with differential scanning calorimetry, and these results were used to calculate the thermal conductivity. Microstructure of the various cast iron samples was quantified by standard metallography and image analysis, and the chemical compositions were determined by optical emission spectroscopy.

  10. Roll Casting of Aluminum Alloy Clad Strip

    SciTech Connect

    Nakamura, R.; Tsuge, H.; Haga, T.; Watari, H.; Kumai, S.

    2011-01-17

    Casting of aluminum alloy three layers of clad strip was tried using the two sets of twin roll casters, and effects of the casting parameters on the cladding conditions were investigated. One twin roll caster was mounted on the other twin roll caster. Base strip was 8079 aluminum alloy and overlay strips were 6022 aluminum alloy. Effects of roll-load of upper and lower casters and melt temperature of the lower caster were investigated. When the roll-load of the upper and lower caster was large enough, the overlay strip could be solidified and be connected. The overlay strip could be connected when the melt of the overlay strip cast by the lower caster was low enough. Sound three layers of clad strip could be cast by proper conditions.

  11. Open Cast Mining: An Environmental Issue.

    ERIC Educational Resources Information Center

    McPartland, Michael

    1993-01-01

    Presents a case study in which students investigate the environmental issue of open cast coal mining. Students examine the issue from different perspectives; interpret the available evidence; draw appropriate conclusions; and evaluate such conclusions. (MDH)

  12. Vacuum casting of thick polymeric films

    NASA Technical Reports Server (NTRS)

    Cuddihy, E. F.; Moacanin, J.

    1979-01-01

    Bubble formation and layering, which often plague vacuum-evaporated films, are prevented by properly regulating process parameters. Vacuum casting may be applicable to forming thick films of other polymer/solvent solutions.

  13. Casting uniform ceramics with direct coagulation

    SciTech Connect

    Graule, T.J.; Baader, F.H.; Gauckler, L.J.

    1995-06-01

    Today complex-shaped ceramic parts are mass fabricated by many different methods, two of which are slip casting and injection molding. The selection of the appropriate technique is governed by the geometric shape, the number of pieces to be manufactured, and the chemistry of the ceramic. Both slip casting and injection molding introduce imperfections in the green part, which lead to inhomogeneous microstructures in the sintered parts. A new fabrication method, direct coagulation casting (DCC), may be suitable for the mass production of complex ceramic parts with high strength and reliability. In DCC, an aqueous suspension is coagulated by a change in pH or an increase in ionic strength after casting, producing a rigid green body. The use of DCC can avoid most of the limitations of conventional shaping techniques, and it can be applied to a large variety of ceramic powders, sols, and polymers, alone or in combination.

  14. Effect of casting methods on castability of pure titanium.

    PubMed

    Takahashi, J; Zhang, J Z; Okazaki, M

    1993-12-01

    Two types of patterns were tested for castability: 1) polyester mesh pattern (20mm x 22mm with 100 open squares) and 2) 20mm x 20mm wax plates 1.0 and 1.5 mm in thickness. These materials were invested using a pre-arranged commercial phosphate-bonded investment for titanium. Three different types of casting machines were selected: 1) a pressure-type casting machine with separate melting and casting chambers, 2) a pressure-type casting machine with one chamber and 3) a centrifugal-type casting machine at 3000 rpm. Pure titanium (> 99.5%) was cast into the molds at a mold temperature of 100 degrees C. The castability of mesh pattern was evaluated in terms of the number of cast segment, and the cast plate was evaluated using X-ray transparent images by a digital imaging technique. The centrifugal casting method showed the best castability among these three casting methods. PMID:8004920

  15. WinMod: An expert advisor for investment casting

    SciTech Connect

    Bivens, H.P.; Williamson, G.A. Jr.; Luger, G.F.; Erdmann, R.G.; Maguire, M.C.; Baldwin, M.D.; Anderson, D.J.

    1998-04-01

    Investment casting is an important method for fabricating a variety of high quality components in mechanical systems. Cast components, unfortunately, have a large design and gate/runner build time associated with their fabrication. In addition, casting engineers often require many years of actual experience in order to consistently pour high quality castings. Since 1989, Sandia National Laboratories has been investigating casting technology and software that will reduce the time overhead involved in producing quality casts. Several companies in the casting industry have teamed up with Sandia to form the FASTCAST Consortium. One result of this research and the formation of the FASTCAST consortium is the creation of the WinMod software, an expert casting advisor that supports the decision making process of the casting engineer through visualization and advice to help eliminate possible casting defects.

  16. Embedding Optical Fibers In Cast Metal Parts

    NASA Technical Reports Server (NTRS)

    Gibler, William N.; Atkins, Robert A.; Lee, Chung E.; Taylor, Henry F.

    1995-01-01

    Use of metal strain reliefs eliminates breakage of fibers during casting process. Technique for embedding fused silica optical fibers in cast metal parts devised. Optical fiber embedded in flange, fitting, or wall of vacuum or pressure chamber, to provide hermetically sealed feedthrough for optical transmission of measurement or control signals. Another example, optical-fiber temperature sensor embedded in metal structural component to measure strain or temperature inside component.

  17. Computed Tomography For Internal Inspection Of Castings

    NASA Technical Reports Server (NTRS)

    Hanna, Timothy L.

    1995-01-01

    Computed tomography used to detect internal flaws in metal castings before machining and otherwise processing them into finished parts. Saves time and money otherwise wasted on machining and other processing of castings eventually rejected because of internal defects. Knowledge of internal defects gained by use of computed tomography also provides guidance for changes in foundry techniques, procedures, and equipment to minimize defects and reduce costs.

  18. Arc Casting Intermetallic Alloy (Materials Preparation Center)

    SciTech Connect

    2010-01-01

    Arc casting of intermetallic (La-Ni-Sn) AB5 alloy used for metal hydride hydrogen storage. Upon solidification the Sn is partially rejected and increases in concentration in the remaining liquid. Upon completing solidification there is a great deal of internal stress in the ingot. As the ingot cools further the stress is relieved. This material was cast at the Ames Laboratorys Materials Preparation Center http://www.mpc.ameslab.gov

  19. Combination Of Investment And Centrifugal Casting

    NASA Technical Reports Server (NTRS)

    Creeger, Gordon A.

    1994-01-01

    Modifications, including incorporation of centrifugal casting, made in investment-casting process reducing scrap rate. Used to make first- and second-stage high-pressure-fuel-turbopump nozzles, containing vanes with thin trailing edges and other thin sections. Investment mold spun for short time while being filled, and stopped before solidification occurs. Centrifugal force drives molten metal into thin trailing edges, ensuring they are filled. With improved filling, preheat and pour temperatures reduced and solidification hastened so less hot tearing.

  20. Apollo 14 composite casting demonstration

    NASA Technical Reports Server (NTRS)

    1971-01-01

    This program assisted in the design and implementation of the composite casting demonstration for the Apollo 14 mission. Both flight and control samples were evaluated. Some conclusions resulting from a comparison of the flight and control samples were: (1) Solidification in neither the flight nor control samples was truly directional. (2) Apparent intermittent contact of the melt with the container in the flight samples led to unusual nucleation and growth structures. (3) There was greater uniformity, on a macro scale, of both pores and structural features in the flight sample; presumably the result of the reduced gravity conditions. (4) It seems quite feasible to produce enhanced dispersions of gases and dense phases in a melt which is solidified in reduced gravity. (5) A two-stage heating/cooling cycle may help directional solidification. (6) Sample materials should be selected from materials in which the dispersant fully wets the matrix material. (7) Experiments should be conducted in two modes: (1) where the melt is in good thermal contact with the container, and (2) where the melt is in a free-float condition.