Advances in multi-scale modeling of solidification and casting processes

NASA Astrophysics Data System (ADS)

Liu, Baicheng; Xu, Qingyan; Jing, Tao; Shen, Houfa; Han, Zhiqiang

2011-04-01

The development of the aviation, energy and automobile industries requires an advanced integrated product/process R&D systems which could optimize the product and the process design as well. Integrated computational materials engineering (ICME) is a promising approach to fulfill this requirement and make the product and process development efficient, economic, and environmentally friendly. Advances in multi-scale modeling of solidification and casting processes, including mathematical models as well as engineering applications are presented in the paper. Dendrite morphology of magnesium and aluminum alloy of solidification process by using phase field and cellular automaton methods, mathematical models of segregation of large steel ingot, and microstructure models of unidirectionally solidified turbine blade casting are studied and discussed. In addition, some engineering case studies, including microstructure simulation of aluminum casting for automobile industry, segregation of large steel ingot for energy industry, and microstructure simulation of unidirectionally solidified turbine blade castings for aviation industry are discussed.

Utilization of Space Station for industrial thermophysical property measurements

NASA Astrophysics Data System (ADS)

Overfelt, Tony; Watkins, John

1996-03-01

The International Space Station represents the largest cooperative space project in history and will be industry's only reasonable access to the low-g environment for long duration R&D. Such access will provide unique and competitive capabilities to industry if private sector entities can commercially utilize the Space Station for their industrial research programs. The metal casting industry has identified the need for accurate thermophysical properties of molten alloys as a priority need. Research over the last decade has demonstrated that experimental techniques exist to containerlessly measure critical thermophysical and related properties of molten metals for improved process design. This paper describes the ``VULCAN'' concept, a proposed commercial instrument for thermophysical properties measurements on the Space Station. Finally, several issues regarding private sector utilization of the Space Station are also discussed.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mohamed Abdelrahman; roger Haggard; Wagdy Mahmoud

The final goal of this project was the development of a system that is capable of controlling an industrial process effectively through the integration of information obtained through intelligent sensor fusion and intelligent control technologies. The industry of interest in this project was the metal casting industry as represented by cupola iron-melting furnaces. However, the developed technology is of generic type and hence applicable to several other industries. The system was divided into the following four major interacting components: 1. An object oriented generic architecture to integrate the developed software and hardware components @. Generic algorithms for intelligent signal analysismore » and sensor and model fusion 3. Development of supervisory structure for integration of intelligent sensor fusion data into the controller 4. Hardware implementation of intelligent signal analysis and fusion algorithms« less

Research on the influence of moulding-casting technology on the quality of castings

NASA Astrophysics Data System (ADS)

Josan, A.; Pinca Bretotean, C.; Raţiu, S.; Ardelean, E.; Ardelean, M.

2017-05-01

The quality of castings has a particularly role in the Romanian foundries. In this context, quality assurance is the overall objective of the foundries. The paper presents the critical analysis performed on moulding-casting technology of the type Lifting mechanism. This casting is a subset of the lifting and rotating mechanism of the furnace vault. The casting analysed is a medium size, with weight of 114 kg. The current moulding-casting technology involves moulding into three mould-parts leading to the occurrence of defects (decentering of the core, displacement of the lower mould and the middle mould and occurrence of burrs in area separated. Thus, to reduce the percentage of defects registered in industrial practice is necessary to change the moulding-casting technology. This requires the use of two mould-parts, re-dimensioning of the core and the core box and dimensioning of the runner network. The adoption of these changes in industrial practice has direct implications on the cost of casting and foundry costs default.

75 FR 54595 - Certain Iron Construction Castings From Brazil, Canada, and the People's Republic of China: Final...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-09-08

...] Certain Iron Construction Castings From Brazil, Canada, and the People's Republic of China: Final Results... construction castings from Brazil, Canada, and the People's Republic of China (PRC), pursuant to section 751(c... antidumping duty orders\\1\\ on certain iron construction castings from Brazil, Canada, and the PRC pursuant to...

Workplace Basic Skills in the Metal Casting Industry for World Class Process and Technology.

ERIC Educational Resources Information Center

Rasmussen, Bonnie

A workplace basic skills project for the metal casting industry was established jointly by Central Alabama Community College and Robinson Foundry, Inc. Evaluation of the project was made through a commercial test of hourly workers' general literacy level gains, instructor-developed pre- and posttests of mastery of the industrial process and…

77 FR 6587 - PHB Die Casting a Subsidiary of PHB, Inc., Including On-Site Leased Workers From Career Concepts...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-02-08

... Contract Worker From Burns Industrial Group (BIG INC) Fairview, PA; Amended Certification Regarding... production of die castings. New information shows that a worker from Burns Industrial Group (BIG Inc) was... amending this certification to include a worker from Burns Industrial Group (BIG Inc) who was contracted by...

Implementation of Cyber-Physical Production Systems for Quality Prediction and Operation Control in Metal Casting.

PubMed

Lee, JuneHyuck; Noh, Sang Do; Kim, Hyun-Jung; Kang, Yong-Shin

2018-05-04

The prediction of internal defects of metal casting immediately after the casting process saves unnecessary time and money by reducing the amount of inputs into the next stage, such as the machining process, and enables flexible scheduling. Cyber-physical production systems (CPPS) perfectly fulfill the aforementioned requirements. This study deals with the implementation of CPPS in a real factory to predict the quality of metal casting and operation control. First, a CPPS architecture framework for quality prediction and operation control in metal-casting production was designed. The framework describes collaboration among internet of things (IoT), artificial intelligence, simulations, manufacturing execution systems, and advanced planning and scheduling systems. Subsequently, the implementation of the CPPS in actual plants is described. Temperature is a major factor that affects casting quality, and thus, temperature sensors and IoT communication devices were attached to casting machines. The well-known NoSQL database, HBase and the high-speed processing/analysis tool, Spark, are used for IoT repository and data pre-processing, respectively. Many machine learning algorithms such as decision tree, random forest, artificial neural network, and support vector machine were used for quality prediction and compared with R software. Finally, the operation of the entire system is demonstrated through a CPPS dashboard. In an era in which most CPPS-related studies are conducted on high-level abstract models, this study describes more specific architectural frameworks, use cases, usable software, and analytical methodologies. In addition, this study verifies the usefulness of CPPS by estimating quantitative effects. This is expected to contribute to the proliferation of CPPS in the industry.

Evaluation of Uranium-235 Measurement Techniques

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kaspar, Tiffany C.; Lavender, Curt A.; Dibert, Mark W.

2017-05-23

Monolithic U-Mo fuel plates are rolled to final fuel element form from the original cast ingot, and thus any inhomogeneities in 235U distribution present in the cast ingot are maintained, and potentially exaggerated, in the final fuel foil. The tolerance for inhomogeneities in the 235U concentration in the final fuel element foil is very low. A near-real-time, nondestructive technique to evaluate the 235U distribution in the cast ingot is required in order to provide feedback to the casting process. Based on the technical analysis herein, gamma spectroscopy has been recommended to provide a near-real-time measure of the 235U distribution inmore » U-Mo cast plates.« less

Construction and Skilled Trades (CAST) Test Preparation, Final Report for period 10/1/2016 - 03/31/2017

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wilson, Charles

Within the energy and utilities sectors, the most significant barrier for consideration and submittal of diverse applicants for skilled labor opportunities is their inability to successfully pass the industry’s Construction And Skilled Trades (CAST) examination. The exam is collectively accepted as the benchmark for prospective candidates and assess if they have the baseline skills and knowledge to apply for skilled positions within those industries. It is an exam that was created by the Edison Electric Institute. Students were taught for a full 40-hr week M-F. We conducted one class in each of the following locations: Philadelphia, Chicago and Washington, DC.more » The students learned and practiced curriculum prepared by the utility industry for increased success for the examination. They were also taught how to successfully navigate the final barrier of employment opportunity: behavior-based interviewing. They were then directed to the website in order to apply for the positions they desired, and then scheduled to take the exam. We were targeting at least 70% of those who sit for the exam to pass the first time. If they were unsuccessful, candidates could re-test within 3 months. We then sent their resumes directly to the hiring recruiters and managers so that they received prime consideration. Our target number of applicants who were successful in being invited for interviews was 15 candidates.« less

Clean Metal Casting

DOE Office of Scientific and Technical Information (OSTI.GOV)

Makhlouf M. Makhlouf; Diran Apelian

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 asmore » 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.« less

Development of a CFD code for casting simulation

NASA Technical Reports Server (NTRS)

Murph, Jesse E.

1992-01-01

The task of developing a computational fluid dynamics (CFD) code to accurately model the mold filling phase of a casting operation was accomplished in a systematic manner. First the state-of-the-art was determined through a literature search, a code search, and participation with casting industry personnel involved in consortium startups. From this material and inputs from industry personnel, an evaluation of the currently available codes was made. It was determined that a few of the codes already contained sophisticated CFD algorithms and further validation of one of these codes could preclude the development of a new CFD code for this purpose. With industry concurrence, ProCAST was chosen for further evaluation. Two benchmark cases were used to evaluate the code's performance using a Silicon Graphics Personal Iris system. The results of these limited evaluations (because of machine and time constraints) are presented along with discussions of possible improvements and recommendations for further evaluation.

Laser surface texturing of cast iron steel: dramatic edge burr reduction and high speed process optimisation for industrial production using DPSS picosecond lasers

NASA Astrophysics Data System (ADS)

Bruneel, David; Kearsley, Andrew; Karnakis, Dimitris

2015-07-01

In this work we present picosecond DPSS laser surface texturing optimisation of automotive grade cast iron steel. This application attracts great interest, particularly in the automotive industry, to reduce friction between moving piston parts in car engines, in order to decrease fuel consumption. This is accomplished by partially covering with swallow microgrooves the inner surface of a piston liner and is currently a production process adopting much longer pulse (microsecond) DPSS lasers. Lubricated interface conditions of moving parts require from the laser process to produce a very strictly controlled surface topography around the laser formed grooves, whose edge burr height must be lower than 100 nm. To achieve such a strict tolerance, laser machining of cast iron steel was investigated using an infrared DPSS picosecond laser (10ps duration) with an output power of 16W and a repetition rate of 200 kHz. The ultrashort laser is believed to provide a much better thermal management of the etching process. All studies presented here were performed on flat samples in ambient air but the process is transferrable to cylindrical geometry engine liners. We will show that reducing significantly the edge burr below an acceptable limit for lubricated engine production is possible using such lasers and remarkably the process window lies at very high irradiated fluences much higher that the single pulse ablation threshold. This detailed experimental work highlights the close relationship between the optimised laser irradiation conditions as well as the process strategy with the final size of the undesirable edge burrs. The optimised process conditions are compatible with an industrial production process and show the potential for removing extra post)processing steps (honing, etc) of cylinder liners on the manufacturing line saving time and cost.

Complex deformation routes for direct recycling aluminium alloy scrap via industrial hot extrusion

NASA Astrophysics Data System (ADS)

Paraskevas, Dimos; Kellens, Karel; Kampen, Carlos; Mohammadi, Amirahmad; Duflou, Joost R.

2018-05-01

This paper presents the final results of an industrial project, aiming for direct hot extrusion of wrought aluminium alloy scrap at an industrial scale. Two types of complex deformation/extrusion routes were tested for the production of the same profile, starting from AA6060 scrap in form of machining chips. More specifically scrap-based billets were extruded through: a 2-porthole and a 4-porthole die-set, modified for enhanced scrap consolidation and grain refinement. For comparison reasons, cast billets of the same alloy were extruded through the modified 2-porthole die set. The tensile testing results as well as microstructural investigations show that the 4-porthole extrusion route further improves scrap consolidation compared to the 2-porthole die output. The successful implementation of solid state recycling, directly at industrial level, indicates the technological readiness level of this research.

Implementation of Cyber-Physical Production Systems for Quality Prediction and Operation Control in Metal Casting

PubMed Central

Lee, JuneHyuck; Noh, Sang Do; Kim, Hyun-Jung; Kang, Yong-Shin

2018-01-01

The prediction of internal defects of metal casting immediately after the casting process saves unnecessary time and money by reducing the amount of inputs into the next stage, such as the machining process, and enables flexible scheduling. Cyber-physical production systems (CPPS) perfectly fulfill the aforementioned requirements. This study deals with the implementation of CPPS in a real factory to predict the quality of metal casting and operation control. First, a CPPS architecture framework for quality prediction and operation control in metal-casting production was designed. The framework describes collaboration among internet of things (IoT), artificial intelligence, simulations, manufacturing execution systems, and advanced planning and scheduling systems. Subsequently, the implementation of the CPPS in actual plants is described. Temperature is a major factor that affects casting quality, and thus, temperature sensors and IoT communication devices were attached to casting machines. The well-known NoSQL database, HBase and the high-speed processing/analysis tool, Spark, are used for IoT repository and data pre-processing, respectively. Many machine learning algorithms such as decision tree, random forest, artificial neural network, and support vector machine were used for quality prediction and compared with R software. Finally, the operation of the entire system is demonstrated through a CPPS dashboard. In an era in which most CPPS-related studies are conducted on high-level abstract models, this study describes more specific architectural frameworks, use cases, usable software, and analytical methodologies. In addition, this study verifies the usefulness of CPPS by estimating quantitative effects. This is expected to contribute to the proliferation of CPPS in the industry. PMID:29734699

AIS/DOE Technology Roadmap Program: Strip Casting: Anticipating New Routes To Steel Sheet

DOE Office of Scientific and Technical Information (OSTI.GOV)

Prof. Alan W. Camb; Prof. Anthony Rollett

2001-08-31

To determine the potential for strip casting in the steel industry and to develop the fundamental knowledge necessary to allow the role of strip casting in the modern steel industry to be understood. Based upon a study of carbon steel strip castings that were either produced for the program at British Steel or were received from a pre-commercial production machine, the following conclusions were made. Strip casting of carbon steels is technically feasible for sheet material from slightly less than 1 mm thick to 3 mm thick, and, assuming that it is economically viable, it will be first applied inmore » carbon steel markets that do not require stringent surface quality or extensive forming. The potential of strip casting as a casting process to be developed for steel castings is very high as the cast strip has some very novel characteristics. Direct cast carbon strip has better surface quality, shape and profile than any other casting process currently available. The more rapidly solidified structure of direct cast strip tends to be strong with low ductility; however, with adequate thermal treatment, it is possible to develop a variety of properties from the same grade. The process is more amenable at this time to production tonnages per year of the order of 500,000 tons and as such will first find niche type applications. This technology is an additional technology for steel production and will be in addition to, rather than a replacement for, current casting machines.« less

Prediction of Shrinkage Porosity Defect in Sand Casting Process of LM25

NASA Astrophysics Data System (ADS)

Rathod, Hardik; Dhulia, Jay K.; Maniar, Nirav P.

2017-08-01

In the present worldwide and aggressive environment, foundry commercial enterprises need to perform productively with least number of rejections and create casting parts in shortest lead time. It has become extremely difficult for foundry industries to meet demands of defects free casting and meet strict delivery schedules. The process of casting solidification is complex in nature. Prediction of shrinkage defect in metal casting is one of the critical concern in foundries and is one of the potential research areas in casting. Due to increasing pressure to improve quality and to reduce cost, it is very essential to upgrade the level of current methodology used in foundries. In the present research work, prediction methodology of shrinkage porosity defect in sand casting process of LM25 using experimentation and ANSYS is proposed. The objectives successfully achieved are prediction of shrinkage porosity distribution in Al-Si casting and determining effectiveness of investigated function for predicting shrinkage porosity by correlating results of simulating studies to those obtained experimentally. The real-time application of the research reflects from the fact that experimentation is performed on 9 different Y junctions at foundry industry and practical data obtained from experimentation are used for simulation.

Electroslag Processing for Marine Application. Summary Report on a Workshop Held in Annapolis, Maryland on 5-6 March 1985.

DTIC Science & Technology

1985-03-01

the ESC process technology to private industry. The task emphasizes four major areas: (1) advancement of ESC technology , (2) preparation of castings (by...to advance the technology . This can possibly be best accomplished by industry or by industry in cooperation with one or more Government agencies... Technology ( CANMET ) has been involved with electroslag casting for the past 4 years. Recently this equipment has been modified to produce thin-wall hollow

A Survey of the Training Needs for the Metal Casting Industry's Electrical Skilled Trades.

ERIC Educational Resources Information Center

Hall, Mary Ann

Additional training needs desired by the electrical skilled personnel of the metal casting industry were the focus of a study. A questionnaire was distributed to electricians and electrical engineers employed in 39 foundries in over 20 states. Of the 150 surveys, 63 responded for a 42 percent return. The questionnaire was divided into three…

In Vitro Screening of 1877 Industrial and Consumer Chemicals, Pesticides and Pharmaceuticals in up to 782 Assays: ToxCast Phase I and II (SOT)

EPA Science Inventory

In Phase II of the ToxCast program, the U.S. EPA and Tox21 partners screened 1,877 chemicals, including pesticides; food, cosmetics and personal care ingredients; pharmaceuticals; and industrial chemicals. Testing used a 782 in vitro assays across 7 technologies and multiple bi...

The Design and Construction Process of a Test Stand for Casting the Power Steering’S Housing with the Use of the Pdcpd Material

NASA Astrophysics Data System (ADS)

Sobek, M.; Baier, A.; Grabowski, Ł.

2018-01-01

The use of new technologies and materials in various industries is a natural process that is directly related to the very high rate of development of these technologies. Certain industries decide to much faster introduce new technologies and materials. One of such branches is the automotive industry, whose representatives are very energetically looking for both financial savings and savings resulting from the vehicles mass reduction. An economically justified approach to construction materials is leading the search for new solutions and materials. The use of a modern material such as the two-component PDCPD composite shows hitherto unknown possibilities of producing subassemblies of many different constructions. The possibility of using a modern composite material with parameters comparable to that of metals and significantly lighter, can be an excellent alternative in the selection of materials for many parts of motor vehicles. The potentiality of precise casting of tolerated surfaces will allow to reduce the operations related to machining process, which is an indispensable part of the production process of elements that are cast of metal. This article describes the process of designing and building a test stand for precise positioning of power steering gear components at the stage of casting their housing. The article presents the principle of operation of the test stand and the process of preparation for the casting and the cast itself will be rudely described. Due to the implementation of research as part of a research project with an industrial partner, the article will only describe some operations. This is related to the confidentiality of the project.

Optimization of permeability for quality improvement by using factorial design

NASA Astrophysics Data System (ADS)

Said, Rahaini Mohd; Miswan, Nor Hamizah; Juan, Ng Shu; Hussin, Nor Hafizah; Ahmad, Aminah; Kamal, Mohamad Ridzuan Mohamad

2017-05-01

Sand castings are used worldwide by the manufacturing process in Metal Casting Industry, whereby the green sand are the commonly used sand mould type in the industry of sand casting. The defects on the surface of casting product is one of the problems in the industry of sand casting. The problems that relates to the defect composition of green sand are such as blowholes, pinholes shrinkage and porosity. Our objective is to optimize the best composition of green sand in order to minimize the occurrence of defects. Sand specimen of difference parameters (Bentonite, Green Sand, Cold dust and water) were design and prepared to undergo permeability test. The 24 factorial design experiment with four factors at difference composition were runs, and the total of 16 runs experiment were conducted. The developed models based on the experimental design necessary models were obtained. The model with a high coefficient of determination (R2=0.9841) and model for predicted and actual fitted well with the experimental data. Using the Analysis of Design Expert software, we identified that bentonite and water are the main interaction effect in the experiments. The optimal settings for green sand composition are 100g silica sand, 21g bentonite, 6.5 g water and 6g coal dust. This composition gives an effect of permeability number 598.3GP.

European Scientific Notes. Volume 36, Number 4.

DTIC Science & Technology

1982-03-30

de of gray cast iron, Mampaey demonstrated that Recherches Scientifiques et Techniques de the minimum riser dimensions needed to obtain I’lndustrie...through the nonprofit He is now making a similar study of ’nodular Industrial association Fabrimetal (Fdlration des cast iron. entreprises de I’industrie...SCIENTIFIC NOTES April 6. PERFORMING ORG. REPORT NUMBER 7. AUTHOR(&) II. CONTRACT OR GRANT NUMBER(e) 9. PERFORMING ORGANIZATION NAME AND ADDRESS 10

Modern Cast Irons in Chemical Engineering

DTIC Science & Technology

1934-11-09

fl’ceew. T I SOCIETY OF CHEMICAL INDUSTRY CHEMICAL ENGINEERING GROUP MODERN CAST IRONS IN CHEMICAL ENGINEERING By J. G. PEARCE, M.Sc., F.Inst.P...CAST IRONS IN CHEMICAL ENGINEERING By J. G. PEARCE, M.Sc., F.Inst.P., M.I.E.E.* INTRODUCTION to chemical or thermal resistance. Small blow-holes Any...consideration of modern cast irons in chemical seldom appear to reduce the mechanical strength of engineering should strictly be prefaced by a definition

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.

Final Report, Volume 2, The Development of Qualification Standards for Cast Duplex Stainless Steel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Russell, Steven, W.; Lundin, Carl, W.

2005-09-30

The scope of testing cast Duplex Stainless Steel (DSS) required testing to several ASTM specifications, while formulating and conducting industry round robin tests to verify and study the reproducibility of the results. ASTM E562 (Standard Test Method for Determining Volume Fraction by Systematic manual Point Count) and ASTM A923 (Standard Test Methods for Detecting Detrimental Intermetallic Phase in Wrought Duplex Austenitic/Ferritic Stainless Steels) were the specifications utilized in conducting this work. An ASTM E562 industry round robin, ASTM A923 applicability study, ASTM A923 industry round robin, and an ASTM A923 study of the effectiveness of existing foundry solution annealing proceduresmore » for producing cast DSS without intermetallic phases were implemented. In the ASTM E562 study, 5 samples were extracted from various cast austenitic and DSS in order to have varying amounts of ferrite. Each sample was metallographically prepared by UT and sent to each of 8 participants for volume fraction of ferrite measurements. Volume fraction of ferrite was measured using manual point count per ASTM E562. FN was measured from the Feritescope® and converted to volume fraction of ferrite. Results indicate that ASTM E562 is applicable to DSS and the results have excellent lab-to-lab reproducibility. Also, volume fraction of ferrite conversions from the FN measured by the Feritescope® were similar to volume fraction of ferrite measured per ASTM E562. In the ASTM A923 applicability to cast DSS study, 8 different heat treatments were performed on 3 lots of ASTM A890-4A (CD3MN) castings and 1 lot of 2205 wrought DSS. The heat treatments were selected to produce a wide range of cooling rates and hold times in order to study the suitability of ASTM A923 to the response of varying amounts on intermetallic phases [117]. The test parameters were identical to those used to develop ASTM A923 for wrought DSS. Charpy V-notch impact samples were extracted from the castings and wrought DSS and tested per ASTM A923 method B (Charpy impact test). Method A (sodium hydroxide etch test) was performed on one half of a fractured Charpy V-notch impact sample and Method C (ferric chloride corrosion weight loss test) was performed on another half. Test results for the three cast lots and one wrought lot indicate that ASTM A923 is relevant for detecting intermetallic phases in cast DSS. In the ASTM A923 round robin study, five laboratories conducted ASTM A923 Methods A & C on cast DSS material and the lab-to-lab reproducibility of the data was determined. Two groups of samples were sent to the participants. Group 1 samples were tested per ASTM A923 Method A, group 2 samples were tested by ASTM A923 Method C. Testing procedures for this round robin study were identical to those used in the ASTM A923 applicability study. Results from this round robin indicate that there is excellent lab-to-lab reproducibility of ASTM A923 with respect to cast DSS and that ASTM A923 could be expanded to cover both wrought and cast DSS. In the ASTM A923 study of the effectiveness of existing foundry solution annealing procedures for producing cast DSS without intermetallic phases, Ten heats of ASTM A890-4A (CD3MN) in the foundry solution annealed condition were tested per ASTM A923 Methods A, B, & C. Testing of these materials per ASTM A923 was used to determine if the foundry solution anneal procedures were adequate to completely eliminate any intermetallic phases, which may have precipitated during the casting and subsequent heat treatment processes. All heats showed no sign of intermetallic phase per Method A, passed minimum Charpy impact energy requirements per Method B (> 40 ft-lbs @ -40°C (-40°F)), and showed negligible weight loss per Method C (< 10 mdd). These results indicate that the solution annealing procedure used by foundries is adequate to produce a product free from intermetallic phases.« less

Final Report, Volume 2, The Development of Qualification Standards for Cast Duplex Stainless Steel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Russell, Steven, W.; Lundin, Carl, D.

2005-09-30

The scope of testing cast Duplex Stainless Steel (DSS) required testing to several ASTM specifications, while formulating and conducting industry round robin tests to verify and study the reproducibility of the results. ASTM E562 (Standard Test Method for Determining Volume Fraction by Systematic manual Point Count) and ASTM A923 (Standard Test Methods for Detecting Detrimental Intermetallic Phase in Wrought Duplex Austenitic/Ferritic Stainless Steels) were the specifications utilized in conducting this work. An ASTM E562 industry round robin, ASTM A923 applicability study, ASTM A923 industry round robin, and an ASTM A923 study of the effectiveness of existing foundry solution annealing proceduresmore » for producing cast DSS without intermetallic phases were implemented. In the ASTM E562 study, 5 samples were extracted from various cast austenitic and DSS in order to have varying amounts of ferrite. Each sample was metallographically prepared by UT and sent to each of 8 participants for volume fraction of ferrite measurements. Volume fraction of ferrite was measured using manual point count per ASTM E562. FN was measured from the Feritescope{reg_sign} and converted to volume fraction of ferrite. Results indicate that ASTM E562 is applicable to DSS and the results have excellent lab-to-lab reproducibility. Also, volume fraction of ferrite conversions from the FN measured by the Feritescope{reg_sign} were similar to volume fraction of ferrite measured per ASTM E562. In the ASTM A923 applicability to cast DSS study, 8 different heat treatments were performed on 3 lots of ASTM A890-4A (CD3MN) castings and 1 lot of 2205 wrought DSS. The heat treatments were selected to produce a wide range of cooling rates and hold times in order to study the suitability of ASTM A923 to the response of varying amounts on intermetallic phases [117]. The test parameters were identical to those used to develop ASTM A923 for wrought DSS. Charpy V-notch impact samples were extracted from the castings and wrought DSS and tested per ASTM A923 method B (Charpy impact test). Method A (sodium hydroxide etch test) was performed on one half of a fractured Charpy V-notch impact sample and Method C (ferric chloride corrosion weight loss test) was performed on another half. Test results for the three cast lots and one wrought lot indicate that ASTM A923 is relevant for detecting intermetallic phases in cast DSS. In the ASTM A923 round robin study, five laboratories conducted ASTM A923 Methods A & C on cast DSS material and the lab-to-lab reproducibility of the data was determined. Two groups of samples were sent to the participants. Group 1 samples were tested per ASTM A923 Method A, group 2 samples were tested by ASTM A923 Method C. Testing procedures for this round robin study were identical to those used in the ASTM A923 applicability study. Results from this round robin indicate that there is excellent lab-to-lab reproducibility of ASTM A923 with respect to cast DSS and that ASTM A923 could be expanded to cover both wrought and cast DSS. In the ASTM A923 study of the effectiveness of existing foundry solution annealing procedures for producing cast DSS without intermetallic phases, Ten heats of ASTM A890-4A (CD3MN) in the foundry solution annealed condition were tested per ASTM A923 Methods A, B, & C. Testing of these materials per ASTM A923 was used to determine if the foundry solution anneal procedures were adequate to completely eliminate any intermetallic phases, which may have precipitated during the casting and subsequent heat treatment processes. All heats showed no sign of intermetallic phase per Method A, passed minimum Charpy impact energy requirements per Method B (> 40 ft-lbs {at} -40 C (-40 F)), and showed negligible weight loss per Method C (< 10 mdd). These results indicate that the solution annealing procedure used by foundries is adequate to produce a product free from intermetallic phases.« less

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

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

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 amore » 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 nuts at a constant input torque and resulting clamp loads were recorded continuously. The clamp load data was used to determine the range of clamp loads to be expected. The bolts were driven to failure. The clamp load corresponding to the target input of 18.5 Nm was recorded for each fastener. In a like fashion, a second set of experiments were run with cast magnesium nuts and ALtracs thread forming fasteners, (a widely used thread forming fastener suitable for magnesium applications). Again all clamp loads were recorded and analyzed similarly to the Taptites in aluminum cast nuts. Results from previous work performed on the same test cell for a Battelle project using standard M8 bolts into standard M8 nuts were included as a comparator for a standard bolt and nut application. The results for the thread forming fasteners in aluminum cast holes were well within industry expectations of +/- 30% for out of the box and robustness range testing. The results for the dry and lubed extreme conditions were only slightly higher than industry expectations at +/- 35.6%. However, when compared to the actual Battelle results (+/- 40%) for a standard bolt and nut the tread forming fasteners performed slightly better. The results for the thread forming fasteners in magnesium cast holes were all well within industry expectations of +/- 30% for all three conditions. The robustness range (.05mm larger and smaller holes than the expected wear pattern of a die casting die at full life cycle) results also fell within the industry expectations for standard threaded fasteners. These results were very encouraging. It was concluded that this work showed that clamp load variation with thread forming fasteners is consistent with industry expectations for standard steel bolts and nuts at +/- 30%. There does not appear to be any significant increase in clamp load variation due to the application of thread forming fasteners in as-cast holes of aluminum or magnesium over the effective life of a die casting mold. The fully implemented potential benefit of thread forming fasteners in as-cast holes of aluminum and magnesium is estimated to be 6 trillion Btu per year for North America. Economic benefit is estimated to be nearly $800 million per year. Environmental benefits and quality improvements will also result from full implementation of this technology.« less

Improving Metal Casting Process

NASA Technical Reports Server (NTRS)

1998-01-01

Don Sirois, an Auburn University research associate, and Bruce Strom, a mechanical engineering Co-Op Student, are evaluating the dimensional characteristics of an aluminum automobile engine casting. More accurate metal casting processes may reduce the weight of some cast metal products used in automobiles, such as engines. Research in low gravity has taken an important first step toward making metal products used in homes, automobiles, and aircraft less expensive, safer, and more durable. Auburn University and industry are partnering with NASA to develop one of the first accurate computer model predictions of molten metals and molding materials used in a manufacturing process called casting. Ford Motor Company's casting plant in Cleveland, Ohio is using NASA-sponsored computer modeling information to improve the casting process of automobile and light-truck engine blocks.

Mathematical Modeling of the Effect of Roll Diameter on the Thermo-Mechanical Behavior of Twin Roll Cast AZ31 Magnesium Alloy Strips

NASA Astrophysics Data System (ADS)

Hadadzadeh, Amir; Wells, Mary

Although the Twin Roll Casting (TRC) process has been used in the aluminum sheet production industry for more than 60 years, the usage of this process to fabricate magnesium sheets is still at its early stages. Similar to other manufacturing processes, the development of the TRC process for magnesium alloys has followed a typical route of preliminary studies using a laboratory-scale facility, followed by pilot-scale testing and most recently attempting to use an industrial-scale twin roll caster. A powerful tool to understand and quantify the trends of the processing conditions and effects of scaling up from a laboratory size TRC machine to an industrial scale one is develop a mathematical model of the process. This can elucidate the coupled fluid-thermo-mechanical behavior of the cast strip during the solidification and then deformation stages of the process. In the present study a Thermal-Fluid-Stress model has been developed for TRC of AZ31 magnesium alloy for three roll diameters by employing the FEM commercial package ALSIM. The roll diameters were chosen as 355mm, 600mm and 1150mm. The effect of casting speed for each diameter was studied in terms of fluid flow, thermal history and stress-strain evolution in the cast strip in the roll bite region.

Detection and reconstruction of solidification cracks - Laser ultrasonic measurements during the continuous casting process of aluminum

NASA Astrophysics Data System (ADS)

Mitter, Thomas; Grün, Hubert; Roither, Jürgen; Betz, Andreas; Bozorgi, Salar; Reitinger, Bernhard; Burgholzer, Peter

2014-05-01

In the continuous casting process the avoidance and rapid detection of occurring solidification cracks in the slab is a crucial issue, in particular for the maintenance of a high quality level in further production processes. Due to the elevated temperatures of the slab surface a remote sensing non-destructive tool for quality inspection is required, which is also applicable for the harsh industrial environment. In this work the application of laser ultrasound (LUS) technique during the continuous casting process in industrial environment is shown. The proof of principle of the detection of the centered solidification cracks is shown by pulse-echo measurements with laser ultrasonic equipment for inline quality inspection. Preliminary examinations in the lab of different casted samples have shown the distinguishability of slabs with and without any solidification cracks. Furthermore the damping of the bulk wave has been used for the prediction of the dimension of the crack. With an adapted "synthetic aperture focusing technique" (SAFT) algorithm the image reconstruction of multiple measurements at different positions around the circumference has provided enough information for the estimation of the localization and extension of the centered solidification cracks. Subsequent first measurements using this laser ultrasonic setup during the continuous casting of aluminum were carried out and showed the proof of principle in an industrial environment with elevated temperatures, dust, cooling water and vibrations.

Structure and mechanical characterization of Mg-Nd-Zn alloys prepared by different processes

NASA Astrophysics Data System (ADS)

Dvorský, D.; Kubásek, J.; Vojtěch, D.; Voňavková, I.; Veselý, M.; Čavojský, M.

2017-02-01

Magnesium alloys containing about 3 wt. % of Nd and 0.5 wt. % of Zn are considered as promising materials for application in transport and medical industry. Properly treated materials can reach ultimate tensile strength (UTS) higher than 300 MPa. Also the corrosion resistance of these alloys is superior to many other magnesium-based materials. Present work is focused on the preparation of Mg-3Nd-0.5Zn magnesium alloy by classical casting and subsequent thermal treatment. As-cast material was extruded at 400 °C, with extrusion ratio equal to 16 and velocity of 0.2 mm/s. The effect of thermal treatment and also strong plastic deformation during extrusion on final structure conditions and mechanical properties is specified. Present results confirm significant improvement of tensile yield strength (TYS) and UTS after extrusion process as a consequence of fine-grained structure combined with precipitation strengthening. Beside, texture strengthening in the direction parallel to the extrusion has been observed too.

10. DETAIL OF CAST IRON COLUMN BASE ON FIRST FLOOR ...

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

10. DETAIL OF CAST IRON COLUMN BASE ON FIRST FLOOR STOREFRONT, SHOWING MANUFACTURER'S STAMP: IOWA IRON WOKS CO. DUBUQUE. VIEW TO SOUTHWEST. - Commercial & Industrial Buildings, Dubuque Seed Company Warehouse, 169-171 Iowa Street, Dubuque, Dubuque County, IA

Alternative granular media for the metal casting industry. Final report, September 30, 1994

DOE Office of Scientific and Technical Information (OSTI.GOV)

Guichelaar, P.J.; Ramrattan, S.N.; Tieder, R.E.

1995-09-01

Silica sand for foundry use is inexpensive to purchase, readily transported and widely available. As a result, it is universally used. However, three factors are becoming increasingly significant as more environmental regulations are promulgated. First, the disposal of waste foundry sand has become an excessively burdensome cost. Second, the phase changes which occur in the silica structure on heating and cooling cause thermal breakdown of the sand into smaller unusable fractions. Third, silica is a relatively weak mineral. Alternatives to silica sand which can withstand the rigors of repetitive reuse must be seriously evaluated as a way to control productionmore » costs of the domestic metal casting industry. Chromite sands, olivine sands and carbon sands have each been successfully used to solve operating problems and thus have developed their specific niches in the foundry materials inventory. However, there are several other materials that are candidates for replacing silica sand, such as fused alumina, sintered bauxite and sintered oil well proppants. These media, and others that are generically similar, are manufactured for specific purposes. Compositions and shapes could be readily tailored for used in a metal casting environment of total recycling and materials conservation. This study examines materials that are readily available as alternatives to silica sand from a functionality perspective and a cost perspective. Some of the alternative materials are natural and others are synthetic and thus referring to them as ``sands`` has the potential to cause confusion; the generic term ``granular medium`` is used in this study to mean any material that could functionally substitute for silica sand in the foundry process.« less

40 CFR Appendix D to Part 403 - Selected Industrial Subcategories Considered Dilute for Purposes of the Combined Wastestream Formula

Code of Federal Regulations, 2011 CFR

2011-07-01

... (40 CFR parts 413/433). Capacitors (Fluid Fill) Carbon and Graphite Products Dry Transformers Ferrite... Resistors Swithchgear Transformer (Fluid Fill) Metal Molding and Casting (40 CFR part 464) Nickel Casting...

40 CFR Appendix D to Part 403 - Selected Industrial Subcategories Considered Dilute for Purposes of the Combined Wastestream Formula

Code of Federal Regulations, 2014 CFR

2014-07-01

... (40 CFR parts 413/433). Capacitors (Fluid Fill) Carbon and Graphite Products Dry Transformers Ferrite... Resistors Swithchgear Transformer (Fluid Fill) Metal Molding and Casting (40 CFR part 464) Nickel Casting...

Benefit from NASA

NASA Image and Video Library

1998-01-01

Don Sirois, an Auburn University research associate, and Bruce Strom, a mechanical engineering Co-Op Student, are evaluating the dimensional characteristics of an aluminum automobile engine casting. More accurate metal casting processes may reduce the weight of some cast metal products used in automobiles, such as engines. Research in low gravity has taken an important first step toward making metal products used in homes, automobiles, and aircraft less expensive, safer, and more durable. Auburn University and industry are partnering with NASA to develop one of the first accurate computer model predictions of molten metals and molding materials used in a manufacturing process called casting. Ford Motor Company's casting plant in Cleveland, Ohio is using NASA-sponsored computer modeling information to improve the casting process of automobile and light-truck engine blocks.

Industrial Location Research Studies: Reports 17-25.

ERIC Educational Resources Information Center

Fantus Co., Inc., New York, NY.

Nine industrial-location research studies of the Appalachian region are presented in this document. These studies relate to the casting, plastic, metal, and food industries. Each study devotes sections to (1) a profile of the industry, (2) the industry's prospects for growth, (3) technology and trends, (4) primary factors influencing selection of…

Focused Molding Using Adhesive Pads in Mehta Casting for Early-Onset Scoliosis.

PubMed

Abraham, Roby; Sponseller, Paul D

2014-11-01

Prospective clinical series. To determine the effect of adhesive pads placed over the apex of scoliosis curves on curve correction 1) after the first cast and 2) after the final cast. Early-onset scoliosis is often effectively managed by serial casting. Properly localizing the apex of the molds with the cast in place is challenging. The authors explored the effectiveness of a novel technique: incorporation of adhesive pads placed over the major curve apex before Mehta casting. The 27 patients who received body casts (2000-2013) were divided into 2 groups: those without and with apical adhesive pads (5-6 layers of pads placed on the major curve's apex during casting): non-pad (NP) group (n = 12) and pad (P) group (n = 15), respectively. Groups were compared regarding the percentage of Cobb angle change from the first cast and curve correction to a Cobb angle of <25° with Student t and chi-square tests (significance was p < .05). The mean percentage of major first-cast curve correction was 39% ± 18% and 56% ± 17% in the NP and P groups, respectively. Of the 26 patients out of a cast, 11 (42%) had a Cobb angle of <25°: 3 (25%) and 8 (57%) in the NP and P groups, respectively. The mean differences between the 2 groups in percentage of major curve correction and this Cobb angle correction were significant: p = .023 and .005, respectively. Adhesive pads placed over major curve(s) during Mehta casting were effective in increasing the amount of major curve correction from the first cast for idiopathic early-onset scoliosis and in decreasing curves to <25° at final follow-up. Copyright © 2014 Scoliosis Research Society. Published by Elsevier Inc. All rights reserved.

Optimizing the use of the thermal integrity system for evaluating auger-cast piles : final report.

DOT National Transportation Integrated Search

2016-07-01

Auger-cast piles (sometimes called auger-cast-in-place, or ACIP, piles) are a subset of the larger : category of deep foundation elements known as bored piles. Although similar to drilled shafts at first : glance, ACIP piles differ in the constructio...

Precision Casting via Advanced Simulation and Manufacturing

NASA Technical Reports Server (NTRS)

1997-01-01

A two-year program was conducted to develop and commercially implement selected casting manufacturing technologies to enable significant reductions in the costs of castings, increase the complexity and dimensional accuracy of castings, and reduce the development times for delivery of high quality castings. The industry-led R&D project was cost shared with NASA's Aerospace Industry Technology Program (AITP). The Rocketdyne Division of Boeing North American, Inc. served as the team lead with participation from Lockheed Martin, Ford Motor Company, Howmet Corporation, PCC Airfoils, General Electric, UES, Inc., University of Alabama, Auburn University, Robinson, Inc., Aracor, and NASA-LeRC. The technical effort was organized into four distinct tasks. The accomplishments reported herein. Task 1.0 developed advanced simulation technology for core molding. Ford headed up this task. On this program, a specialized core machine was designed and built. Task 2.0 focused on intelligent process control for precision core molding. Howmet led this effort. The primary focus of these experimental efforts was to characterize the process parameters that have a strong impact on dimensional control issues of injection molded cores during their fabrication. Task 3.0 developed and applied rapid prototyping to produce near net shape castings. Rocketdyne was responsible for this task. CAD files were generated using reverse engineering, rapid prototype patterns were fabricated using SLS and SLA, and castings produced and evaluated. Task 4.0 was aimed at developing technology transfer. Rocketdyne coordinated this task. Casting related technology, explored and evaluated in the first three tasks of this program, was implemented into manufacturing processes.

Understanding the Biology and Technology of ToxCast and Tox21 Assays

EPA Science Inventory

The ToxCast high-throughput toxicity (HTT) testing methods have been developed to evaluate the hazard potential of diverse environmental, industrial and consumer product chemicals. The main goal is prioritizing the compounds of greatest concern for more detailed toxicological stu...

Three-dimensional microstructure simulation of Ni-based superalloy investment castings

NASA Astrophysics Data System (ADS)

Pan, Dong; Xu, Qingyan; Liu, Baicheng

2011-05-01

An integrated macro and micro multi-scale model for the three-dimensional microstructure simulation of Ni-based superalloy investment castings was developed, and applied to industrial castings to investigate grain evolution during solidification. A ray tracing method was used to deal with the complex heat radiation transfer. The microstructure evolution was simulated based on the Modified Cellular Automaton method, which was coupled with three-dimensional nested macro and micro grids. Experiments for Ni-based superalloy turbine wheel investment casting were carried out, which showed a good correspondence with the simulated results. It is indicated that the proposed model is able to predict the microstructure of the casting precisely, which provides a tool for the optimizing process.

Cast iron cutting with nano TiN and multilayer TiN-CrN coated inserts

NASA Astrophysics Data System (ADS)

Perucca, M.; Durante, S.; Semmler, U.; Rüger, C.; Fuentes, G. G.; Almandoz, E.

2012-09-01

During the past decade great success has been achieved in the development of duplex and multilayer multi-functional surface systems. Among these surface systems outstanding properties have nanoscale multilayer coatings. Within the framework of the M3-2S project funded in the 7th European Framework Programme, several nanoscale multilayer coatings have been developed and investigated for experimental and industrial validation. This paper shows the performance of TiN and TiN/CrN nanoscale multilayer coatings on WC cutting inserts when machining GJL250 cast iron. The thin films have been deposited by cathodic arc evaporation in an industrial PVD system. The multilayer deposition characteristic and its properties are shown. The inserts have been investigated in systematic cutting experiments of cast iron bars on a turning machine specifically equipped for force measurements, accompanied by wear determination. Furthermore, equivalent experiments have been carried out on an industrial turning unit. Industrial validation criteria have been applied to assess the comparative performance of the coatings. The choice of the material and the machined parts is driven by an interest in automotive applications. The industrial tests show the need to further optimise the multi-scale modelling approach in order to reduce the lead time of the coating development as well as to improve simulation reliability.

Freckle Defect Formation near the Casting Interfaces of Directionally Solidified Superalloys

PubMed Central

Hong, Jianping; Ma, Dexin; Wang, Jun; Wang, Fu; Sun, Baode; Dong, Anping; Li, Fei; Bührig-Polaczek, Andreas

2016-01-01

Freckle defects usually appear on the surface of castings and industrial ingots during the directional solidification process and most of them are located near the interface between the shell mold and superalloys. Ceramic cores create more interfaces in the directionally solidified (DS) and single crystal (SX) hollow turbine blades. In order to investigate the location of freckle occurrence in superalloys, superalloy CM247 LC was directionally solidified in an industrial-sized Bridgman furnace. Instead of ceramic cores, Alumina tubes were used inside of the casting specimens. It was found that freckles occur not only on the casting external surfaces, but also appear near the internal interfaces between the ceramic core and superalloys. Meanwhile, the size, initial position, and area of freckle were investigated in various diameters of the specimens. The initial position of the freckle chain reduces when the diameter of the rods increase. Freckle area follows a linear relationship in various diameters and the average freckle fraction is 1.1% of cross sectional area of casting specimens. The flow of liquid metal near the interfaces was stronger than that in the interdendritic region in the mushy zone, and explained why freckle tends to occur on the outer or inner surfaces of castings. This new phenomenon suggests that freckles are more likely to occur on the outer or inner surfaces of the hollow turbine blades. PMID:28774050

Freckle Defect Formation near the Casting Interfaces of Directionally Solidified Superalloys.

PubMed

Hong, Jianping; Ma, Dexin; Wang, Jun; Wang, Fu; Sun, Baode; Dong, Anping; Li, Fei; Bührig-Polaczek, Andreas

2016-11-16

Freckle defects usually appear on the surface of castings and industrial ingots during the directional solidification process and most of them are located near the interface between the shell mold and superalloys. Ceramic cores create more interfaces in the directionally solidified (DS) and single crystal (SX) hollow turbine blades. In order to investigate the location of freckle occurrence in superalloys, superalloy CM247 LC was directionally solidified in an industrial-sized Bridgman furnace. Instead of ceramic cores, Alumina tubes were used inside of the casting specimens. It was found that freckles occur not only on the casting external surfaces, but also appear near the internal interfaces between the ceramic core and superalloys. Meanwhile, the size, initial position, and area of freckle were investigated in various diameters of the specimens. The initial position of the freckle chain reduces when the diameter of the rods increase. Freckle area follows a linear relationship in various diameters and the average freckle fraction is 1.1% of cross sectional area of casting specimens. The flow of liquid metal near the interfaces was stronger than that in the interdendritic region in the mushy zone, and explained why freckle tends to occur on the outer or inner surfaces of castings. This new phenomenon suggests that freckles are more likely to occur on the outer or inner surfaces of the hollow turbine blades.

20180416 - Understanding the Biology and Technology of ToxCast and Tox21 Assays (SETAC Durham NC)

EPA Science Inventory

The ToxCast high-throughput toxicity (HTT) testing methods have been developed to evaluate the hazard potential of diverse environmental, industrial and consumer product chemicals. The main goal is prioritizing the compounds of greatest concern for more detailed toxicological stu...

Rapid Prototyping Technology for Manufacturing GTE Turbine Blades

NASA Astrophysics Data System (ADS)

Balyakin, A. V.; Dobryshkina, E. M.; Vdovin, R. A.; Alekseev, V. P.

2018-03-01

The conventional approach to manufacturing turbine blades by investment casting is expensive and time-consuming, as it takes a lot of time to make geometrically precise and complex wax patterns. Turbine blade manufacturing in pilot production can be sped up by accelerating the casting process while keeping the geometric precision of the final product. This paper compares the rapid prototyping method (casting the wax pattern composition into elastic silicone molds) to the conventional technology. Analysis of the size precision of blade casts shows that silicon-mold casting features sufficient geometric precision. Thus, this method for making wax patterns can be a cost-efficient solution for small-batch or pilot production of turbine blades for gas-turbine units (GTU) and gas-turbine engines (GTE). The paper demonstrates how additive technology and thermographic analysis can speed up the cooling of wax patterns in silicone molds. This is possible at an optimal temperature and solidification time, which make the process more cost-efficient while keeping the geometric quality of the final product.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nick Cannell; Dr. Mark Samonds; Adi Sholapurwalla

The investment casting process is an expendable mold process where wax patterns of the part and rigging are molded, assembled, shelled and melted to produce a ceramic mold matching the shape of the component to be cast. Investment casting is an important manufacturing method for critical parts because of the ability to maintain dimensional shape and tolerances. However, these tolerances can be easily exceeded if the molding components do not maintain their individual shapes well. In the investment casting process there are several opportunities for the final casting shape to not maintain the intended size and shape, such as shrinkagemore » of the wax in the injection tool, the modification of the shape during shell heating, and with the thermal shrink and distortion in the casting process. Studies have been completed to look at the casting and shell distortions through the process in earlier phases of this project. Dr. Adrian Sabau at Oak Ridge National Labs performed characterizations and validations of 17-4 PH stainless steel in primarily fused silica shell systems with good agreement between analysis results and experimental data. Further tasks provided material property measurements of wax and methodology for employing a viscoelastic definition of wax materials into software. The final set of tasks involved the implementation of the findings into the commercial casting analysis software ProCAST, owned and maintained by ESI Group. This included: o the transfer of the wax material property data from its raw form into separate temperature-dependent thermophysical and mechanical property datasets o adding this wax material property data into an easily viewable and modifiable user interface within the pre-processing application of the ProCAST suite, namely PreCAST o and validating the data and viscoelastic wax model with respect to experimental results« less

Solidification Based Grain Refinement in Steels

DTIC Science & Technology

2011-09-27

project (Tasks 7-9). An industrial trial on an investment casting was done using rare earth silicide additions in a furnace prior to pouring (Task 7...an investment casting was done using rare earth silicide additions in a furnace prior to pounng (la.sk 7). Some of the test parts had a finer...poured at the end of a six casting batch. One test tree with no RE addition was poured. Before the second test tree was poured, sufficient RE silicide was

Influence of casting conditions on durability and structural performance of HPC-AR : optimization of self-consolidating concrete to guarantee homogeneity during casting of long structural elements : final report.

DOT National Transportation Integrated Search

2017-05-01

This report is a summary of the research done on dynamic segregation of self-consolidating concrete (SCC) including the casting of pre-stressed beams at Coreslab Structures. SCC is a highly flowable concrete that spreads into place with little to no ...

Chantey Castings: A Hands-On Simulation to Teach Constraint Management and Demand-Driven Supply Chain Approaches

ERIC Educational Resources Information Center

Grandzol, Christian J.; Grandzol, John R.

2018-01-01

Supply chain design and constraint management are widely-adopted techniques in industry, necessitating that operations and supply chain educators teach these topics in ways that enhance student learning and retention, optimize resource utilization (especially time), and maximize student interest. The Chantey Castings Simulation provides a platform…

An investigation of the properties of Mg-Zn-Al alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Z.; Couture, A.; Luo, A.

1998-06-05

During the past ten years, the use of magnesium castings in the automotive and electronics industries has been expanding at an impressive rate. Die casting is one of the most effective fabrication methods and has been extensively used to produce magnesium components, especially in the automotive industry. However, the number of available Mg-based alloys for die casting is very limited. Therefore, it is pressing to develop some new Mg die casting alloys with good creep resistance, acceptable castability and low cost. Mg-Zn-Al (ZA) is a promising alloy system which is able to meet the requirements. But up to now, onlymore » a small amount of research has been carried out on this system. The aim of the present work is to examine and evaluate the microstructural features, tensile properties and creep resistance in order to get a better overall understanding of alloys of this system and to identify the most promising compositions. The influence of small additions of Ca and Sr on the tensile and creep properties of ZA alloys was also investigated.« less

Fabrication of Ti-0.48Al Alloy by Centrifugal Casting.

PubMed

Park, Jong Bum; Lee, Jung-Il; Ryu, Jeong Ho

2018-09-01

Many of the unique properties of TiAl alloys that make are attractive for use in high-temperature structural applications also make it challenging to process them into useful products. Cast TiAl is rapidly nearing commercialization, particularly in the vehicle industry, owing to its low production cost. In this study, the centrifugal casting of a TiAl (Ti-48%Al, mole fraction) turbocharger was simulated and an experimental casting was created in vacuum using an induction melting furnace coupled to a ceramic composite mold. Numerical simulation results agreed with the experiment. The crystal structure, microstructure, and chemical composition of the TiAl prepared by centrifugal casting were studied by X-ray diffractometry, optical microscopy, field emission scanning electron microscopy (FE-SEM) and energy dispersive spectroscopy (EDS). FE-SEM and EDS examinations of the TiAl casting revealed that the thickness of the oxide layer (α-case) was typically less than 35 μm.

Development of cast alumina-forming austenitic stainless steels

DOE PAGES

Muralidharan, G.; Yamamoto, Y.; Brady, M. P.; ...

2016-09-06

Cast Fe-Ni-Cr chromia-forming austenitic stainless steels with Ni levels up to 45 wt. % are used at high temperatures in a wide range of industrial applications that demand microstructural stability, corrosion resistance, and creep strength. Although alumina scales offer better corrosion protection at these temperatures, designing cast austenitic alloys that form a stable alumina scale and achieve creep strength comparable to existing cast chromia-forming alloys is challenging. This work outlines the development of cast Fe-Ni-Cr-Al austenitic stainless steels containing about 25 wt. % Ni with good creep strength and the ability to form a protective alumina scale for use atmore » temperatures up to 800 C - 850 C in H 2O-, S-, and C- containing environments. Creep properties of the best alloy were comparable to that of HK-type cast chromia-forming alloy along with improved oxidation resistance typical of alumina-forming alloys. Lastly, challenges in the design of cast alloys and a potential path to increasing the temperature capability are discussed.« less

Development of Cast Alumina-Forming Austenitic Stainless Steels

NASA Astrophysics Data System (ADS)

Muralidharan, G.; Yamamoto, Y.; Brady, M. P.; Walker, L. R.; Meyer, H. M., III; Leonard, D. N.

2016-11-01

Cast Fe-Ni-Cr chromia-forming austenitic stainless steels with Ni levels up to 45 wt.% are used at high temperatures in a wide range of industrial applications that demand microstructural stability, corrosion resistance, and creep strength. Although alumina scales offer better corrosion protection at these temperatures, designing cast austenitic alloys that form a stable alumina scale and achieve creep strength comparable to existing cast chromia-forming alloys is challenging. This work outlines the development of cast Fe-Ni-Cr-Al austenitic stainless steels containing about 25 wt.% Ni with good creep strength and the ability to form a protective alumina scale for use at temperatures up to 800-850°C in H2O-, S-, and C-containing environments. Creep properties of the best alloy were comparable to that of HK-type cast chromia-forming alloys along with improved oxidation resistance typical of alumina-forming alloys. Challenges in the design of cast alloys and a potential path to increasing the temperature capability are discussed.

Prospects for the domestic production of large-sized cast blades and vanes for industrial gas turbines

NASA Astrophysics Data System (ADS)

Kazanskiy, D. A.; Grin, E. A.; Klimov, A. N.; Berestevich, A. I.

2017-10-01

Russian experience in the production of large-sized cast blades and vanes for industrial gas turbines is analyzed for the past decades. It is noted that the production of small- and medium-sized blades and vanes made of Russian alloys using technologies for aviation, marine, and gas-pumping turbines cannot be scaled for industrial gas turbines. It is shown that, in order to provide manufacturability under large-scale casting from domestic nickel alloys, it is necessary to solve complex problems in changing their chemical composition, to develop new casting technologies and to optimize the heat treatment modes. An experience of PAO NPO Saturn in manufacturing the blades and vanes made of ChS88U-VI and IN738-LC foundry nickel alloys for the turbines of the GTE-110 gas turbine unit is considered in detail. Potentialities for achieving adopted target parameters for the mechanical properties of working blades cast from ChS88UM-VI modified alloy are established. For the blades made of IN738-LC alloy manufactured using the existing foundry technology, a complete compliance with the requirements of normative and technical documentation has been established. Currently, in Russia, the basis of the fleet of gas turbine plants is composed by foreign turbines, and, for the implementation of the import substitution program, one can use the positive experience of PAO NPO Saturn in casting blades from IN738-LC alloy based on a reverse engineering technique. A preliminary complex of studies of the original manufacturer's blades should be carried out, involving, first of all, the determination of geometric size using modern measurement methods as well as the studies on the chemical compositions of the used materials (base metal and protective coatings). Further, verifying the constructed calculation models based on the obtained data, one could choose available domestic materials that would meet the operating conditions of the blades according to their heat resistance and corrosion resistance.

Influence of mean stress on fatigue strength of ferritic-pearlite ductile cast iron with small defects

NASA Astrophysics Data System (ADS)

Deguchi, T.; Kim, H. J.; Ikeda, T.; Yanase, K.

2017-05-01

Because of their excellent mechanical properties, low cost and good workability, the application of ductile cast iron has been increased in various industries such as the automotive, construction and rail industries. For safety designing of the ductile cast iron component, it is necessary to understand the effect of stress ratio, R, on fatigue limit of ductile cast iron in the presence of small defects. Correspondingly in this study, rotating bending fatigue tests at R = -1 and tension-compression fatigue tests at R = -1 and 0.1 were performed by using a ferritic-pearlitic ductile cast iron. To study the effects of small defects, we introduced a small drilled hole at surface of a specimen. The diameter and depth of a drilled hole were 50, 200 and 500 μm, respectively. The non-propagating cracks emanating from graphite particles and holes edge were observed at fatigue limit, irrespective of the value of stress ratio. From the microscopic observation of crack propagation behavior, it can be concluded that the fatigue limit is determined by the threshold condition for propagation of a small crack. It was found that the effect of stress ratio on the fatigue limit of ductile cast iron with small defects can be successfully predicted based on \\sqrt {area} parameter model. Furthermore, a use of the tensile strength, σ B, instead of the Vickers hardness, HV, is effective for fatigue limit prediction.

Workplace injuries, safety climate and behaviors: application of an artificial neural network.

PubMed

Abubakar, A Mohammed; Karadal, Himmet; Bayighomog, Steven W; Merdan, Ethem

2018-05-09

This article proposes and tests a model for the interaction effect of the organizational safety climate and behaviors on workplace injuries. Using artificial neural network and survey data from 306 metal casting industry employees in central Anatolia, we found that an organizational safety climate mitigates workplace injuries, and safety behaviors enforce the strength of the negative impact of the safety climate on workplace injuries. The results suggest a complex relationship between the organizational safety climate, safety behavior and workplace injuries. Theoretical and practical implications are discussed in light of decreasing workplace injuries in the Anatolian metal casting industry.

A free gingival impression for achieving optimal interdental papilla height: a case report.

PubMed

Nozawa, Takeshi; Kitami, Norikazu; Tsurumaki, Shunzo; Enomoto, Hiroaki; Ito, Koichi

2011-02-01

Failure to tend to inadequate crown contours in the crown trial can cause long-term disharmony of the free gingival form. This case report describes a novel technique for free gingival impression from a final provisional restoration to a zirconia crown. Two die casts were manufactured from a silicone impression. The first die cast was for the zirconia crown; the second die cast was for the final provisional restoration and the provisionalized transfer coping. A free gingival impression was taken using a provisionalized transfer coping, and a soft gingival model was manufactured. The proximal contact position was managed using the predicted convex curve of the interdental papillae. One year after zirconia crown placement, no inflammation was observed around the pyramidal interdental papillae, and symmetric interdental papilla heights were evident. A free gingival impression using a two die-cast technique appears to be useful for achieving optimal interdental papilla height.

Crew Autonomous Scheduling Test (CAST)

NASA Image and Video Library

2017-07-18

iss052e016190 (July 18, 2017) --- Astronaut Peggy Whitson is photographed sitting in front of the Cupola windows during the final Crew Autonomous Scheduling Test (CAST) session. The CAST investigation analyzes whether crews can develop plans in a reasonable period of time with appropriate input, whether proximity of planners to the planned operations increases efficiency, and if crew members are more satisfied when given a role in plan development.

Microstructures and properties of aluminum die casting alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

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.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

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

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 designsmore » 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 provided to NADCA for distribution to the industry. Power law based meta-models for predicting machine tie bar loading and for predicting maximum parting surface separation were successfully developed and tested against simulation results for a wide range of machines and experimental data. The models proved to be remarkably accurate, certainly well within the requirements for practical application. In addition to making die structural modeling more accessible, the work advanced the state-of-the-art by developing improved modeling of cavity pressure effects, which is typically modeled as a hydrostatic boundary condition, and performing a systematic analysis of the influence of ejector die design variables on die deflection and parting plane separation. This cavity pressure modeling objective met with less than complete success due to the limits of current finite element based fluid structure interaction analysis methods, but an improved representation of the casting/die interface was accomplished using a combination of solid and shell elements in the finite element model. This approximation enabled good prediction of final part distortion verified with a comprehensive evaluation of the dimensions of test castings produced with a design experiment. An extra deliverable of the experimental work was development of high temperature mechanical properties for the A380 die casting alloy. The ejector side design objective was met and the results were incorporated into the metamodels described above. This new technology was predicted to result in an average energy savings of 2.03 trillion BTU's/year over a 10 year period. Current (2011) annual energy saving estimates over a ten year period, based on commercial introduction in 2009, a market penetration of 70% by 2014 is 4.26 trillion BTU's/year by 2019. Along with these energy savings, reduction of scrap and improvement in casting yield will result in a reduction of the environmental emissions associated with the melting and pouring of the metal which will be saved as a result of this technology. The average annual estimate of CO2 reduction per year through 2020 is 0.085 Million Metric Tons of Carbon Equivalent (MM TCE).« less

Rough case-based reasoning system for continues casting

NASA Astrophysics Data System (ADS)

Su, Wenbin; Lei, Zhufeng

2018-04-01

The continuous casting occupies a pivotal position in the iron and steel industry. The rough set theory and the CBR (case based reasoning, CBR) were combined in the research and implementation for the quality assurance of continuous casting billet to improve the efficiency and accuracy in determining the processing parameters. According to the continuous casting case, the object-oriented method was applied to express the continuous casting cases. The weights of the attributes were calculated by the algorithm which was based on the rough set theory and the retrieval mechanism for the continuous casting cases was designed. Some cases were adopted to test the retrieval mechanism, by analyzing the results, the law of the influence of the retrieval attributes on determining the processing parameters was revealed. A comprehensive evaluation model was established by using the attribute recognition theory. According to the features of the defects, different methods were adopted to describe the quality condition of the continuous casting billet. By using the system, the knowledge was not only inherited but also applied to adjust the processing parameters through the case based reasoning method as to assure the quality of the continuous casting and improve the intelligent level of the continuous casting.

Breaking into the Business: Experiences of Actors with Disabilities in the Entertainment Industry

ERIC Educational Resources Information Center

Raynor, Olivia; Hayward, Katharine

2009-01-01

The pursuit of an acting career is a difficult one for anybody. However, studies have yet to factor how disability affects casting opportunities. This study describes the employment of actors with disabilities, along with the unique barriers they encounter in the audition and casting process. Actors with disabilities from the Screen Actors Guild…

Crosscutting Technology Development at the Center for Advanced Separation Technologies

DOE Office of Scientific and Technical Information (OSTI.GOV)

Christopher Hull

2009-10-31

The U.S. is the largest producer of mining products in the world. In 2003, U.S. mining operations produced $57 billion worth of raw materials that contributed a total of $564 billion to the nation's wealth. Despite these contributions, the mining industry has not been well supported with research and development funds as compared to mining industries in other countries. To overcome this problem, the Center for Advanced Separation Technologies (CAST) was established to develop technologies that can be used by the U.S. mining industry to create new products, reduce production costs, and meet environmental regulations. Originally set up by Virginiamore » Tech and West Virginia University, this endeavor has been expanded into a seven-university consortium -- Virginia Tech, West Virginia University, University of Kentucky, University of Utah, Montana Tech, New Mexico Tech and University of Nevada, Reno - that is supported through U.S. DOE Cooperative Agreement No. DE-FC26-02NT41607: Crosscutting Technology Development at the Center for Advanced Separation Technologies. Much of the research to be conducted with Cooperative Agreement funds will be longer-term, high-risk, basic research and will be carried out in five broad areas: (1) Solid-solid separation; (2) Solid-liquid separation; (3) Chemical/biological extraction; (4) Modeling and control; and (5) Environmental control. Distribution of funds is handled via competitive solicitation of research proposals through Site Coordinators at the seven member universities. These were first reviewed and ranked by a group of technical reviewers (selected primarily from industry). Based on these reviews, and an assessment of overall program requirements, the CAST Technical Committee made an initial selection/ranking of proposals and forwarded these to the DOE/NETL Project Officer for final review and approval. The successful projects are listed by category, along with brief abstracts of their aims and objectives.« less

Wide Strip Casting Technology of Magnesium Alloys

NASA Astrophysics Data System (ADS)

Park, W.-J.; Kim, J. J.; Kim, I. J.; Choo, D.

Extensive investigations relating to the production of high performance and low cost magnesium sheet by strip casting have been performed for the application to automotive parts and electronic devices. Research on magnesium sheet production technology started in 2004 by Research Institute of Industrial Science and Technology (RIST) with support of Pohang Iron and Steel Company (POSCO). POSCO has completed the world's first plant to manufacture magnesium coil. Another big project in order to develop wide strip casting technology for the automotive applications of magnesium sheets was started in succession.

A computational study of low-head direct chill slab casting of aluminum alloy AA2024

NASA Astrophysics Data System (ADS)

Hasan, Mainul; Begum, Latifa

2016-04-01

The steady state casting of an industrial-sized AA2024 slab has been modeled for a vertical low-head direct chill caster. The previously verified 3-D CFD code is used to investigate the solidification phenomena of the said long-range alloy by varying the pouring temperature, casting speed and the metal-mold contact heat transfer coefficient from 654 to 702 °C, 60-180 mm/min, and 1.0-4.0 kW/(m2 K), respectively. The important predicted results are presented and thoroughly discussed.

Effects of silicon, copper and iron on static and dynamic properties of alloy 206 (aluminum-copper) in semi-solids produced by the SEED process

NASA Astrophysics Data System (ADS)

Lemieux, Alain

The advantages of producing metal parts by rheocasting are generally recognised for common foundry alloys of Al-Si. However, other more performing alloys in terms of mechanical properties could have a great interest in specialized applications in the automotive industry, while remaining competitive in the forming. Indeed, the growing demand for more competitive products requires the development of new alloys better suited to semi-solid processes. Among others, Al-Cu alloys of the 2XX series are known for their superior mechanical strength. However, in the past, 2XX alloys were never candidates for pressure die casting. The main reason is their propensity to hot tearing. Semi-solid processes provide better conditions for molding with the rheological behavior of dough and molding temperatures lower reducing this type of defect. In the initial phase, this research has studied factors that reduce hot tearing susceptibility of castings produced by semi-solid SEED of alloy 206. Subsequently, a comparative study on the tensile properties and fatigue was performed on four variants of the alloy 206. The results of tensile strength and fatigue were compared with the specifications for applications in the automotive industry and also to other competing processes and alloys. During this study, several metallurgical aspects were analyzed. The following main points have been validated: i) the main effects of compositional variations of silicon, iron and copper alloy Al-Cu (206) on the mechanical properties, and ii) certain relationships between the mechanism of hot cracking and the solidification rate in semi-solid. Parts produced from the semi-solid paste coming from the SEED process combined with modified 206 alloys have been successfully molded and achieved superior mechanical properties than the requirements of the automotive industry. The fatigue properties of the two best modified 206 alloys were higher than those of A357 alloy castings and are close to those of the wrought alloy AA6061. At present, there is simply no known application for pressure die-cast alloy with 206 (Liquid Die-casting). This is mainly due to the high propensity to hot cracking and limitations facing the part geometry and the subsequent assembly. This study demonstrated that in addition to pieces produced by semi-solid die-casting using large variations in chemical composition, the SEED process allows obtaining spare sound (sound part) and more complex geometry. Moreover, as the semi-solid parts have less porosity, they can also be machined and welded for some applications. The conclusions of this study demonstrate significant progress in identifying the main issues related to the feasibility of die-casting good parts with high performance using the modified 206 alloy combined with SEED process. This work is therefore a baseline work in the development of new Al-Cu alloys for industries of semi-solid and, at the same time, for the expansion of aluminum for high performance applications in the industry. N.B. This thesis is part of a research project developed by the NSERC / Rio Tinto Akan Industrial Research Chair in Metallurgy of Innovative Aluminum Transformation (CIMTAL).

Quengel Casting for the Management of Pediatric Knee Flexion Contractures: A 26-Year Single Institution Experience.

PubMed

Wiley, Marcel R; Riccio, Anthony I; Felton, Kevin; Rodgers, Jennifer A; Wimberly, Robert L; Johnston, Charles E

Quengel casting was introduced in 1922 for nonsurgical treatment of knee flexion contractures (KFC) associated with hemophilic arthropathy. It consists of an extension-desubluxation hinge fixed to a cast allowing for gradual correction of a flexion deformity while preventing posterior tibial subluxation. The purpose of this study is to report 1 center's experience with this technique for the treatment of pediatric KFC. A retrospective review was conducted over a 26-year period. All patients with KFC treated with Quengel casting were included. Demographic data, associated medical conditions, adjunctive soft tissue releases, complications, and the need for late surgical intervention were recorded. Tibiofemoral angle measurements in maximal extension were recorded at initiation and termination of casting, 1-year follow-up, and final follow-up. Success was defined as no symptomatic recurrence of KFC or need for subsequent surgery. Eighteen patients (26 knees) were treated for KFC with Quengel casting. Average age at initiation of casting was 8.1 years with average follow-up of 59.9 months. Fifteen knees (58%) underwent soft tissue releases before casting. An average of 1.5 casts per knee were applied over an average of 23.9 days. Average KFC before casting was 50.6 degrees (range, 15 to 100 degrees) which improved to 5.96 degrees (0 to 40 degrees) at cast removal (P<0.00001). Sixteen patients (22 knees) had 1-year follow-up or failed casting before 1 year. Of these, 11 knees (50%) had a successful outcome. Residual KFC of those treated successfully was 6.8 degrees (range, 0 to 30 degrees) at 1 year and 8.2 degrees (range, 0 to 30 degrees) at final follow-up, averaging 71.4 months (P=0.81). Of the 11 knees deemed failures, all had recurrence of deformity within an average of 1 year from cast removal. Surgical release before Quengel casting did not improve the chances for success (P=0.09). Quengel casting can improve pediatric KFC an average of 44.2 degrees with minimal complications. Although 50% of treated patients will demonstrate significant recurrence or need later surgery, the majority of those treated successfully have durable results at intermediate term follow-up. Level IV-therapeutic study.

Software Analytical Instrument for Assessment of the Process of Casting Slabs

NASA Astrophysics Data System (ADS)

Franěk, Zdeněk; Kavička, František; Štětina, Josef; Masarik, Miloš

2010-06-01

The paper describes the original proposal of ways of solution and function of the program equipment for assessment of the process of casting slabs. The program system LITIOS was developed and implemented in EVRAZ Vitkovice Steel Ostrava on the equipment of continuous casting of steel (further only ECC). This program system works on the data warehouse of technological parameters of casting and quality parameters of slabs. It enables an ECC technologist to analyze the course of casting melt and with using statistics methods to set the influence of single technological parameters on the duality of final slabs. The system also enables long term monitoring and optimization of the production.

75 FR 22114 - Aluminum Extrusions from the People's Republic of China: Initiation of Countervailing Duty...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-04-27

... sampling method. Section 771(4)(A) of the Act defines the ``industry'' as the producers as a whole of a... the PRC. At this time, given the unique nature of the alleged subsidy and the complex methodological... process, such as aluminum products produced by a method of casting. Cast aluminum products are properly...

75 FR 22554 - Notice of Petitions by Firms for Determination of Eligibility To Apply for Trade Adjustment...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-04-29

... Drills, Cotton Box 1438, Dodge City, KS Harvesting, Seed 67801. Handling, Grain Carts and Industrial... 76106. cast aluminum for heavy industry pressure leaf filters. NCAD Products, Inc P.O. Box 622188...

50 CFR 600.1010 - Referenda.

Code of Federal Regulations, 2011 CFR

2011-10-01

... Wildlife and Fisheries FISHERY CONSERVATION AND MANAGEMENT, NATIONAL OCEANIC AND ATMOSPHERIC ADMINISTRATION... in the fishery who participate in the fishery cast ballots in favor of an industry fee system. (b... authorize an industry fee system despite any such difference between the reduction amendment specifications...

Effect of mold designs on molten metal behaviour in high-pressure die casting

NASA Astrophysics Data System (ADS)

Ibrahim, M. D.; Rahman, M. R. A.; Khan, A. A.; Mohamad, M. R.; Suffian, M. S. Z. M.; Yunos, Y. S.; Wong, L. K.; Mohtar, M. Z.

2017-04-01

This paper presents a research study conducted in a local automotive component manufacturer that produces aluminium alloy steering housing local and global markets. This study is to investigate the effect of design modification of mold in die casting as to improve the production rate. Design modification is carried out on the casting shot of the mold. Computer flow simulation was carried out to study the flow of molten metal in the mold with respect to the mold design modification. The design parameters of injection speed, die temperature and clamping force has been included in the study. The result of the simulation showed that modifications of casting shot give significant impact towards the molten flow behaviour in casting process. The capabilities and limitations of die casting process simulation to conduct defect analysis had been optimized. This research will enhance the efficiency of the mass production of the industry of die casting with the understanding of defect analysis, which lies on the modification of the mold design, a way early in its stages of production.

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.

Determining the Mechanical Properties of Lattice Block Structures

NASA Technical Reports Server (NTRS)

Wilmoth, Nathan

2013-01-01

Lattice block structures and shape memory alloys possess several traits ideal for solving intriguing new engineering problems in industries such as aerospace, military, and transportation. Recent testing at the NASA Glenn Research Center has investigated the material properties of lattice block structures cast from a conventional aerospace titanium alloy as well as lattice block structures cast from nickel-titanium shape memory alloy. The lattice block structures for both materials were sectioned into smaller subelements for tension and compression testing. The results from the cast conventional titanium material showed that the expected mechanical properties were maintained. The shape memory alloy material was found to be extremely brittle from the casting process and only compression testing was completed. Future shape memory alloy lattice block structures will utilize an adjusted material composition that will provide a better quality casting. The testing effort resulted in baseline mechanical property data from the conventional titanium material for comparison to shape memory alloy materials once suitable castings are available.

Development of High-Performance Cast Crankshafts. Final Technical Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bauer, Mark E

The objective of this project was to develop technologies that would enable the production of cast crankshafts that can replace high performance forged steel crankshafts. To achieve this, the Ultimate Tensile Strength (UTS) of the new material needs to be 850 MPa with a desired minimum Yield Strength (YS; 0.2% offset) of 615 MPa and at least 10% elongation. Perhaps more challenging, the cast material needs to be able to achieve sufficient local fatigue properties to satisfy the durability requirements in today’s high performance gasoline and diesel engine applications. The project team focused on the development of cast steel alloysmore » for application in crankshafts to take advantage of the higher stiffness over other potential material choices. The material and process developed should be able to produce high-performance crankshafts at no more than 110% of the cost of current production cast units, perhaps the most difficult objective to achieve. To minimize costs, the primary alloy design strategy was to design compositions that can achieve the required properties with minimal alloying and post-casting heat treatments. An Integrated Computational Materials Engineering (ICME) based approach was utilized, rather than relying only on traditional trial-and-error methods, which has been proven to accelerate alloy development time. Prototype melt chemistries designed using ICME were cast as test specimens and characterized iteratively to develop an alloy design within a stage-gate process. Standard characterization and material testing was done to validate the alloy performance against design targets and provide feedback to material design and manufacturing process models. Finally, the project called for Caterpillar and General Motors (GM) to develop optimized crankshaft designs using the final material and manufacturing processing path developed. A multi-disciplinary effort was to integrate finite element analyses by engine designers and geometry-specific casting simulations with existing materials models to optimize crankshaft cost and performance. Prototype crankshafts of the final design were to be produced and validated using laboratory bench testing and on-engine durability testing. ICME process simulation tools were used to investigate a broad range of processing concepts. These concepts included casting orientation, various mold and core materials, and various filling and feeding strategies. Each crankshaft was first simulated without gating and risers, which is termed natural solidification. The natural solidification results were used as a baseline for strategy development of each concept. Casting process simulations and ICME tools were proven to be reasonable predictors of real world results. Potential alloys were developed that could meet the project material property goals with appropriate normalization and temper treatments. For the alloys considered, post-normalization temper treatments proved to be necessary to achieve the desired yield strengths and elongations and appropriate heat treatments were designed using ICME tools. The experimental data of all the alloys were analyzed in combination with ICME tools to establish chemistry-process-structure relations. Several GM small gas engine (SGE) crankshafts were successfully cast in sand molds using two different sprue, runner, gate, riser, chill designs. These crankshafts were cast in two different steel alloys developed during the project, but casting finishing (e.g. riser removal) remains a cost challenge. A long list of future work was left unfinished when this project was unexpectedly terminated.« less

Solidification structures grown under induced flow and continuous casting of steel

NASA Technical Reports Server (NTRS)

Tsavaras, A. A.

1984-01-01

The use of induced flow as a means to control solidification structures in strand cast steel is investigated. The quality problems in strand cast steel stemming from columnar growth can be partially controlled, by Electro Magnetic Stirring (EMS). Induced flow changes the normal morphology of dendrites. Solids grown under intense stirring conditions show both negative and positive segregation which is considered unacceptable by some steel producers. The inclusion size and population is strongly affected by induced flow (EMS). Laboratory and industrial data show substantial reduction in inclusion size and content, but the overall effect of flow on inclusions is affected by the particular type of flow patterns utilized in each case. Productivity and quality are raised substantially in steel strand casting by utilizing EMS.

Cast Ductile Iron 155mm M804 Bodies

DTIC Science & Technology

1990-07-12

for the final delivery. The balance of the parts were returned to Wagner Castings for analysis, scrap, or de-militarization. The radiographic...as possible to avoid pre-cure. Mixing/ mulling time should be consistent with the system " worklife " or poor composite properties will result. Tensile...Burn-in on castings is caused by poor sand density, poor mixing, out of balance mix or improper drying of the wash. Long set times are an indication

Energy Saving Melting and Revert Reduction Technology (Energy SMARRT): Development of CCT Diagrams

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chumbley, L Scott

2011-08-20

One of the most energy intensive industries in the U.S. today is in the melting and casting of steel alloys for use in our advanced technological society. While the majority of steel castings involve low or mild carbon steel for common construction materials, highly-alloyed steels constitute a critical component of many industries due to their excellent properties. However, as the amount of alloying additions increases, the problems associated with casting these materials also increases, resulting in a large waste of energy due to inefficiency and a lack of basic information concerning these often complicated alloy systems. Superaustenitic stainless steels constitutemore » a group of Fe-based alloys that are compositionally balanced to have a purely austenitic matrix and exhibit favorable pitting and crevice corrosion resistant properties and mechanical strength. However, intermetallic precipitates such as sigma (³) and Laves can form during casting or exposure to high-temperature processing, which degrade the corrosion and mechanical properties of the material. Knowledge of the times and temperatures at which these detrimental phases form is imperative if a company is to efficiently produce castings of high quality in the minimum amount of time, using the lowest amount of energy possible, while producing the least amount of material waste. Anecdotal evidence from company representatives revealed that large castings frequently had to be scrapped due to either lower than expected corrosion resistance or extremely low fracture toughness. It was suspected that these poor corrosion and / or mechanical properties were directly related to the type, amount, and location of various intermetallic phases that formed during either the cooling cycle of the castings or subsequent heat treatments. However, no reliable data existed concerning either the time-temperature-transformation (TTT) diagrams or the continuous-cooling-transformation (CCT) diagrams of the super-austenitics. The goal of this study was to accurately characterize the solid-solid phase transformations seen in cast superaustenitic stainless steels. Heat treatments were performed to understand the time and temperature ranges for intermetallic phase formations in alloys CN3MN and CK3McuN. Microstructures were characterized using scanning electron microscopy (SEM), transmission electron microscopy (TEM), and energy and wavelength dispersive spectroscopy (EDS, WDS). In this way TTT and CCT diagrams could be developed for the matrix of samples chosen. As this study consisted of basic research into the development of TTT and CCT diagrams as an aid to the US steel casting industry, there is no formal commercialization plan associated with this task other than presentations and publications via the Steel Founders Society of America to their members. The author is confident that the data contained in this report can be used by steel foundries to refine their casting procedures in such a way as to reduce the amount of waste produced and energy wasted by significantly reducing or eliminating the need for remelting or recasting of material due to unwanted, premature intermetallic formation. This development of high alloy steel CCT diagrams was predicted to result in an average energy savings of 0.05 trillion BTU's/year over a 10 year period (with full funding). With 65% of the proposed funding, current (2011) annual energy saving estimates, based on initial dissemination to the casting industry in 2011and market penetration of 97% by 2020, is 0.14 trillion BTU's/year. The reduction of scrap and improvement in casting yield will also result in a reduction of environmental emissions associated with the melting and pouring of the steel. The average annual estimate of CO2 reduction per year through 2020 is 0.003 Million Metric Tons of Carbon Equivalent (MM TCE)« less

Precision technique for trimming dies using a magnification device.

PubMed

Beck, D B

1980-05-01

This article described a technique for trimming a die under magnification. However, the microscope is also useful for checking (1) margins of wax patterns for completeness, (2) the internal surfaces of castings for imperfections, bubbles, or retained investment particles which could prevent proper seating of the castings on the dies, (3) for cracks or contamination in dental porcelain as well as porcelain flash on margins; and (4) precision attachment operation after casting or soldering procedures. Attention to detail in these laboratory procedures greatly improves the final fit of dental castings and saves subsequent chairside adjustments and remakes.

Upgrade Recycling of Cast Iron Scrap Chips towards β-FeSi₂ Thermoelectric Materials.

PubMed

Laila, Assayidatul; Nanko, Makoto; Takeda, Masatoshi

2014-09-04

The upgrade recycling of cast-iron scrap chips towards β-FeSi₂ thermoelectric materials is proposed as an eco-friendly and cost-effective production process. By using scrap waste from the machining process of cast-iron components, the material cost to fabricate β-FeSi₂ is reduced and the industrial waste is recycled. In this study, β-FeSi₂ specimens obtained from cast iron scrap chips were prepared both in the undoped form and doped with Al and Co elements. The maximum figure of merit ( ZT ) indicated a thermoelectric performance of approximately 70% in p-type samples and nearly 90% in n-type samples compared to β-FeSi₂ prepared from pure Fe and other published studies. The use of cast iron scrap chips to produce β-FeSi₂ shows promise as an eco-friendly and cost-effective production process for thermoelectric materials.

Optimization to Develop Multiple Response Microstructure and Hardness of Ductile Iron Casting by using GRA

NASA Astrophysics Data System (ADS)

Kabnure, Bahubali Bhupal; Shinde, Vasudev Dhondiram; Kolhapure, Rakesh Ramchandra

2018-05-01

Ductile irons are important engineering materials because of its high strength to weight ratio and castability. The ductile iron castings are used widely for automobile applications due to their wide spectrum of property range. Weight reduction is important in automobile to improve its fuel efficiency which can be achieved by thinning down the casting sections without altering its functionality. Generally, automobile castings are having varying section thickness. Varying thickness castings offers different cooling rates while solidification of the casting. The solidification cooling rate decides the final microstructure of the cast components. Cooling rate was found to affect directly the amount of pearlite and ultimately the as cast properties in varying thickness ductile iron castings. In view of this, the automobile impeller casting is selected for study in the present work as it consists of varying section thickness in which small sections are connected to central hub. The casting solidification simulations were performed and analyzed. The solidification cooling rates were analyzed further to correlate the experimental processing parameters. The samples from poured castings were analyzed for microstructure and hardness at different section thickness. Multiple response optimization of microstructure and hardness was carried out by combined Taguchi and Grey Relational Analysis (GRA). Contribution of input variables on the output variables is attained using ANOVA.

Application of Rapid Prototyping to the Investment Casting of Test Hardware (MSFC Center Director's Discretionary Fund Final Report, Project No. 98-08)

NASA Technical Reports Server (NTRS)

Cooper, K. G.; Wells, D.

2000-01-01

Investment casting masters of a selected propulsion hardware component, a fuel pump housing, were rapid prototyped on the several processes in-house, along with the new Z-Corp process acquired through this project. Also, tensile samples were prototyped and cast using the same significant parameters. The models were then shelled in-house using a commercial grade zircon-based slurry and stucco technique. Next, the shelled models were fired and cast by our in-house foundry contractor (IITRI), with NASA-23, a commonly used test hardware metal. The cast models are compared by their surface finish and overall appearance (i.e., the occurrence of pitting, warping, etc.), as well as dimensional accuracy.

HFIR Fuel Casting Support

DOE Office of Scientific and Technical Information (OSTI.GOV)

Imhoff, Seth D.; Gibbs, Paul Jacob; Solis, Eunice Martinez

Process exploration for fuel production for the High Flux Isotope Reactor (HFIR) using cast LEU-10wt.%Mo as an initial processing step has just begun. This project represents the first trials concerned with casting design and quality. The studies carried out over the course of this year and information contained in this report address the initial mold development to be used as a starting point for future operations. In broad terms, the final billet design is that of a solid rolling blank with an irregular octagonal cross section. The work covered here is a comprehensive view of the initial attempts to producemore » a sound casting. This report covers the efforts to simulate, predict, cast, inspect, and revise the initial mold design.« less

Blended polymer materials extractable with supercritical carbon dioxide

NASA Astrophysics Data System (ADS)

Cai, Mei

Supercritical carbon dioxide is drawing more and more attention because of its unique solvent properties along with being environmentally friendly. Historically most of the commercial interests of supercritical carbon dioxide extraction are in the food industry, pharmaceutical industry, environmental preservation and polymer processing. Recently attention has shifted from the extraction of relatively simple molecules to more complex systems with a much broader range of physical and chemical transformations. However the available data show that a lot of commercially valuable substances are not soluble in supercritical carbon dioxide due to their polar structures. This fact really limits the application of SCF extraction technology to much broader industrial applications. Therefore, the study of a polymer's solubility in a given supercritical fluid and its thermodynamic behavior becomes one of the most important research topics. The major objective of this dissertation is to develop a convenient and economic way to enhance the polymer's solubility in supercritical carbon dioxide. Further objective is to innovate a new process of making metal casting parts with blended polymer materials developed in this study. The key technique developed in this study to change a polymer's solubility in SCF CO2 is to thermally blend a commercially available and CO2 non-soluble polymer material with a low molecular weight CO2 soluble organic chemical that acts as a co-solute. The mixture yields a plastic material that can be completely solubilized in SCF CO2 over a range of temperatures and pressures. It also exhibits a variety of physical properties (strength, hardness, viscosity, etc.) depending on variations in the mixture ratio. The three organic chemicals investigated as CO2 soluble materials are diphenyl carbonate, naphthalene, and benzophenone. Two commercial polymers, polyethylene glycol and polystyrene, have been investigated as CO2 non-soluble materials. The chemical, physical, thermal, and phase behavior of the blended polymers studied in this dissertation includes solubility in SCF CO2, the melt viscosity, the melting temperature depression, and phase equilibrium under SCF conditions. Several hypotheses are investigated to determine which mechanism plays the major role in the extraction. Finally a novel metal casting process is discussed with the materials developed in this study. This new method utilizes an adhesive or binder film composition for the purpose of building up a casting pattern of resin-bonded aggregate particles. The pattern is then encased in a conventional rigid shell mold that is not susceptible to degradation by SCF CO2. The pattern is then disintegrated within an unaffected mold by exposure to SCF CO 2. This is an efficient and low cost method of making patterns and molds, especially for the casting of a relatively low number of parts such as in prototype evaluations.

Results of clubfoot treatment after manipulation and casting using the Ponseti method: experience in Harare, Zimbabwe.

PubMed

Smythe, Tracey; Chandramohan, Daniel; Bruce, Jane; Kuper, Hannah; Lavy, Christopher; Foster, Allen

2016-10-01

The objective of this study was to evaluate the outcomes of the Ponseti manipulation and casting method for clubfoot in a tertiary hospital in Zimbabwe and explore predictors of these outcomes. A cohort study included children with idiopathic clubfoot managed from 2011 to 2013 at Parirenyatwa Hospital. Demographic data, clinical features and treatment outcomes were extracted from clinic records. The primary outcome measure was the final Pirani score (clubfoot severity measure) after manipulation and casting. Secondary outcomes included change in Pirani score (pre-treatment to end of casting), number of casts for correction, proportion receiving tenotomy and proportion lost to follow up. A total of 218 children (337 feet) were eligible for inclusion. The median age at treatment was 8 months; 173 children (268 feet) completed casting treatment within the study period. The mean length of time for corrective treatment was 10.2 weeks (9.5-10.9 weeks). Of the 45 children who did not complete treatment, 28 were under treatment and 17 were lost to follow up. A Pirani score of 1 or less was achieved in 85% of feet. Mean Pirani score at presentation was 3.80 (SD 1.15) and post-treatment 0.80 (SD 0.56, P-value <0.0001). Severity of deformity and being male were associated with a higher (worse) final Pirani score. Severity and age over two were associated with an increase in the number of casts required to correct deformity. This case series demonstrates that the majority (80%+) of children with clubfoot can achieve a good outcome with the Ponseti manipulation and casting method. © 2016 John Wiley & Sons Ltd.

Optimizing the use of the thermal integrity system for evaluating auger-cast piles [summary].

DOT National Transportation Integrated Search

2016-07-01

Auger-cast-in-place (ACIP) piles offer an efficient method of constructing and installing piles, : but because the ACIP process is essentially blind and the configuration of the final pile cannot be : assured, applications for ACIP piles have been li...

Non-rigid Reconstruction of Casting Process with Temperature Feature

NASA Astrophysics Data System (ADS)

Lin, Jinhua; Wang, Yanjie; Li, Xin; Wang, Ying; Wang, Lu

2017-09-01

Off-line reconstruction of rigid scene has made a great progress in the past decade. However, the on-line reconstruction of non-rigid scene is still a very challenging task. The casting process is a non-rigid reconstruction problem, it is a high-dynamic molding process lacking of geometric features. In order to reconstruct the casting process robustly, an on-line fusion strategy is proposed for dynamic reconstruction of casting process. Firstly, the geometric and flowing feature of casting are parameterized in manner of TSDF (truncated signed distance field) which is a volumetric block, parameterized casting guarantees real-time tracking and optimal deformation of casting process. Secondly, data structure of the volume grid is extended to have temperature value, the temperature interpolation function is build to generate the temperature of each voxel. This data structure allows for dynamic tracking of temperature of casting during deformation stages. Then, the sparse RGB features is extracted from casting scene to search correspondence between geometric representation and depth constraint. The extracted color data guarantees robust tracking of flowing motion of casting. Finally, the optimal deformation of the target space is transformed into a nonlinear regular variational optimization problem. This optimization step achieves smooth and optimal deformation of casting process. The experimental results show that the proposed method can reconstruct the casting process robustly and reduce drift in the process of non-rigid reconstruction of casting.

Mississippi State University Center for Air Sea Technology FY95 Research Program

NASA Technical Reports Server (NTRS)

Yeske, Lanny; Corbin, James H.

1995-01-01

The Mississippi State University (MSU) Center for Air Sea Technology (CAST) evolved from the Institute for Naval Oceanography's (INO) Experimental Center for Mesoscale Ocean Prediction (ECMOP) which was started in 1989. MSU CAST subsequently began operation on 1 October 1992 under an Office of Naval Research (ONR) two-year grant which ended on 30 September 1994. In FY95 MSU CAST was successful in obtaining five additional research grants from ONR, as well as several other research contracts from the Naval Oceanographic Office via NASA, the Naval Research Laboratory, the Army Corps of Engineers, and private industry. In the past, MSU CAST technical research and development has produced tools, systems, techniques, and procedures that improve efficiency and overcome deficiency for both the operational and research communities residing with the Department of Defense, private industry, and university ocean modeling community. We continued this effort with the following thrust areas: to develop advanced methodologies and tools for model evaluation, validation and visualization, both oceanographic and atmospheric; to develop a system-level capability for conducting temporally and ; spatially scaled ocean simulations driven by or are responsive to ocean models, and take into consideration coupling to atmospheric models; to continue the existing oceanographic/atmospheric data management task with emphasis on distributed databases in a network environment, with database optimization and standardization, including use of Mosaic and World Wide Web (WWW) access; and to implement a high performance parallel computing technology for CAST ocean models

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

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 themore » 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).« less

Microgravity

NASA Image and Video Library

1997-06-27

This is a computer generated model of a ground based casting. The objective of the therophysical properties program is to measure thermal physical properties of commercial casting alloys for use in computer programs that predict soldification behavior. This could reduce trial and error in casting design and promote less scrap, sounder castings, and less weight. In order for the computer models to reliably simulate the details of industrial alloy solidification, the input thermophysical property data must be absolutely reliable. Recently Auburn University and TPRL Inc. formed a teaming relationship to establish reliable measurement techniques for the most critical properties of commercially important alloys: transformation temperatures, thermal conductivity, electrical conductivity, specific heat, latent heat, density, solid fraction evolution, surface tension, and viscosity. A new initiative with the American Foundrymens Society has been started to measure the thermophysical properties of commercial ferrous and non-ferrous casting alloys and make the thermophysical property data widely available. Development of casting processes for the new gamma titanium aluminide alloys as well as existing titanium alloys will remain a trial-and-error procedure until accurate thermophysical properties can be obtained. These molten alloys react with their containers on earth and change their composition - invalidating the measurements even while the data are being acquired in terrestrial laboratories. However, measurements on the molten alloys can be accomplished in space using freely floating droplets which are completely untouched by any container. These data are expected to be exceptionally precise because of the absence of impurity contamination and buoyancy convection effects. Although long duration orbital experiments will be required for the large scale industrial alloy measurement program that results from this research, short duration experiments on NASA's KC-135 low-g aircraft are already providing preliminary data and experience.

Ultrasonically assisted single screw extrusion, film blowing and film casting of LLDPE/clay and PA6/clay nanocomposites

NASA Astrophysics Data System (ADS)

Niknezhad, Setareh

The major objective of this study was to investigate the effect of ultrasonic treatment on the dispersion of modified clay particles in LLDPE and PA6 matrices and the final properties of nanocomposites. LLDPE and PA6 are two polymers that are widely used in packaging industry. Blown and cast films were manufactured from the prepared nanocomposites. To achieve one step film processing, an online ultrasonic film casting was developed. Ultrasonic waves caused high-energy mixing and dispersion due to the acoustic cavitation, causing the clay agglomorates to separate into individual platelets in polymer matrix. Ultrasonic waves also broke down the polymer molecular chains reducing viscosity of the melt, facilating dispersion of the clay platelets throughout the matrix. Ultrasound also led to a breakage of the clay platelets reducing the particle size and improving their distribution. Clay particles acted as a heterogenous nucleation agent generating smaller size polymer crystals. In turn, these improved different properties including mechanical properties, oxygen permeability and transparency of films. In LLDPE/clay 20A nanocomposites, the effect of ultrasound was more obvious at higher clay loadings. Exfoliated structure for ultrasonically treated nanocomposites containing 2.5, 5 and 7.5 wt% of clay 20A and highly intercalated structure for ultrasonically treated nanocomposites containing 10 wt% of clay 20A were achieved. However, in blown films, the exfoliated structure transferred to the intercalated structure due to the addition of more shear and thermal degradation of surfactants of the clay particles. While, manufacturing cast films using the new developed online ultrasonic cast film machine revealed the exfoliated structure with ultrasonic treatment till 7.5 wt% of clay loadings. Cast films of nanocomposites containing 5 wt% of clay loadings were also prepared with addition of different compatibilizers. The compatibilizer containing higher amount of grafted maleic anhydride (MA) affected mechanical properties and oxygen permeability with ultrasonic treatment to higher extent. However, use of compatibilizers led to a higher die pressure and resulted in opaque cast films. The mechanical properties were in agreement with crystallinity of samples. The exfoliated structure was achieved for PA6/clay 30B nanocomposites prepared using ultrasonically assisted single screw extrusion except for untreated nanocomposites containing 10 wt% of clay 30B. Untreated 92.5/7.5 and 90/10 PA6/clay 30B blown films showed the intercalated structure, but the exfoliated structure was achieved with ultrasonic treatment. All cast films of PA6/clay 30B showed the exfoliated structure. FTIR spectroscopy along with XRD results confirmed the existence of alpha and gamma-type crystals in the cast films, with clay particles favoring the formation of gamma-type crystals, and ultrasonic treatment favoring the formation of alpha-type crystals. Both parameters increased crystallinity of cast films improving their mechanical properties and oxygen permeability.

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2011 CFR

2011-07-01

... or final product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or... product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or other cast shapes... into a mold, except for ingots, pigs, or other cast shapes related to nonferrous (primary) metals...

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2010 CFR

2010-07-01

... or final product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or... product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or other cast shapes... into a mold, except for ingots, pigs, or other cast shapes related to nonferrous (primary) metals...

JPRS Report, Nuclear Developments

DTIC Science & Technology

1989-06-28

the Industrial Devel- opment Corporation, the Department of Posts and Tele- communications , the weather bureau, the Department of Trade and...Industry, the SABC [South African Broad- casting Corporation] and the academic space research community had been appointed to keep up with space- related...wanted to launch its own space programme for communication , commercial, industrial and military purposes. JPRS-TND-89-013 28 June 1989 CHINA

Simulation of cracking cores when molding piston components

NASA Astrophysics Data System (ADS)

Petrenko, Alena; Soukup, Josef

2014-08-01

The article deals with pistons casting made from aluminum alloy. Pistons are casting at steel mold with steel core. The casting is provided by gravity casting machine. The each machine is equipped by two metal molds, which are preheated above temperature 160 °C before use. The steel core is also preheated by flame. The metal molds and cores are heated up within the casting process. The temperature of the metal mold raise up to 200 °C and temperature of core is higher. The surface of the core is treated by nitration. The mold and core are cooled down by water during casting process. The core is overheated and its top part is finally cracked despite its intensive water-cooling. The life time cycle of the core is decreased to approximately 5 to 15 thousands casting, which is only 15 % of life time cycle of core for production of other pistons. The article presents the temperature analysis of the core.

Influence of rotational speed of centrifugal casting process on appearance, microstructure, and sliding wear behaviour of Al-2Si cast alloy

NASA Astrophysics Data System (ADS)

Mukunda, P. G.; Shailesh, Rao A.; Rao, Shrikantha S.

2010-02-01

Although the manner in which the molten metal flows plays a major role in the formation of the uniform cylinder in centrifugal casting, not much information is available on this topic. The flow in the molten metal differs at various rotational speeds, which in turn affects the final casting. In this paper, the influence of the flow of molten metal of hyper eutectic Al-2Si alloys at various rotational speeds is discussed. At an optimum speed of 800 rpm, a uniform cylinder was formed. For the rotational speeds below and above these speeds, an irregular shaped casting was formed, which is mainly due to the influence of melt. Primary á-Al particles were formed in the tube periphery at low rotational speed, and their sizes and shapes were altered with changes in rotational speeds. The wear test for the inner surface of the casting showed better wear properties for the casting prepared at the optimum speed of rotation.

Modeling of interdendritic porosity defects in an integrated computational materials engineering approach for metal casting

DOE PAGES

Sabau, Adrian S.

2016-04-22

Modeling and simulation of multiphysical phenomena needs to be considered in the design and optimization of mechanical properties of cast components in order to accelerate the introduction of new cast alloys. The data on casting defects, including microstructure features, is crucial for evaluating the final performance-related properties of the component. Here in this paper, the required models for the prediction of interdendritic casting defects, such as microporosity and hot tears, are reviewed. The data on calculated solidification shrinkage is presented and its effects on microporosity levels discussed. Numerical simulation results for microporosity are presented for A356, 356 and 319 aluminummore » alloys using ProCAST TM software. The calculated pressure drop of the interdendritic liquid was observed to be quite significant and the regions of high-pressure drop can be used as an indicator of the severity of interdendritic microporosity defects.« less

Modeling of Casting Defects in an Integrated Computational Materials Engineering Approach

NASA Astrophysics Data System (ADS)

Sabau, Adrian S.

To accelerate the introduction of new cast alloys the modeling and simulation of multiphysical phenomena needs to be considered in the design and optimization of mechanical properties of cast components. The required models related to casting defects, such as microporosity and hot tears are reviewed. Three aluminum alloys are considered A356, 356 and 319. The data on calculated solidification shrinkage is presented and its effects on microporosity levels discussed. Examples are given for predicting microporosity defects and microstructure distribution for a plate casting. Models to predict fatigue life and yield stress are briefly highlighted here for the sake of completion and to illustrate how the length scales of the microstructure features as well as porosity defects are taken into account for modeling the mechanical properties. The data on casting defects including microstructure features, is crucial for evaluating the final performance-related properties of the component.

Structure and properties of stir-cast zinc alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

LeHuy, H.; Blain J.; Masounave, J.

Stir casting (or rheocasting) of ZA-27 zinc alloys was investigated experimentally. By vigorously agitating the alloys during cooling, the dendrites that were forming were fragmented giving a unique structure composed of spherical and rosette shaped particles suspended in the remaining liquid. Under high shear rates ({center dot}{gamma} = 300s{sup {minus}1} or more) the slurries with primary particle concentrations as high as 60% displayed viscosities as low as 20 poises and could easily be casted. The effects of processing variables such as shearing and cooling rates and casting temperatures were studied. Their relative importance on the rheological and microstructural behavior ofmore » the stir cast alloys are discussed. Results from viscosity measurements on slurries show that non-dendritical ZA-27 alloys obey a power law fluid model. Finally, results from mechanical and compressive studies carried out on solidified slurries are discussed and compared to conventional casted and wrought alloy properties.« less

Stress-strain relationship and seismic performance of cast-in-situ phosphogypsum.

PubMed

Zhang, Yichao; Dai, Shaobin; Weng, Wanlin; Huang, Jun; Su, Ying; Cai, Yue

2017-06-16

Phosphogypsum is a waste by-product during the production of phosphoric acid. It not only occupies landfill, but also pollutes the environment, which becomes an important factor restricting the sustainable development of the phosphate fertilizer industry. Research into cast-in-situ phosphogypsum will greatly promote the comprehensive utilization of stored phosphogypsum. The aim of this study was to clarify the mechanical properties of phosphogypsum. Stress-strain relationships of cast-in-situ phosphogypsum were investigated through axial compressive experiments, and seismic performance of cast-in-situ phosphogypsum walls and aerated-concrete masonry walls were simulated based on the experimental results and using finite element analysis. The results showed that the stress-strain relationship fitted into a polynomial equation. Moreover, the displacement ductility index and the energy dissipation index of cast-in-situ phosphogypsum wall were 6.587 and 3.425, respectively. The stress-strain relationship for earthquake-resistant performance of cast-in-situ phosphogypsum walls is better than that of aerated-concrete masonry walls. The curve of stress-strain relationship and the evaluation of earthquake-resistant performance provide theoretical support for the application of cast-in-situ phosphogypsum in building walls.

Army Investment Casting Industry Report

DTIC Science & Technology

1987-04-01

Page 9 #5 Capacity Utilization Rates Page 10 #6 Labor Intensity Indicator Page 11 #7 Market Share By Firm Size Page 12 #8 Market Share By Type of Firm...information gathered from the U.S. casters. These similarities coupled with the relatively small Canadian market share resulted in similar conclusions...investment castings further expanding into the Defense market some foreseeable difficulties that could arise would be: a. Lack of adequate tooling. b

Prediction model of austenite growth and the role of MnS inclusions in non-quenched and tempered steel

NASA Astrophysics Data System (ADS)

Jiang, Bo; Wu, Meng; Sun, He; Wang, Zhilin; Zhao, Zhigang; Liu, Yazheng

2018-01-01

The austenite growth behavior of non-quenched and tempered steels (casted by continuous casting and molding casting processes) was studied. The austenite grain size of steel B casted by continuous casting process is smaller than that of steel A casted by molding casting process at the same heating parameters. The abnormal austenite growth temperature of the steels A and B are 950 °C and 1000 °C, respectively. Based on the results, the models for the austenite grain growth below and above the abnormal austenite growth temperature of the investigated steels were established. The dispersedly distributed fine particles MnS in steel B is the key factor refining the austenite grain by pinning the migration of austenite grain boundary. The elongated inclusions MnS are ineffective in preventing the austenite grain growth at high heating temperature. For the non-quenched and tempered steel, the continuous casting process should be adopted and the inclusion MnS should be elliptical, smaller in size and distributed uniformly in order to refine the final microstructure and also improve the mechanical properties.

A gradiometric version of contactless inductive flow tomography: theory and first applications

PubMed Central

Wondrak, Thomas; Stefani, Frank

2016-01-01

The contactless inductive flow tomography (CIFT) is a measurement technique that allows reconstructing the flow of electrically conducting fluids by measuring the flow-induced perturbations of one or various applied magnetic fields and solving the underlying inverse problem. One of the most promising application fields of CIFT is the continuous casting of steel, for which the online monitoring of the flow in the mould would be highly desirable. In previous experiments at a small-scale model of continuous casting, CIFT has been applied to various industrially relevant problems, including the sudden changes of flow structures in case of argon injection and the influence of a magnetic stirrer at the submerged entry nozzle. The application of CIFT in the presence of electromagnetic brakes, which are widely used to stabilize the flow in the mould, has turned out to be more challenging due to the extreme dynamic range between the strong applied brake field and the weak flow-induced perturbations of the measuring field. In this paper, we present a gradiometric version of CIFT, relying on gradiometric field measurements, that is capable to overcome those problems and which seems, therefore, a promising candidate for applying CIFT in the steel casting industry. This article is part of the themed issue ‘Supersensing through industrial process tomography’. PMID:27185963

Ensuring the Environmental and Industrial Safety in Solid Mineral Deposit Surface Mining

NASA Astrophysics Data System (ADS)

Trubetskoy, Kliment; Rylnikova, Marina; Esina, Ekaterina

2017-11-01

The growing environmental pressure of mineral deposit surface mining and severization of industrial safety requirements dictate the necessity of refining the regulatory framework governing safe and efficient development of underground resources. The applicable regulatory documentation governing the procedure of ore open-pit wall and bench stability design for the stage of pit reaching its final boundary was issued several decades ago. Over recent decades, mining and geomechanical conditions have changed significantly in surface mining operations, numerous new software packages and computer developments have appeared, opportunities of experimental methods of source data collection and processing, grounding of the permissible parameters of open pit walls have changed dramatically, and, thus, methods of risk assessment have been perfected [10-13]. IPKON RAS, with the support of the Federal Service for Environmental Supervision, assumed the role of the initiator of the project for the development of Federal norms and regulations of industrial safety "Rules for ensuring the stability of walls and benches of open pits, open-cast mines and spoil banks", which contribute to the improvement of economic efficiency and safety of mineral deposit surface mining and enhancement of the competitiveness of Russian mines at the international level that is very important in the current situation.

Aspects of fabrication aluminium matrix heterophase composites by suspension method

NASA Astrophysics Data System (ADS)

Dolata, A. J.; Dyzia, M.

2012-05-01

Composites with an aluminium alloy matrix (AlMMC) exhibit several advantageous properties such as good strength, stiffness, low density, resistance and dimensional stability to elevated temperatures, good thermal expansion coefficient and particularly high resistance to friction wear. Therefore such composites are more and more used in modern engineering constructions. Composites reinforced with hard ceramic particles (Al2O3, SiC) are gradually being implemented into production in automotive or aircraft industries. Another application of AlMMC is in the electronics industry, where the dimensional stability and capacity to absorb and remove heat is used in radiators. However the main problems are still: a reduction of production costs, developing methods of composite material tests and final product quality assessment, standardisation, development of recycling and mechanical processing methods. AlMMC production technologies, based on liquid-phase methods, and the shaping of products by casting methods, belong to the cheapest production methods. Application of a suspension method for the production of composites with heterophase reinforcement may turn out to be a new material and technological solution. The article presents the material and technological aspects of the transfer procedures for the production of composite suspensions from laboratory scale to a semi-industrial scale.

Detection of a Pool in Semi-Continuous Castings Made of Heat-Treatable Aluminum Alloys

NASA Astrophysics Data System (ADS)

Krushenko, G. G.; Nazarov, V. P.

2017-12-01

Various products (sheets, sections, etc.) manufactured by metal forming (rolled products, forged pieces, etc.) from semi-continuous castings are widely used in the aerospace industry. The so-called pool, which is the conical volume of a liquid metal, exists at the top of the liquid metal. Experience demonstrates that the geometry, the depth, and the shape of the pool substantially affect the structure formation in a casting and its quality. The application of a titanium nitride nanopowder, which is introduced in a melt in the volume of a rod, as a modifier allowed us to find the exact geometry of the pool.

Nucleated casting for the production of large superalloy ingots

NASA Astrophysics Data System (ADS)

Carter, William T.; Jones, Robin M. Forbes

2005-04-01

The gas turbine industry is continuously driven to achieve higher thermodynamic efficiency, higher electrical output, and higher reliability through turbine design improvements. The specific component of interest in this article is the turbine wheel, which is the rotating hub on which turbine blades are mounted. The wheel is mechanically loaded by both axial and centrifugal forces and thermally loaded by heat that is conducted from the turbine blades. Currently, the turbine wheel is forged from an ingot that is triple-melted, but nucleated casting is under development as a long-term option. This article describes the investigation into nucleated casting technology for future turbine wheel production.

Continuation of Crosscutting Technology Development at Cast

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yoon, Roe-Hoan

2012-03-31

This Final Technical Report describes progress made on the sub-projects awarded in the Cooperative Agreement DE-FC26-05NT42457: Continuation of Crosscutting Technology Development at Center for Advanced Separation Technologies (CAST). The final reports for each sub-project are attached in the appendix. Much of the research to be conducted with Cooperative Agreement funds will be longer-term, high-risk, basic research and will be carried out in five broad areas: a) Solid-solid separation b) Solid-liquid separation c) Chemical/Biological Extraction d) Modeling and Control, and e) Environmental Control.

Argon Bubble Transport and Capture in Continuous Casting with an External Magnetic Field Using GPU-Based Large Eddy Simulations

NASA Astrophysics Data System (ADS)

Jin, Kai

Continuous casting produces over 95% of steel in the world today, hence even small improvements to this important industrial process can have large economic impact. In the continuous casting of steel process, argon gas is usually injected at the slide gate or stopper rod to prevent clogging, but entrapped bubbles may cause defects in the final product. Many defects in this process are related to the transient fluid flow in the mold region of the caster. Electromagnetic braking (EMBr) device is often used at high casting speed to modify the mold flow, reduce the surface velocity and fluctuation. This work studies the physics in continuous casting process including effects of EMBr on the motion of fluid flow in the mold region, and transport and capture of bubbles in the solidification processes. A computational effective Reynolds-averaged Navier-Stokes (RANS) model and a high fidelity Large Eddy Simulation (LES) model are used to understand the motion of the molten steel flow. A general purpose multi-GPU Navier-Stokes solver, CUFLOW, is developed. A Coherent-Structure Smagorinsky LES model is implemented to model the turbulent flow. A two-way coupled Lagrangian particle tracking model is added to track the motion of argon bubbles. A particle/bubble capture model based on force balance at dendrite tips is validated and used to study the capture of argon bubbles by the solidifying steel shell. To investigate the effects of EMBr on the turbulent molten steel flow and bubble transport, an electrical potential method is implemented to solve the magnetohydrodynamics equations. Volume of Fluid (VOF) simulations are carried out to understand the additional resistance force on moving argon bubbles caused by adding transverse magnetic field. A modified drag coefficient is extrapolated from the results and used in the two-way coupled Eulerian-Lagrangian model to predict the argon bubble transport in a caster with EMBr. A hook capture model is developed to understand the effects of hooks on argon bubble capture.

Effect of steady and time-harmonic magnetic fields on macrosegragation in alloy solidification

DOE Office of Scientific and Technical Information (OSTI.GOV)

Incropera, F.P.; Prescott, P.J.

Buoyancy-induced convection during the solidification of alloys can contribute significantly to the redistribution of alloy constituents, thereby creating large composition gradients in the final ingot. Termed macrosegregation, the condition diminishes the quality of the casting and, in the extreme, may require that the casting be remelted. The deleterious effects of buoyancy-driven flows may be suppressed through application of an external magnetic field, and in this study the effects of both steady and time-harmonic fields have been considered. For a steady magnetic field, extremely large field strengths would be required to effectively dampen convection patterns that contribute to macrosegregation. However, bymore » reducing spatial variations in temperature and composition, turbulent mixing induced by a time-harmonic field reduces the number and severity of segregates in the final casting.« less

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2014 CFR

2014-07-01

... intermediate or final product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or... product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or other cast shapes... into a mold, except for ingots, pigs, or other cast shapes related to nonferrous (primary) metals...

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2012 CFR

2012-07-01

... intermediate or final product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or... product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or other cast shapes... into a mold, except for ingots, pigs, or other cast shapes related to nonferrous (primary) metals...

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2013 CFR

2013-07-01

... intermediate or final product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or... product by pouring or forcing the molten metal into a mold, except for ingots, pigs, or other cast shapes... into a mold, except for ingots, pigs, or other cast shapes related to nonferrous (primary) metals...

Development of polymer nano composite patterns using fused deposition modeling for rapid investment casting process

NASA Astrophysics Data System (ADS)

Vivek, Tiwary; Arunkumar, P.; Deshpande, A. S.; Vinayak, Malik; Kulkarni, R. M.; Asif, Angadi

2018-04-01

Conventional investment casting is one of the oldest and most economical manufacturing techniques to produce intricate and complex part geometries. However, investment casting is considered economical only if the volume of production is large. Design iterations and design optimisations in this technique proves to be very costly due to time and tooling cost for making dies for producing wax patterns. However, with the advent of Additive manufacturing technology, plastic patterns promise a very good potential to replace the wax patterns. This approach can be very useful for low volume production & lab requirements, since the cost and time required to incorporate the changes in the design is very low. This research paper discusses the steps involved for developing polymer nanocomposite filaments and checking its suitability for investment castings. The process parameters of the 3D printer machine are also optimized using the DOE technique to obtain mechanically stronger plastic patterns. The study is done to develop a framework for rapid investment casting for lab as well as industrial requirements.

Development of a Thin-Wall Magnesium side door Inner Panel for Automobiles

DOE Office of Scientific and Technical Information (OSTI.GOV)

Jekl, J.; Auld, J.; Sweet, C.

Cast magnesium side door inner panels can provide a good combination of weight, functional, manufacturing and economical requirements. However, several challenges exist including casting technology for thin-wall part design, multi-material incompatibility and relatively low strength vs steel. A project has been initiated, supported by the US Department of Energy, to design and develop a lightweight frame-under-glass door having a thin-wall, full die-cast, magnesium inner panel. This development project is the first of its kind within North America. Phase I of the project is now complete and the 2.0mm magnesium design, through casting process enablers, has met or exceeded all stiffnessmore » requirements, with significant mass reduction and part consolidation. In addition, a corrosion mitigation strategy has been established using industry-accepted galvanic isolation methods and coating technologies.« less

Accuracy of Small Base Metal Dental Castings,

DTIC Science & Technology

1980-07-10

onre r puf~ eece an dif bydo:k itse Base metal al oy, c s ii.ing c ucyicatin nesmncatn ecnqe an.DISRBTOTTMN in( sten te hiquestatetrdISoc20itifrntrmRpr...34alternatives" to conventional dental golds. Determination and evaluation of composition , structure, physical and chemical properties, biologic features...maxillary right first molar was made from an industrial grade silicone . Then the tooth was machined to receive a full crown cast restoration. The tapered

Fan Fuel Casting Final Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Imhoff, Seth D.

LANL was approached to provide material and design guidance for a fan-shaped fuel element. A total of at least three castings were planned. The first casting is a simple billet mold to be made from high carbon DU-10Mo charge material. The second and third castings are for optimization of the actual fuel plate mold. The experimental scope for optimization is only broad enough for a second iteration of the mold design. It is important to note that partway through FY17, this project was cancelled by the sponsor. This report is being written in order to capture the knowledge gained shouldmore » this project resume at a later date.« less

Predicting Pattern Tooling and Casting Dimensions for Investment Casting, Phase III

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sabau, Adrian S

2008-04-01

Efforts during Phase III focused mainly on the shell-alloy systems. A high melting point alloy, 17-4PH stainless steel, was 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. Shell molds made of fused-silica and alumino-silicates were considered. A literature review was conducted on thermophysical and thermomechanical properties alumino-silicates. Material property data, which were not available from material suppliers, was obtained. For all the properties of 17-4PH stainless steel, the experimental data available in the literature did not cover the entire temperature range necessarymore » for process simulation. Thus, some material properties were evaluated using ProCAST, based on CompuTherm database. A comparison between the predicted material property data and measured property data was made. It was found that most material properties were accurately predicted only over several temperature ranges. No experimental data for plastic modulus were found. Thus, several assumptions were made and ProCAST recommendations were followed in order to obtain a complete set of mechanical property data at high temperatures. Thermal expansion measurements for the 17-4PH alloy were conducted during heating and cooling. As a function of temperature, the thermal expansion for both the alloy and shell mold materials showed different evolution on heating and cooling. Numerical simulations were performed using ProCAST for the investment casting of 17-4PH stainless steel parts in fused silica molds using the thermal expansion obtained on heating and another one with thermal expansion obtained on cooling. Since the fused silica shells had the lowest thermal expansion properties in the industry, the dewaxing phase, including the coupling between wax-shell systems, was neglected. The shell mold was considered to be a pure elastic material. The alloy dimensions were obtained from numerical simulations. For 17-4PH stainless steel parts, the alloy shrinkage factors were over-predicted, as compared with experimental data. Additional R&D focus was placed on obtaining material property data for filled waxes, waxes that are common in the industry. For the first time in the investment casting industry, the thermo-mechanical properties of unfilled and filled waxes were measured. Test specimens of three waxes were injected at commercial foundries. Rheometry measurement of filled waxes was conducted at ORNL. The analysis of the rheometry data to obtain viscoelastic properties was not completed due to the reduction in the budget of the project (approximately 50% funds were received).« less

A Numerical Simulation of Transport Phenomena During the Horizontal Single Belt Casting Process Using an Inclined Feeding System

NASA Astrophysics Data System (ADS)

Xu, Mianguang; Isac, Mihaiela; Guthrie, Roderick I. L.

2018-03-01

Horizontal single belt casting (HSBC) has great potential to replace current conventional continuous casting (CCC) processes for sheet metal production, by directly casting 3 to 1 mm sheet for the automobile industry. In the present paper, two-dimensional mathematical models were developed to study transport phenomena, for the case of an inclined wall feeding system for a liquid aluminum wrought alloy (AA6111). Based on the commercial software ANSYS FLUENT 14.5 and user-defined functions, a two-layer turbulence model was used to examine the fluid flow emanating from a slot nozzle set above a water-cooled, high-speed, steel belt. The Volume of Fluid (VOF) method was used to predict the shape of the melt-air interface. A transformed coordinate system (x', y') was established in order to analyze the fluid flow on the inclined wall of the feeding system. The total pressure gauge gradient (∂p total/∂x) was used to describe the behavior of the melt film inside the slot nozzle of the head box. The modeling results show that during the melt film falling process, the total gauge pressure varies within the slot nozzle, which can decrease the stability of the falling film. The first impingement between the falling film and the inclined refractory wall of the feeding system gives rise to a local oscillation, and this influences the stability of the melt film moving downwards. At the rear meniscus position between the inclined wall and the moving belt, there is a clear vibration of the air-melt interface, together with a recirculation zone. The weak vibration of the air-melt interface could be induced by the periodic variation of the melt-air interface. Moreover, the formation of tiny air pockets is predicted. Finally, on the inclined wall of the feeding system, a suitable length of the transition area is needed to avoid over-acceleration of the melt film due to the force of gravity.

A Numerical Simulation of Transport Phenomena During the Horizontal Single Belt Casting Process Using an Inclined Feeding System

NASA Astrophysics Data System (ADS)

Xu, Mianguang; Isac, Mihaiela; Guthrie, Roderick I. L.

2018-06-01

Horizontal single belt casting (HSBC) has great potential to replace current conventional continuous casting (CCC) processes for sheet metal production, by directly casting 3 to 1 mm sheet for the automobile industry. In the present paper, two-dimensional mathematical models were developed to study transport phenomena, for the case of an inclined wall feeding system for a liquid aluminum wrought alloy (AA6111). Based on the commercial software ANSYS FLUENT 14.5 and user-defined functions, a two-layer turbulence model was used to examine the fluid flow emanating from a slot nozzle set above a water-cooled, high-speed, steel belt. The Volume of Fluid (VOF) method was used to predict the shape of the melt-air interface. A transformed coordinate system ( x', y') was established in order to analyze the fluid flow on the inclined wall of the feeding system. The total pressure gauge gradient ( ∂p total/ ∂x) was used to describe the behavior of the melt film inside the slot nozzle of the head box. The modeling results show that during the melt film falling process, the total gauge pressure varies within the slot nozzle, which can decrease the stability of the falling film. The first impingement between the falling film and the inclined refractory wall of the feeding system gives rise to a local oscillation, and this influences the stability of the melt film moving downwards. At the rear meniscus position between the inclined wall and the moving belt, there is a clear vibration of the air-melt interface, together with a recirculation zone. The weak vibration of the air-melt interface could be induced by the periodic variation of the melt-air interface. Moreover, the formation of tiny air pockets is predicted. Finally, on the inclined wall of the feeding system, a suitable length of the transition area is needed to avoid over-acceleration of the melt film due to the force of gravity.

Process for forming a long gas turbine engine blade having a main wall with a thin portion near a tip

DOEpatents

Campbell, Christian X; Thomaidis, Dimitrios

2014-05-13

A process is provided for forming an airfoil for a gas turbine engine involving: forming a casting of a gas turbine engine airfoil having a main wall and an interior cavity, the main wall having a wall thickness extending from an external surface of the outer wall to the interior cavity, an outer section of the main wall extending from a location between a base and a tip of the airfoil casting to the tip having a wall thickness greater than a final thickness. The process may further involve effecting movement, using a computer system, of a material removal apparatus and the casting relative to one another such that a layer of material is removed from the casting at one or more radial portions along the main wall of the casting.

Characterization and Evaluation of Incorporation the Casting Sand in Mortar

NASA Astrophysics Data System (ADS)

Zanelato, E. B.; Azevedo, A. R. G.; Alexandre, J.; Xavier, C. G.; Monteiro, S. N.; Mendonça, T. A. O.

The process of casting metals and alloys occurs through the fusion of this metal and its subsequent casting into a mold with the dimensions and geometry close to the final piece. Most foundries use sand casting molds for making you. This work aims to characterize and evaluate the foundry sand to allow its use in segments of Civil Engineering, creating a viable destination for a residue is that discarded. The following characterization tests were performer: particle size, chemical analysis, X-ray Diffraction and Density Real grain. For the execution of the test specimens was used to 1:3 cement and sand, and the incorporation of 10% and 20% of the total mass replacing the sand, and the trace reference. The results show that best results in compression and bending tests were obtained by replacing 10 % of common sand for sand casting.

Grain Refinement and Improvement of Solidification Defects in Direct-Chill Cast Billets of A4032 Alloy by Melt Conditioning

NASA Astrophysics Data System (ADS)

Li, Hu-Tian; Zhao, Pizhi; Yang, Rongdong; Patel, Jayesh B.; Chen, Xiangfu; Fan, Zhongyun

2017-10-01

Melt-conditioned, direct-chill (MC-DC) casting is an emerging technology to manipulate the solidification process by melt conditioning via intensive shearing in the sump during DC casting to tailor the solidification microstructure and defect formation. When using MC-DC casting technology in an industrial scale DC cast billet of an A4032 aluminum alloy, significant grain refinement and uniform microstructure can be achieved in the primary α-Al phase with fine secondary dendritic arm spacing (SDAS). Improved macrosegregation is quantitatively characterized and correlated with the suppression of channel segregation. The mechanisms for the prevention of channel segregation are attributed to the increased local cooling rate in the liquid-solid phase region in the sump and the formation of fine equiaxed dendritic grains under intensive melt shearing during MC-DC casting. A critical cooling rate has been identified to be around 0.5 to 1 K/s (°C/s) for the channel segregation to happen in the investigated alloy based on quantitative metallographic results of SDAS. Reduction and refinement of microporosity is attributed to the improved permeability in the liquid-solid phase region estimated by the Kozeny-Carman relationship. The potential improvement in the mechanical properties achievable in MC-DC cast billets is indicated by the finer and more uniform forging streamline in the forgings of MC-DC cast billet.

Aluminum-fly ash metal matrix composites for automotive parts. [Reports for October 1 to December 1998, and January 31 to March 31, 1999

DOE Office of Scientific and Technical Information (OSTI.GOV)

Weiss, David; Purgert, Robert; Rhudy, Richard

1999-04-21

Some highlights are: (1) Material development, process development, and part validation are occurring simultaneously on a fast track schedule. (2) Prior project activity has resulted in a program emphasis on three components--manifolds, mounting brackets, and motor mounts; and three casting techniques--squeeze casting, pressure die casting, and sand casting. (3) With the project focus, it appears possible to offer manifolds and mounting brackets for automotive qualification testing on a schedule in line with the PNGV Year 2004 goal. (4) Through an iterative process of fly ash treatment, MMC ingot preparation, foundry process refinement, and parts production, both foundries (Eck Industries andmore » Thompson Aluminum Casting Company) are addressing the pre-competitive issues of: (a) Optimum castability with fly ash shapes and sizes; (b) Best mechanical properties derived from fly ash shapes and sizes; (c) Effective fly ash classification processes; (d) Mechanical properties resulting from various casting processes and fly ash formulations. Eck and TAC continued experiments with batch ingot provided by both Eck and the University of Wisconsin at Milwaukee. Castings were run that contained varying amounts of fly ash and different size fractions. Components were cast using cenosphere material to ascertain the effects of squeeze casting and to determine whether the pressure would break the cenospheres. Test parts are currently being machined into substandard test bars for mechanical testing. Also, the affect of heat treatments on ashalloy are being studied through comparison to two lots, one heat treated and one in the ''as cast'' condition.« less

Aluminum-fly ash metal matrix composites for automotive parts. [Reports for October 1 to December 31, 1999, and January 1 - to March 31, 2000

DOE Office of Scientific and Technical Information (OSTI.GOV)

Weiss, David; Purgert, Robert; Rhudy, Richard

2000-04-21

The highlights of this report are: (1) fly ash classified by less than 100 microns in size was mixed into a 300 lb melt of alloy 535 without the need of a magnesium additive; (2) a vibratory feeder fitted with a sieve was used as the means to minimize particle clustering while introducing fly ash into the aluminum alloy 535 melt; and (3) the industrial-size field test was successful in that sand mold castings and permanent mold castings of tensile bars, K mold bars, and ingots were made from aluminum alloy 535-fly ash mix. Use of aluminum alloy 535 containingmore » 7% magnesium precluded the need to introduce additional magnesium into the melt. The third round of sand mold castings as well as permanent mold castings produced components and ingots of alloy 535 instead of alloy 356. The ingots will be remelted and cast into parts to assess the improvement of flyash distribution which occurs through reheating and the solidification wetting process. Microstructure analysis continues on sand and permanent mold castings to study particle distribution in the components. A prototype sand cast intake manifold casting was found to be pressure tight which is a major performance requirement for this part. Another heat of pressure die cast brackets of A380-classified fly ash will be made to examine their strength and fly ash distribution. Ingots of A356-fly ash have been made at Eck for remelting at Thompson Aluminum for squeeze casting into motor mounts.« less

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).

JOBS. A Partnership between Education and Industry.

ERIC Educational Resources Information Center

Mann, Sandra; And Others

This packet contains 15 lessons developed in a workplace basic skills project for the metal casting industry established jointly by Central Alabama Community College and Robinson Foundry, Inc. The lessons cover the following topics: (1) green sand schedule; (2) the core room; (3) the core room (continued); (4) figuring time; (5) the cleaning room;…

Industrial robots: Handbook

NASA Astrophysics Data System (ADS)

Kozyrev, Iu. G.

Topics covered include terms, definitions, and classification; operator-directed manipulators; autooperators as used in automated pressure casting; construction and application of industrial robots; and the operating bases of automated systems. Attention is given to adaptive and interactive robots; gripping mechanisms; applications to foundary production, press-forging plants, heat treatment, welding, and assembly operations. A review of design recommendations includes a determination of fundamental structural and technological indicators for industrial robots and a consideration of drive mechanisms.

Properties of TiNi intermetallic compound industrially produced by combustion synthesis

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kaieda, Yoshinari

Most TiNi shape memory intermetallic compounds are conventionally produced by the process including high frequency induction vacuum melting and casting. A gravity segregation occurs in a cast TiNi ingot because of the big difference in the specific gravity between Ti and Ni. It is difficult to control accurately the phase transformation temperature of TiNi shape memory intermetallic compound produced by the conventional process, because the martensitic transformation temperature shifts by 10K due to the change in 0.1 % of Ni content. Homogeneous TiNi intermetallic compound is produced by the industrial process including combustion synthesis method, which is a newly developedmore » manufacturing process. In the new process, phase transformation temperatures of TiNi can be controlled accurately by controlling the ratio of Ti and Ni elemental starting powders. The chemical component, the impurities and the phase transformation temperatures of the TiNi products industrially produced by the process are revealed. These properties are vitally important when combustion synthesis method is applied to an industrial mass production process for producing TiNi shape memory intermetallic compounds. TiNi shape memory products are industrially and commercially produced today the industrial process including combustion synthesis. The total production weight in a year is 30 tins in 1994.« less

Production of footbridge with double curvature made of UHPC

NASA Astrophysics Data System (ADS)

Kolísko, J.; Čítek, D.; Tej, P.; Rydval, M.

2017-09-01

This article present a mix design, preparation and production of thin-walled footbridge made from UHPFRC. In this case an experimental pedestrian bridge was design and prepared. Bridge with span of 10 m and the clear width of 1.50 m designed as single-span bridge. Optimization of UHPFRC matrix and parameters of this material leads to the design of very thin structures. Total thickness of shell structure 30 - 45 mm. Bridge was cast as a prefabricated element in one piece. Self-compacting character of UHPFRC with high flowability allows the production of the final structure. Extensive research was done before production of footbridge. Experimental reached data were compared with extensive numerical analysis and the final design of structure and UHPFRC matrix were optimized in many details. Two versions of large scale mock-ups were casted and tested. According to the complexity of whole experiment a casting technology and production of formwork were tested and optimized many times.

Corrosion Resistance of a Cast-Iron Material Coated With a Ceramic Layer Using Thermal Spray Method

NASA Astrophysics Data System (ADS)

Florea, C. D.; Bejinariu, C.; Munteanu, C.; Istrate, B.; Toma, S. L.; Alexandru, A.; Cimpoesu, R.

2018-06-01

Cast-iron 250 used for breake systems present many corrosion signs after a mean usage time based on the environment conditions they work. In order to improve them corrosion resistance we propose to cover the active part of the material using a ceramic material. The deposition process is an industrial deposition system based on thermal spraying that can cover high surfaces in low time. In this articol we analyze the influence of a ceramic layer (40-50 µm) on the corrosion resistance of FC250 cast iron. The results were analyzed using scanning electron microscopy (SEM), X-ray energy dispersive (EDS) and linear and cyclic potentiometry.

Simulation of the Continuous Casting and Cooling Behavior of Metallic Glasses

PubMed Central

Pei, Zhipu; Ju, Dongying

2017-01-01

The development of melt spinning technique for preparation of metallic glasses was summarized. The limitations as well as restrictions of the melt spinning embodiments were also analyzed. As an improvement and variation of the melt spinning method, the vertical-type twin-roll casting (VTRC) process was discussed. As the thermal history experienced by the casting metals to a great extent determines the qualities of final products, cooling rate in the quenching process is believed to have a significant effect on glass formation. In order to estimate the ability to produce metallic glasses by VTRC method, temperature and flow phenomena of the melt in molten pool were computed, and cooling rates under different casting conditions were calculated with the simulation results. Considering the fluid character during casting process, the material derivative method based on continuum theory was adopted in the cooling rate calculation. Results show that the VTRC process has a good ability in continuous casting metallic glassy ribbons. PMID:28772779

Simulation of the Continuous Casting and Cooling Behavior of Metallic Glasses.

PubMed

Pei, Zhipu; Ju, Dongying

2017-04-17

The development of melt spinning technique for preparation of metallic glasses was summarized. The limitations as well as restrictions of the melt spinning embodiments were also analyzed. As an improvement and variation of the melt spinning method, the vertical-type twin-roll casting (VTRC) process was discussed. As the thermal history experienced by the casting metals to a great extent determines the qualities of final products, cooling rate in the quenching process is believed to have a significant effect on glass formation. In order to estimate the ability to produce metallic glasses by VTRC method, temperature and flow phenomena of the melt in molten pool were computed, and cooling rates under different casting conditions were calculated with the simulation results. Considering the fluid character during casting process, the material derivative method based on continuum theory was adopted in the cooling rate calculation. Results show that the VTRC process has a good ability in continuous casting metallic glassy ribbons.

Microstructure of As-cast Co-Cr-Mo Alloy Prepared by Investment Casting

NASA Astrophysics Data System (ADS)

Park, Jong Bum; Jung, Kyung-Hwan; Kim, Kang Min; Son, Yong; Lee, Jung-Il; Ryu, Jeong Ho

2018-04-01

The microstructure of a cobalt-base alloy (Co-Cr-Mo) obtained by an investment casting process was studied. This alloy complies with the ASTM F75 standard and is widely used in the manufacturing of orthopedic implants owing to its high strength, good corrosion resistance, and excellent biocompatibility. This work focuses on the resulting microstructures arising from normal industrial environmental conditions. The characterization of the samples was carried out using optical microscopy, field emission scanning electron microscopy and energy-dispersive spectroscopy. In this study, the as-cast microstructure is an γ-Co (face-centered cubic) dendritic matrix with the presence of a secondary phase, such as M23C6 carbides precipitated at grain boundaries and interdendritic zones. These precipitates are the main strengthening mechanism in this type of alloy. Other minority phases, such as the σ phase, were also detected, and their presence could be linked to the manufacturing process and environment.

Fatigue behavior in rheocast aluminum 357 suspension arms using the SEED process

NASA Astrophysics Data System (ADS)

Samuel, Ehab; Zheng, Chang-Qing; Bouaicha, Amine; Bouazara, Mohamed

Extensive studies have been devoted to the use of aluminum alloys in the automotive industry, by virtue of the favourable mechanical properties that can be attained. Moreover, the aluminum casting method employed has also been the subject of scrutiny, given the multitude of casting options available. The present work serves to illustrate the advancements made in the area of rheocasting, using the SEED method, as carried out at the National Research Council Canada — Aluminum Technology Centre. The SEED (Swirled Enthalpy Equilibration Device) process, which relies on heat extraction of the liquid aluminum alloy via mechanical agitation in a confined cylinder to form the semi-solid billet, has already proven successful in producing sound aluminum castings having an excellent combination of strength and ductility. Moreover, fatigue testing on the cast alloy parts has shown enormous potential for this emerging technology.

Predictive Capabilities of Multiphysics and Multiscale Models in Modeling Solidification of Steel Ingots and DC Casting of Aluminum

NASA Astrophysics Data System (ADS)

Combeau, Hervé; Založnik, Miha; Bedel, Marie

2016-08-01

Prediction of solidification defects, such as macrosegregation and inhomogeneous microstructures, constitutes a key issue for industry. The development of models of casting processes needs to account for several imbricated length scales and different physical phenomena. For example, the kinetics of the growth of microstructures needs to be coupled with the multiphase flow at the process scale. We introduce such a state-of-the-art model and outline its principles. We present the most recent applications of the model to casting of a heavy steel ingot and to direct chill casting of a large Al alloy sheet ingot. Their ability to help in the understanding of complex phenomena, such as the competition between nucleation and growth of grains in the presence of convection of the liquid and of grain motion is shown, and its predictive capabilities are discussed. Key issues for future developments and research are addressed.

Microstructural and mechanical evolutions during the forging step of the COBAPRESS, a casting/forging process

NASA Astrophysics Data System (ADS)

Perrier, Frédéric; Desrayaud, Christophe; Bouvier, Véronique

Aluminum casting/forging processes are used to produce parts for the automotive industry. In this study, we examined the influence of the forging step on the microstructure and the mechanical properties of an A356 aluminum alloy modified with strontium. Firstly, a design of samples which allows us to test mechanically the alloy before and after forging was created. A finite element analysis with the ABAQUS software predicts a maximum of strain in the core of the specimens. Observations with the EBSD technique confirm a more intense sub-structuration of the dendrite cells in this zone. Yield strength, ultimate tensile strength, elongation and fatigue lives were then improved for the casting/forging samples compared to the only cast specimens. The closure of the porosities and the improvement of the surface quality during the forging step enhance also the fatigue resistance of the samples.

En Route towards European Clinical Breakpoints for Veterinary Antimicrobial Susceptibility Testing: A Position Paper Explaining the VetCAST Approach.

PubMed

Toutain, Pierre-Louis; Bousquet-Mélou, Alain; Damborg, Peter; Ferran, Aude A; Mevius, Dik; Pelligand, Ludovic; Veldman, Kees T; Lees, Peter

2017-01-01

VetCAST is the EUCAST sub-committee for Veterinary Antimicrobial Susceptibility Testing. Its remit is to define clinical breakpoints (CBPs) for antimicrobial drugs (AMDs) used in veterinary medicine in Europe. This position paper outlines the procedures and reviews scientific options to solve challenges for the determination of specific CBPs for animal species, drug substances and disease conditions. VetCAST will adopt EUCAST approaches: the initial step will be data assessment; then procedures for decisions on the CBP; and finally the release of recommendations for CBP implementation. The principal challenges anticipated by VetCAST are those associated with the differing modalities of AMD administration, including mass medication, specific long-acting product formulations or local administration. Specific challenges comprise mastitis treatment in dairy cattle, the range of species and within species breed considerations and several other variable factors not relevant to human medicine. Each CBP will be based on consideration of: (i) an epidemiological cut-off value (ECOFF) - the highest MIC that defines the upper end of the wild-type MIC distribution; (ii) a PK/PD breakpoint obtained from pre-clinical pharmacokinetic data [this PK/PD break-point is the highest possible MIC for which a given percentage of animals in the target population achieves a critical value for the selected PK/PD index ( f AUC/MIC or f T > MIC)] and (iii) when possible, a clinical cut-off, that is the relationship between MIC and clinical cure. For the latter, VetCAST acknowledges the paucity of such data in veterinary medicine. When a CBP cannot be established, VetCAST will recommend use of ECOFF as surrogate. For decision steps, VetCAST will follow EUCAST procedures involving transparency, consensus and independence. VetCAST will ensure freely available dissemination of information, concerning standards, guidelines, ECOFF, PK/PD breakpoints, CBPs and other relevant information for AST implementation. Finally, after establishing a CBP, VetCAST will promulgate expert comments and/or recommendations associated with CBPs to facilitate their sound implementation in a clinical setting.

En Route towards European Clinical Breakpoints for Veterinary Antimicrobial Susceptibility Testing: A Position Paper Explaining the VetCAST Approach

PubMed Central

Toutain, Pierre-Louis; Bousquet-Mélou, Alain; Damborg, Peter; Ferran, Aude A.; Mevius, Dik; Pelligand, Ludovic; Veldman, Kees T.; Lees, Peter

2017-01-01

VetCAST is the EUCAST sub-committee for Veterinary Antimicrobial Susceptibility Testing. Its remit is to define clinical breakpoints (CBPs) for antimicrobial drugs (AMDs) used in veterinary medicine in Europe. This position paper outlines the procedures and reviews scientific options to solve challenges for the determination of specific CBPs for animal species, drug substances and disease conditions. VetCAST will adopt EUCAST approaches: the initial step will be data assessment; then procedures for decisions on the CBP; and finally the release of recommendations for CBP implementation. The principal challenges anticipated by VetCAST are those associated with the differing modalities of AMD administration, including mass medication, specific long-acting product formulations or local administration. Specific challenges comprise mastitis treatment in dairy cattle, the range of species and within species breed considerations and several other variable factors not relevant to human medicine. Each CBP will be based on consideration of: (i) an epidemiological cut-off value (ECOFF) – the highest MIC that defines the upper end of the wild-type MIC distribution; (ii) a PK/PD breakpoint obtained from pre-clinical pharmacokinetic data [this PK/PD break-point is the highest possible MIC for which a given percentage of animals in the target population achieves a critical value for the selected PK/PD index (fAUC/MIC or fT > MIC)] and (iii) when possible, a clinical cut-off, that is the relationship between MIC and clinical cure. For the latter, VetCAST acknowledges the paucity of such data in veterinary medicine. When a CBP cannot be established, VetCAST will recommend use of ECOFF as surrogate. For decision steps, VetCAST will follow EUCAST procedures involving transparency, consensus and independence. VetCAST will ensure freely available dissemination of information, concerning standards, guidelines, ECOFF, PK/PD breakpoints, CBPs and other relevant information for AST implementation. Finally, after establishing a CBP, VetCAST will promulgate expert comments and/or recommendations associated with CBPs to facilitate their sound implementation in a clinical setting. PMID:29326661

ScienceCasts: Cassini's Grand Finale

NASA Image and Video Library

2017-08-15

Cassini is in the process of executing 22 daring ‘Grand Finale’ dives in the 1,200-mile gap between Saturn and its innermost ring, concluding with an epic final plunge into the gas giant’s upper atmosphere.

Awareness Programs and Change in Taste-Based Caste Prejudice

PubMed Central

Banerjee, Ritwik; Datta Gupta, Nabanita

2015-01-01

Becker's theory of taste-based discrimination predicts that relative employment of the discriminated social group will improve if there is a decrease in the level of prejudice for the marginally discriminating employer. In this paper we experimentally test this prediction offered by Garry Becker in his seminal work on taste based discrimination, in the context of caste in India, with management students (potential employers in the near future) as subjects. First, we measure caste prejudice and show that awareness through a TV social program reduces implicit prejudice against the lower caste and the reduction is sustained over time. Second, we find that the treatment reduces the prejudice levels of those in the left tail of the prejudice distribution - the group which can potentially affect real outcomes as predicted by the theory. And finally, a larger share of the treatment group subjects exhibit favorable opinion about reservation in jobs for the lower caste. PMID:25902290

Awareness programs and change in taste-based caste prejudice.

PubMed

Banerjee, Ritwik; Datta Gupta, Nabanita

2015-01-01

Becker's theory of taste-based discrimination predicts that relative employment of the discriminated social group will improve if there is a decrease in the level of prejudice for the marginally discriminating employer. In this paper we experimentally test this prediction offered by Garry Becker in his seminal work on taste based discrimination, in the context of caste in India, with management students (potential employers in the near future) as subjects. First, we measure caste prejudice and show that awareness through a TV social program reduces implicit prejudice against the lower caste and the reduction is sustained over time. Second, we find that the treatment reduces the prejudice levels of those in the left tail of the prejudice distribution--the group which can potentially affect real outcomes as predicted by the theory. And finally, a larger share of the treatment group subjects exhibit favorable opinion about reservation in jobs for the lower caste.

Casting Molding of PDCPD Material for Purpose of Car’s Power Steering Body

NASA Astrophysics Data System (ADS)

Grabowski, L.; Baier, A.; Sobek, M.

2018-01-01

The growing industry of polymer and composite materials is facing new challenges posed by the automotive industry. In this industry, traditional materials such as steel and aluminum are widely replaced with plastic materials, including polymers. In the past, such behavior concerned design and interior elements, but more and more often plastics are used in the case of load-bearing elements, i.e. those that require high strength and durability nowadays. This kind of materials are also often used in safety systems or driver assistance systems. Therefore, the aim of the activities described in this article are to carry out an innovative process of injection of cold polymeric material, PDCPD (Polidicyclopentadiene), polymerizing with the use of Metathesis reaction, which in 2005 was awarded the Nobel Prize. This injection applies to the worm gear components of the system, supports the power steering system of the passenger car. Also the process of selecting the appropriate parameters to carry out this process, guaranteeing the best quality of the obtained elements is necessary. The aim of the activities was to achieve a fully useful power steering support system, using a polymer body, which is replacing the aluminum. These activities were aimed at reducing the costs and weight of the final product. The injection process and the way to achieve the finished product were carried out in an innovative way, never used in industry before.

Aluminum-fly ash metal matrix composites for automotive parts. [Reports for April 1 to June 30, 1999, and July 1 to September 30, 1999

DOE Office of Scientific and Technical Information (OSTI.GOV)

Weiss, David; Purgert, Robert; Rhudy, Richard

1999-10-15

Some highlights are: (1) During this quarter's field trials, sand mold castings of parts and permanent mold tensile testing bars, K mold bars, and ingots were made from aluminum alloy-fly ash melts. (2) Another objective was met, i.e., to use class ''F'' type precipitator fly ash consisting of particle sizes less than 100 microns. It was possible to pour the composite melt into the sand mold through a filter. (3) Trials were run to determine the required amount of the wetting agent, magnesium, to ensure appropriate mixing of the aluminum alloy and fly ash. The magnesium content required to mixmore » ''F'' fly ash was much lower compared to that required to mix hybrid ''C-F'' fly ash in similar melts. Fly ash particles of less than 100 microns were mixed in aluminum melt. Large scale field trials were undertaken at Eck Industries with the goal of standardizing procedures for producing aluminum-fly ash composite melts and to analyze the structure and properties of the resulting material. Limited testing of tensile properties has been done on pressure die cast parts, and attempts are underway to improve the distribution of fly ash in both sand cast and pressure die cast samples. Eck Industries performed radiographic, heat treatment, and tensile tests on permanent mold cast tensile test bars. After fly ash mixing experiments, the Lanxide high speed-high shear mixer (originally designed for mixing Al-SiC melts) was employed in an attempt to avoid fly ash agglomeration. It led to demixing (instead of deagglomerating) of some fly ash. However, the permanent mold tensile bars poured after high shear mixing displayed good distribution of fly ash in castings. A modified impeller design is being considered for high speed-high shear mixing of aluminum-fly ash melts.« less

Cast-In-Situ, Large-Sized Monolithic Silica Xerogel Prepared in Aqueous System.

PubMed

Ding, Wenhui; Wang, Xiaodong; Chen, Dong; Li, Tiemin; Shen, Jun

2018-05-15

This paper reports the preparation of cast-in-situ, large-sized monolithic silica xerogels by a two-step acid⁻base catalyzed approach under ambient pressure drying. Low-cost industrial silica sol and deionized water were used as the silicon source and the solvent, respectively. Hexadecetyltrimethylammonium bromide (CTAB) was used as a modification agent. Different amounts of polyethylene glycol 400 (PEG400) was added as a pore-forming agent. The prepared silica xerogels under ambient pressure drying have a mesoporous structure with a low density of 221 mg·cm -3 and a thermal conductivity of 0.0428 W·m -1 ·K -1 . The low-cost and facile preparation process, as well as the superior performance of the monolithic silica xerogels make it a promising candidate for industrial thermal insulation materials.

Methodology of ecooriented assessment of constructive schemes of cast in-situ RC framework in civil engineering

NASA Astrophysics Data System (ADS)

Avilova, I. P.; Krutilova, M. O.

2018-01-01

Economic growth is the main determinant of the trend to increased greenhouse gas (GHG) emission. Therefore, the reduction of emission and stabilization of GHG levels in the atmosphere become an urgent task to avoid the worst predicted consequences of climate change. GHG emissions in construction industry take a significant part of industrial GHG emission and are expected to consistently increase. The problem could be successfully solved with a help of both economical and organizational restrictions, based on enhanced algorithms of calculation and amercement of environmental harm in building industry. This study aims to quantify of GHG emission caused by different constructive schemes of RC framework in concrete casting. The result shows that proposed methodology allows to make a comparative analysis of alternative projects in residential housing, taking into account an environmental damage, caused by construction process. The study was carried out in the framework of the Program of flagship university development on the base of Belgorod State Technological University named after V.G. Shoukhov

Investigation of Heat Transfer at the Mold/Metal Interface in Permanent Mold Casting of Light Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Robert D. Pehlke; John T. Berry

2005-12-16

Accurate modeling of the metal casting process prior to creating a mold design demands reliable knowledge of the interfacial heat transfer coefficient at the mold metal interface as a function of both time and location. The phenomena concerned with the gap forming between the mold and the solidifying metal are complex but need to be understood before any modeling is attempted. The presence of mold coatings further complicates the situation. A commercial casting was chosen and studied in a gravity permanent mold casting process. The metal/mold interfacial heat transfer coefficient (IHTC) was the focus of the research. A simple, directmore » method has been used to evaluate the IHTC. Both the simulation and experiments have shown that a reasonably good estimate of the heat transfer coefficient could be made in the case studied. It has been found that there is a good agreement between experiments and simulations in the temperature profiles during the solidification process, given that the primary mechanism of heat transfer across the gap in permanent mold casting of light alloys is by conduction across the gap. The procedure utilized to determine the interfacial heat transfer coefficient can be applied to other casting processes. A recently completed project involving The University of Michigan and Mississippi State University, together with several industrial partners, which was supported by the USDOE through the Cast Metals Coalition, examined a number of cases of thermal contact. In an investigation which gave special consideration to the techniques of measurement, several mold coatings were employed and results presented as a function of time. Realistic conditions of coating thickness and type together with an appropriate combination of mold preheat and metal pouring temperature were strictly maintained throughout the investigation. Temperature sensors, in particular thermocouples, play an important part in validating the predictions of solidification models. Cooling curve information, as well as temperature gradient history both in the solidifying metal and within the mold are invariably required to be validated. This validation depends upon the response of the sensor concerned, but also on its own effect upon the thermal environment. A joint university/industry team has completed an investigation of the invasive effects of thermocouples upon temperature history in permanent molds determining the degree of uncertainty associated with placement and indicating how the time-temperature history may be recovered. In addition to its relevance to the all important study of thermal contact of the casting with metallic molds, the observations also impact the determination of heat flux and interfacial heat transfer coefficients. In these respects the study represents the first of its kind that has tackled the problem in depth for permanent mold castings. An important ramification of this investigation has been the errors likely to be encountered in mold temperature measurement with thin section aluminum castings, especially with respect to the plans for thermocouple placement. A comparison between the degree of uncertainty experienced in sand molds compared with that found in permanent molds reveals that the associated problems have a lesser impact. These conclusions and the related recommendations have been disseminated to industry and the technical community through project reports and publications.« less

Fatigue Analysis of Magnesium Alloys Components for Car Industry

NASA Astrophysics Data System (ADS)

Marsavina, Liviu; Rusu, Lucian; Șerban, Dan Andrei; Negru, Radu Marcel; Cernescu, Anghel

2017-12-01

The use of magnesium alloys in the automotive industry increased in the last decade because of their low weight and relative good mechanical properties. However, the variable loading conditions require a good fatigue behavior. This paper summaries the fatigue properties of magnesium alloys and presents new fatigue curve results for die cast AM50 magnesium alloy.

Modelling the Cast Component Weight in Hot Chamber Die Casting using Combined Taguchi and Buckingham's π Approach

NASA Astrophysics Data System (ADS)

Singh, Rupinder

2018-02-01

Hot chamber (HC) die casting process is one of the most widely used commercial processes for the casting of low temperature metals and alloys. This process gives near-net shape product with high dimensional accuracy. However in actual field environment the best settings of input parameters is often conflicting as the shape and size of the casting changes and one have to trade off among various output parameters like hardness, dimensional accuracy, casting defects, microstructure etc. So for online inspection of the cast components properties (without affecting the production line) the weight measurement has been established as one of the cost effective method (as the difference in weight of sound and unsound casting reflects the possible casting defects) in field environment. In the present work at first stage the effect of three input process parameters (namely: pressure at 2nd phase in HC die casting; metal pouring temperature and die opening time) has been studied for optimizing the cast component weight `W' as output parameter in form of macro model based upon Taguchi L9 OA. After this Buckingham's π approach has been applied on Taguchi based macro model for the development of micro model. This study highlights the Taguchi-Buckingham based combined approach as a case study (for conversion of macro model into micro model) by identification of optimum levels of input parameters (based on Taguchi approach) and development of mathematical model (based on Buckingham's π approach). Finally developed mathematical model can be used for predicting W in HC die casting process with more flexibility. The results of study highlights second degree polynomial equation for predicting cast component weight in HC die casting and suggest that pressure at 2nd stage is one of the most contributing factors for controlling the casting defect/weight of casting.

Tribological and Wear Performance of Nanocomposite PVD Hard Coatings Deposited on Aluminum Die Casting Tool.

PubMed

Paiva, Jose Mario; Fox-Rabinovich, German; Locks Junior, Edinei; Stolf, Pietro; Seid Ahmed, Yassmin; Matos Martins, Marcelo; Bork, Carlos; Veldhuis, Stephen

2018-02-28

In the aluminum die casting process, erosion, corrosion, soldering, and die sticking have a significant influence on tool life and product quality. A number of coatings such as TiN, CrN, and (Cr,Al)N deposited by physical vapor deposition (PVD) have been employed to act as protective coatings due to their high hardness and chemical stability. In this study, the wear performance of two nanocomposite AlTiN and AlCrN coatings with different structures were evaluated. These coatings were deposited on aluminum die casting mold tool substrates (AISI H13 hot work steel) by PVD using pulsed cathodic arc evaporation, equipped with three lateral arc-rotating cathodes (LARC) and one central rotating cathode (CERC). The research was performed in two stages: in the first stage, the outlined coatings were characterized regarding their chemical composition, morphology, and structure using glow discharge optical emission spectroscopy (GDOES), scanning electron microscopy (SEM), and X-ray diffraction (XRD), respectively. Surface morphology and mechanical properties were evaluated by atomic force microscopy (AFM) and nanoindentation. The coating adhesion was studied using Mersedes test and scratch testing. During the second stage, industrial tests were carried out for coated die casting molds. In parallel, tribological tests were also performed in order to determine if a correlation between laboratory and industrial tests can be drawn. All of the results were compared with a benchmark monolayer AlCrN coating. The data obtained show that the best performance was achieved for the AlCrN/Si₃N₄ nanocomposite coating that displays an optimum combination of hardness, adhesion, soldering behavior, oxidation resistance, and stress state. These characteristics are essential for improving the die mold service life. Therefore, this coating emerges as a novelty to be used to protect aluminum die casting molds.

The Simulation of Magnesium Wheel Low Pressure Die Casting Based on PAM-CAST™

NASA Astrophysics Data System (ADS)

Peng, Yinghong; Wang, Yingchun; Li, Dayong; Zeng, Xiaoqin

2004-06-01

Magnesium is the lightest metal commonly used in engineering, with various excellent characteristics such as high strength and electromagnetic interference shielding capability. Particularly, the usage of magnesium in automotive industry can meet better the need to reduce fuel consumption and CO2 emissions. Nowadays, most current magnesium components in automobiles are made by die casting. In this paper, commercial software for die casting, PAM-CAST™, was utilized to simulate the low pressure die casting process of magnesium wheel. Through calculating temperature field and velocity field during filling and solidification stages, the evolution of temperature distribution and liquid fraction was analyzed. Then, the potential defects including the gas entrapments in the middle of the spokes, shrinkages between the rim and the spokes were forecasted. The analytical results revealed that the mold geometry and die casting parameters should be improved in order to get the sound magnesium wheel. The reasons leading to these defects were also analyzed and the solutions to eliminate them were put forward. Furthermore, through reducing the pouring velocity, the air gas entrapments and partial shrinkages were eliminated effectively.

Constitutive behavior of as-cast AA1050, AA3104, and AA5182

NASA Astrophysics Data System (ADS)

van Haaften, W. M.; Magnin, B.; Kool, W. H.; Katgerman, L.

2002-07-01

Recent thermomechanical modeling to calculate the stress field in industrially direct-chill (DC) cast-aluminum slabs has been successful, but lack of material data limits the accuracy of these calculations. Therefore, the constitutive behavior of three aluminum alloys (AA1050, AA3104, and AA5182) was determined in the as-cast condition using tensile tests at low strain rates and from room temperature to solidus temperature. The parameters of two constitutive equations, the extended Ludwik equation and a combination of the Sellars-Tegart equation with a hardening law, were determined. In order to study the effect of recovery, the constitutive behavior after prestraining at higher temperatures was also investigated. To evaluate the quantified constitutive equations, tensile tests were performed simulating the deformation and cooling history experienced by the material during casting. It is concluded that both constitutive equations perform well, but the combined hardening-Sellars-Tegart (HST) equation has temperature-independent parameters, which makes it easier to implement in a DC casting model. Further, the deformation history of the ingot should be taken into account for accurate stress calculations.

A Practical Recycling Project . . .

ERIC Educational Resources Information Center

Durant, Raymond H.; Mikuska, James M.

1973-01-01

Descirbes a school district's recycling program of aluminum lunch trays that are collected after their use. The trays are used as scrap metal in industrial education workshop and used for sand castings. (PS)

Numerical simulation of the casting process of titanium removable partial denture frameworks.

PubMed

Wu, Menghuai; Wagner, Ingo; Sahm, Peter R; Augthun, Michael

2002-03-01

The objective of this work was to study the filling incompleteness and porosity defects in titanium removal partial denture frameworks by means of numerical simulation. Two frameworks, one for lower jaw and one for upper jaw, were chosen according to dentists' recommendation to be simulated. Geometry of the frameworks were laser-digitized and converted into a simulation software (MAGMASOFT). Both mold filling and solidification of the castings with different sprue designs (e.g. tree, ball, and runner-bar) were numerically calculated. The shrinkage porosity was quantitatively predicted by a feeding criterion, the potential filling defect and gas pore sensitivity were estimated based on the filling and solidification results. A satisfactory sprue design with process parameters was finally recommended for real casting trials (four replica for each frameworks). All the frameworks were successfully cast. Through X-ray radiographic inspections it was found that all the castings were acceptably sound except for only one case in which gas bubbles were detected in the grasp region of the frame. It is concluded that numerical simulation aids to achieve understanding of the casting process and defect formation in titanium frameworks, hence to minimize the risk of producing defect casting by improving the sprue design and process parameters.

Triple Plate Mold Final Report: Optimization of the Mold Design and Casting Parameters for a Thin U-10mo Fuel Casting

DOE Office of Scientific and Technical Information (OSTI.GOV)

Aikin, Jr., Robert M.

This work describes the experiments and modeling that have been performed to improve and try to optimize the simultaneous casting of three plates of U-10wt%Mo in a single coil vacuum induction melting (VIM) furnace. The plates of interest are 280 mm wide by 203 mm tall by 5 mm thick (11" x 8" x 0.2"). The initial mold design and processing parameters were supplied by Y-12. The mold and casting cavity were instrumented with a number of thermocouples, and the casting performed to determine the thermal history of the mold and casting. The resulting cast plates were radiographed and numerousmore » defects identified. Metallography was performed to help identify the nature of the radiographically observed defects. This information was then used to validate a mold filling and solidification model of that casting. Based on the initial casting, good casting design practice, and process simulation of several design alternatives, a revised design was developed with the goal of minimizing casting defects such as porosity. The redesigned mold had a larger hot-top and had its long axis along the horizontal direction. These changes were to try to develop a strong thermal gradient conducive to good feeding and minimization of micro- and macroporosity in the cast plates. An instrumented casting was then performed with the revised mold design and a linear distributor. This design yielded cast plates with significantly less radiographically identified defects. Unfortunately, there was significant variation in plate weight and metal content in their hot-tops. Fluid flow simulations were then performed on this mold/distributor design. This helped identify the issue with this linear distributor design. Additional simulations were then performed on candidate distributor redesigns and a preferred distributor annular design was identified. This improved annular design was used to produce a third instrumented casting with favorable results. These refined designs and their radiographic characterization are compared to the initial design.« less

Advances in Integrated Computational Materials Engineering "ICME"

NASA Astrophysics Data System (ADS)

Hirsch, Jürgen

The methods of Integrated Computational Materials Engineering that were developed and successfully applied for Aluminium have been constantly improved. The main aspects and recent advances of integrated material and process modeling are simulations of material properties like strength and forming properties and for the specific microstructure evolution during processing (rolling, extrusion, annealing) under the influence of material constitution and process variations through the production process down to the final application. Examples are discussed for the through-process simulation of microstructures and related properties of Aluminium sheet, including DC ingot casting, pre-heating and homogenization, hot and cold rolling, final annealing. New results are included of simulation solution annealing and age hardening of 6xxx alloys for automotive applications. Physically based quantitative descriptions and computer assisted evaluation methods are new ICME methods of integrating new simulation tools also for customer applications, like heat affected zones in welding of age hardening alloys. The aspects of estimating the effect of specific elements due to growing recycling volumes requested also for high end Aluminium products are also discussed, being of special interest in the Aluminium producing industries.

An overview of thixoforming process

NASA Astrophysics Data System (ADS)

Husain, N. H.; Ahmad, A. H.; Rashidi, M. M.

2017-10-01

Thixoforming is a forming process which exploits metal rheological behaviour during solidus and liquidus range temperature. Many research works in thixoforming are currently focusing on the raw material used to produce superior mechanical properties and excellent formability components, especially in automotive industries. Furthermore, the thixoforming process also produced less casting defect component such as macrosegration, shrinkage and porosity. These advantages are sufficient to attract more exploration works of thixoforming operation. However, the weakness of this process such as high production cost due to leftover billet which cannot be recycled, encourage researcher works to overcome thixoforming limitations by using various methods. The thixoforming methods that widely used are thixocasting, thixoforging, thixorolling, thixoextrusion and thixomoulding. Each method provides varieties of final product characteristics; hence offer the extensive possibility of component invention. On the other hand, new thixoforming method leads to exploration research such as microstructure evolution, heating and pouring temperature, die temperature, mechanical properties, viscosity and final product quality. This review paper presents findings in the rheological material behaviour of thixoforming, advantages and disadvantanges of thixoforming, parameters affecting the thixoforming operation, morphology of thixoforming and various methods which have been used in this research area.

Fibreglass Total Contact Casting, Removable Cast Walkers, and Irremovable Cast Walkers to Treat Diabetic Neuropathic Foot Ulcers: A Health Technology Assessment

PubMed Central

Costa, Vania; Tu, Hong Anh; Wells, David; Weir, Mark; Holubowich, Corinne; Walter, Melissa

2017-01-01

Background Diabetic neuropathic foot ulcers are a risk factor for lower leg amputation. Many experts recommend offloading with fibreglass total contact casting, removable cast walkers, and irremovable cast walkers as a way to treat these ulcers. Methods We completed a health technology assessment, which included an evaluation of clinical benefits and harms, value for money, and patient preferences for offloading devices. We performed a systematic literature search on August 17, 2016, to identify randomized controlled trials that compared fibreglass total contact casting, removable cast walkers, and irremovable cast walkers with other treatments (offloading or non-offloading) in patients with diabetic neuropathic foot ulcers. We developed a decision-analytic model to assess the cost-effectiveness of fibreglass total contact casting, removable cast walkers, and irremovable cast walkers, and we conducted a 5-year budget impact analysis. Finally, we interviewed people with diabetes who had lived experience with foot ulcers, asking them about the different offloading devices and the factors that influenced their treatment choices. Results We identified 13 randomized controlled trials. The evidence suggests that total contact casting, removable cast walkers, and irremovable cast walkers are beneficial in the treatment of neuropathic, noninfected foot ulcers in patients with diabetes but without severe peripheral arterial disease. Compared to removable cast walkers, ulcer healing was improved with total contact casting (moderate quality evidence; risk difference 0.17 [95% confidence interval 0.00–0.33]) and irremovable cast walkers (low quality evidence; risk difference 0.21 [95% confidence interval 0.01–0.40]). We found no difference in ulcer healing between total contact casting and irremovable cast walkers (low quality evidence; risk difference 0.02 [95% confidence interval −0.11–0.14]). The economic analysis showed that total contact casting and irremovable cast walkers were less expensive and led to more health outcome gains (e.g., ulcers healed and quality-adjusted life-years) than removable cast walkers. Irremovable cast walkers were as effective as total contact casting and were associated with lower costs. The 5-year budget impact of funding total contact casting, removable cast walkers, and irremovable cast walkers (device costs only at 100% access) would be $17 to $20 million per year. The patients we interviewed felt that wound healing was improved with total contact casting than with removable cast walkers, but that removable cast walkers were more convenient and came with a lower cost burden. They reported no experience or familiarity with irremovable cast walkers. Conclusions Ulcer healing improved with total contact casting, irremovable cast walkers, and removable cast walkers, but total contact casting and irremovable cast walkers had higher rates of ulcer healing than removable cast walkers. Increased access to offloading devices could result in cost savings for the health system because of fewer amputations. Patients with diabetic foot ulcers reported a preference for total contact casting over removable cast walkers, largely because they perceived wound healing to be improved with total contact casting. However, cost, comfort, and convenience are concerns for patients. PMID:28989556

Fibreglass Total Contact Casting, Removable Cast Walkers, and Irremovable Cast Walkers to Treat Diabetic Neuropathic Foot Ulcers: A Health Technology Assessment.

PubMed

2017-01-01

Diabetic neuropathic foot ulcers are a risk factor for lower leg amputation. Many experts recommend offloading with fibreglass total contact casting, removable cast walkers, and irremovable cast walkers as a way to treat these ulcers. We completed a health technology assessment, which included an evaluation of clinical benefits and harms, value for money, and patient preferences for offloading devices. We performed a systematic literature search on August 17, 2016, to identify randomized controlled trials that compared fibreglass total contact casting, removable cast walkers, and irremovable cast walkers with other treatments (offloading or non-offloading) in patients with diabetic neuropathic foot ulcers. We developed a decision-analytic model to assess the cost-effectiveness of fibreglass total contact casting, removable cast walkers, and irremovable cast walkers, and we conducted a 5-year budget impact analysis. Finally, we interviewed people with diabetes who had lived experience with foot ulcers, asking them about the different offloading devices and the factors that influenced their treatment choices. We identified 13 randomized controlled trials. The evidence suggests that total contact casting, removable cast walkers, and irremovable cast walkers are beneficial in the treatment of neuropathic, noninfected foot ulcers in patients with diabetes but without severe peripheral arterial disease. Compared to removable cast walkers, ulcer healing was improved with total contact casting (moderate quality evidence; risk difference 0.17 [95% confidence interval 0.00-0.33]) and irremovable cast walkers (low quality evidence; risk difference 0.21 [95% confidence interval 0.01-0.40]). We found no difference in ulcer healing between total contact casting and irremovable cast walkers (low quality evidence; risk difference 0.02 [95% confidence interval -0.11-0.14]). The economic analysis showed that total contact casting and irremovable cast walkers were less expensive and led to more health outcome gains (e.g., ulcers healed and quality-adjusted life-years) than removable cast walkers. Irremovable cast walkers were as effective as total contact casting and were associated with lower costs. The 5-year budget impact of funding total contact casting, removable cast walkers, and irremovable cast walkers (device costs only at 100% access) would be $17 to $20 million per year. The patients we interviewed felt that wound healing was improved with total contact casting than with removable cast walkers, but that removable cast walkers were more convenient and came with a lower cost burden. They reported no experience or familiarity with irremovable cast walkers. Ulcer healing improved with total contact casting, irremovable cast walkers, and removable cast walkers, but total contact casting and irremovable cast walkers had higher rates of ulcer healing than removable cast walkers. Increased access to offloading devices could result in cost savings for the health system because of fewer amputations. Patients with diabetic foot ulcers reported a preference for total contact casting over removable cast walkers, largely because they perceived wound healing to be improved with total contact casting. However, cost, comfort, and convenience are concerns for patients.

A Review of Permanent Magnet Stirring During Metal Solidification

NASA Astrophysics Data System (ADS)

Zeng, Jie; Chen, Weiqing; Yang, Yindong; Mclean, Alexander

2017-12-01

Rather than using conventional electromagnetic stirring (EMS) with three-phase alternating current, permanent magnet stirring (PMS), based on the use of sintered NdFeB material which has excellent magnetic characteristics, can be employed to generate a magnetic field for the stirring of liquid metal during solidification. Recent experience with steel casting indicates that PMS requires less than 20 pct of the total energy compared with EMS. Despite the excellent magnetic density properties and low power consumption, this relatively new technology has received comparatively little attention by the metal casting community. This paper reviews simulation modeling, experimental studies, and industrial trials of PMS conducted during recent years. With the development of magnetic simulation software, the magnetic field and associated flow patterns generated by PMS have been evaluated. Based on the results obtained from laboratory experiments, the effects of PMS on metal solidification structures and typical defects such as surface pinholes and center cavities are summarized. The significance of findings obtained from trials of PMS within the metals processing sector, including the continuous casting of steel, are discussed with the aim of providing an overview of the relevant parameters that are of importance for further development and industrial application of this innovative technology.

Anechoic chamber in industrial plants. [construction materials and structural design

NASA Technical Reports Server (NTRS)

Halpert, E.; Juncu, O.; Lorian, R.; Marfievici, D.; Mararu, I.

1974-01-01

A light anechoic chamber for routine acoustical measurements in the machine building industry is reported. The outer housing of the chamber consists of modules cast in glass fiber reinforced polyester resin; the inner housing consists of pyramidal modules cut out of sound absorbing slates. The parameters of this anechoic chamber facilitate acoustical measurements according to ISO and CAEM recommendations.

Energy Saving Melting and Revert Reduction Technology (Energy SMARRT): Manufacturing Advanced Engineered Components Using Lost Foam Casting Technology

DOE Office of Scientific and Technical Information (OSTI.GOV)

Littleton, Harry; Griffin, John

2011-07-31

This project was a subtask of Energy Saving Melting and Revert Reduction Technology (Energy SMARRT) Program. Through this project, technologies, such as computer modeling, pattern quality control, casting quality control and marketing tools, were developed to advance the Lost Foam Casting process application and provide greater energy savings. These technologies have improved (1) production efficiency, (2) mechanical properties, and (3) marketability of lost foam castings. All three reduce energy consumption in the metals casting industry. This report summarizes the work done on all tasks in the period of January 1, 2004 through June 30, 2011. Current (2011) annual energy savingmore » estimates based on commercial introduction in 2011 and a market penetration of 97% by 2020 is 5.02 trillion BTU's/year and 6.46 trillion BTU's/year with 100% market penetration by 2023. Along with these energy savings, reduction of scrap and improvement in casting yield will result in a reduction of the environmental emissions associated with the melting and pouring of the metal which will be saved as a result of this technology. The average annual estimate of CO2 reduction per year through 2020 is 0.03 Million Metric Tons of Carbon Equivalent (MM TCE).« less

FE Modelling of Tensile and Impact Behaviours of Squeeze Cast Magnesium Alloy AM60

NASA Astrophysics Data System (ADS)

DiCecco, Sante; Altenhof, William; Hu, Henry

In response to the need for reduced global emissions, the transportation industry has been steadily increasing the magnesium content in vehicles. This trend has resulted in experimental documentation of numerous alloy and casting combinations, while comparatively little work has been done regarding the development of numerical material models for vehicle crashworthiness simulations. In this study, material mechanical behaviour was implemented into an existing material model within the nonlinear FEA code LS-DYNA to emulate the mechanical behaviour of squeeze cast magnesium alloy AM60 with a relatively thick section of 10 mm thickness. Model validation was achieved by comparing the numerical and experimental results of a tensile test and Charpy impact event. Validation found an average absolute error of 5.44% between numerical and experimental tensile test data, whereas a relatively large discrepancy was found during Charpy evaluation. This discrepancy has been attributed to the presence of microstructure inhomogeneity in the squeeze cast magnesium alloy AM60.

Producing thin strips by twin-roll casting—part I: Process aspects and quality issues

NASA Astrophysics Data System (ADS)

Li, Ben Q.

1995-05-01

This two-part paper discusses recent advances in research and development for the direct production of coilable thin strips by twin-roll casting in both the aluminum and steel industries. While the former is empowering the casters to approach the theoretical productivity limit, the latter is striving to put pilot casters into commercial operation. These intensive R&D efforts are derived from the advantages, both economic and metallurgical, offered by the process. As twin-roll casting combines solidification and hot rolling into a single operation, the process requires low capital investment and low operational cost. Also, because of the high solidification rate attained in the process, the thin strips produced have a refined metallurgical structure, characterized by columnar and equiaxed zones with fine intermetallic particles. The enthusiasm about twin-roll casting is now being spread worldwide. This paper focuses on the process aspects and quality control of twin-roll casting. Part II, which will appear in the August issue, will review process modeling and pilot-plant development activities.

Virtual aluminum castings: An industrial application of ICME

NASA Astrophysics Data System (ADS)

Allison, John; Li, Mei; Wolverton, C.; Su, Xuming

2006-11-01

The automotive product design and manufacturing community is continually besieged by Hercule an engineering, timing, and cost challenges. Nowhere is this more evident than in the development of designs and manufacturing processes for cast aluminum engine blocks and cylinder heads. Increasing engine performance requirements coupled with stringent weight and packaging constraints are pushing aluminum alloys to the limits of their capabilities. To provide high-quality blocks and heads at the lowest possible cost, manufacturing process engineers are required to find increasingly innovative ways to cast and heat treat components. Additionally, to remain competitive, products and manufacturing methods must be developed and implemented in record time. To bridge the gaps between program needs and engineering reality, the use of robust computational models in up-front analysis will take on an increasingly important role. This article describes just such a computational approach, the Virtual Aluminum Castings methodology, which was developed and implemented at Ford Motor Company and demonstrates the feasibility and benefits of integrated computational materials engineering.

Research on Soft Reduction Amount Distribution to Eliminate Typical Inter-dendritic Crack in Continuous Casting Slab of X70 Pipeline Steel by Numerical Model

NASA Astrophysics Data System (ADS)

Liu, Ke; Wang, Chang; Liu, Guo-liang; Ding, Ning; Sun, Qi-song; Tian, Zhi-hong

2017-04-01

To investigate the formation of one kind of typical inter-dendritic crack around triple point region in continuous casting(CC) slab during the operation of soft reduction, fully coupled 3D thermo-mechanical finite element models was developed, also plant trials were carried out in a domestic continuous casting machine. Three possible types of soft reduction amount distribution (SRAD) in the soft reduction region were analyzed. The relationship between the typical inter-dendritic cracks and soft reduction conditions is presented and demonstrated in production practice. Considering the critical strain of internal crack formation, a critical tolerance for the soft reduction amount distribution and related casing parameters have been proposed for better contribution of soft reduction to the internal quality of slabs. The typical inter-dendritic crack around the triple point region had been eliminated effectively through the application of proposed suggestions for continuous casting of X70 pipeline steel in industrial practice.

Comparison of cast materials for the treatment of congenital idiopathic clubfoot using the Ponseti method: a prospective randomized controlled trial

PubMed Central

Hui, Catherine; Joughin, Elaine; Nettel-Aguirre, Alberto; Goldstein, Simon; Harder, James; Kiefer, Gerhard; Parsons, David; Brauer, Carmen; Howard, Jason

2014-01-01

Background The Ponseti method of congenital idiopathic clubfoot correction has traditionally specified plaster of Paris (POP) as the cast material of choice; however, there are negative aspects to using POP. We sought to determine the influence of cast material (POP v. semirigid fibreglass [SRF]) on clubfoot correction using the Ponseti method. Methods Patients were randomized to POP or SRF before undergoing the Ponseti method. The primary outcome measure was the number of casts required for clubfoot correction. Secondary outcome measures included the number of casts by severity, ease of cast removal, need for Achilles tenotomy, brace compliance, deformity relapse, need for repeat casting and need for ancillary surgical procedures. Results We enrolled 30 patients: 12 randomized to POP and 18 to SRF. There was no difference in the number of casts required for clubfoot correction between the groups (p = 0.13). According to parents, removal of POP was more difficult (p < 0.001), more time consuming (p < 0.001) and required more than 1 method (p < 0.001). At a final follow-up of 30.8 months, the mean times to deformity relapse requiring repeat casting, surgery or both were 18.7 and 16.4 months for the SRF and POP groups, respectively. Conclusion There was no significant difference in the number of casts required for correction of clubfoot between the 2 materials, but SRF resulted in a more favourable parental experience, which cannot be ignored as it may have a positive impact on psychological well-being despite the increased cost associated. PMID:25078929

A low cost hermetic packaging for high power industry fiber lasers

NASA Astrophysics Data System (ADS)

Ding, Jianwu; Liu, Jinhui

2018-02-01

For water-cooled fiber lasers, humidity and the resulting water-condensation has always been the biggest threat for laser reliability or power degradation, especially when used in harsh industrial environment. Here we present an innovative fiber laser packaging method featuring cast aluminum frame and an almost screw-free exterior packaging. A CW fiber laser with 1.5KW laser output power in such a compact and light-weight package has been demonstrated with an excellent beam quality and power stability for industry applications.

3D analysis of macrosegregation in twin-roll cast AA3003 alloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Šlapáková, Michaela, E-mail: slapakova@karlov.mff.

Twin-roll cast aluminium alloys have a high potential for industrial applications. However, one of the drawbacks of such materials is an inhomogeneous structure generated by macrosegregation, which appears under certain conditions in the center of sheets during solidification. Segregations in AA3003 alloy form as manganese, iron and silicon rich channels spread in the rolling direction. Their spatial distribution was successfully detected by X-ray computed tomography. Scanning electron microscopy was used for a detailed observation of microstructure, morphology and chemical analysis of the segregation. - Highlights: •Macrosegregations in twin-roll cast sheets stretch along the rolling direction. •X-ray computed tomography is anmore » effective tool for visualization of the segregation. •The segregations copy the shape of grain boundaries.« less

The Influence of Vanadium Microalloying on the Production of Thin Slab Casting and Direct Rolled Steel Strip

NASA Astrophysics Data System (ADS)

Li, Yu; Milbourn, David

Vanadium microalloying is highly effective in high strength strip steels produced by thin slab casting and direct rolled process. Because of the high solubility of V(C,N) in austenite, vanadium is likely to remain in solution during casting, equalisation and rolling. Vanadium microalloyed steels have better hot ductility and are less prone to transverse cracking than niobium containing steels. Despite a coarse as-cast austenite grain size before rolling, significant grain refinement can be achieved in vanadium microalloyed steels by repeated recrystallization during rolling, resulting in a fine uniform ferrite microstructure in final strip. Almost all vanadium present in microalloyed steels is available to precipitate in ferrite as very fine particles, contributing to precipitation strengthening. Vanadium microalloyed steels show less sensitivity to rolling process variables and exhibit excellent combination of strength and toughness.

Background and survey of bioreplication techniques.

PubMed

Pulsifer, Drew Patrick; Lakhtakia, Akhlesh

2011-09-01

Bioreplication is the direct reproduction of a biological structure in order to realize at least one specific functionality. Current bioreplication techniques include the sol-gel technique, atomic layer deposition, physical vapor deposition, and imprint lithography and casting. The combined use of a focused ion beam and a scanning electron microscope could develop into a bioreplication technique as well. Some of these techniques are more suitable for reproducing surface features, others for bulk three-dimensional structures. Industrial upscaling appears possible only for imprint lithography and casting (which can be replaced by stamping).

Origin of Toughness in Dispersion-Cast Nafion Membranes

DOE PAGES

Kim, Yu Seung; Welch, Cynthia F.; Hjelm, Rex Paul; ...

2015-03-23

In this study, the gelation behavior of Nafion dispersions was investigated using small-angle neutron scattering to better understand the mechanical toughness of dispersion-cast Nafion membranes. Three types of gelation were observed, depending on dispersing fluids: (i) homogeneous, thermally reversible gelation that was present in most aprotic polar dispersing fluids; (ii) inhomogeneous, thermally irreversible gelation as films, found in alcohols; and (iii) inhomogeneous, thermally irreversible gelation which precipitates in water/monohydric alcohol mixtures. The mechanical toughness of dispersion-cast Nafion membranes depends on the dispersing fluid, varying by more than 4 orders of magnitude. Excellent correlation between the critical gelation concentration and mechanicalmore » toughness was demonstrated with the Nafion membranes cast at 140 °C. Additional thermal effects among Nafion membranes cast at 190 °C were qualitatively related to the boiling point of dispersing fluids. Little correlation between mechanical toughness and percent crystalline area of Nafion was observed, suggesting that the origin of mechanical toughness of dispersion-cast Nafion membranes is due to chain entanglements rather than crystallinity. Finally, the correlation between critical gelation concentration and mechanical toughness is a new way of predicting mechanical behavior in dispersion-cast polymer systems in which both polymer-dispersing fluid and polymer–polymer interactions play a significant role in the formation of polymer chain entanglements.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Asmussen, R. Matthew; Pearce, Carolyn I.; Miller, Brian W.

A cementitious waste form, Cast Stone, is a possible candidate technology for the immobilization of low activity nuclear waste (LAW) at the Hanford site. This paper focuses on the addition of getter materials to Cast Stone that can sequester Tc from the LAW, and in turn, lower Tc release from the Cast Stone. Two getters which produce different products upon sequestering Tc from LAW were tested: Sn(II) apatite (Sn-A) that removes Tc as a Tc(IV)-oxide and potassium metal sulfide (KMS-2) that removes Tc as a Tc(IV)-sulfide species, allowing for a comparison of stability of the form of Tc upon enteringmore » the waste form. The Cast Stone with KMS-2 getter had the best performance with addition equivalent to ~0.08 wt% of the total waste form mass. The observed diffusion (D obs) of Tc decreased from 4.6 ± 0.2 × 10 -12 cm 2/s for Cast Stone that did not contain a getter to 5.4 ± 0.4 × 10 -13 cm 2/s for KMS-2 containing Cast Stone. Finally, it was found that Tc-sulfide species are more stable against re-oxidation within getter containing Cast Stone compared with Tc-oxide and is the origin of the decrease in Tc D obs when using the KMS-2.« less

Energy Saving Melting and Revert Reduction Technology (Energy-SMARRT): Clean Steel Casting Production

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kuyucak, Selcuk; Li, Delin

2013-12-31

Inclusions in steel castings can cause rework, scrap, poor machining, and reduced casting performance, which can obviously result in excess energy consumption. Significant progress in understanding inclusion source, formation and control has been made. Inclusions can be defined as non-metallic materials such as refractory, sand, slag, or coatings, embedded in a metallic matrix. This research project has focused on the mold filling aspects to examine the effects of pouring methods and gating designs on the steel casting cleanliness through water modeling, computer modeling, and melting/casting experiments. Early in the research project, comprehensive studies of bottom-pouring water modeling and low-alloy steelmore » casting experiments were completed. The extent of air entrainment in bottom-poured large castings was demonstrated by water modeling. Current gating systems are designed to prevent air aspiration. However, air entrainment is equally harmful and no prevention measures are in current practice. In this study, new basin designs included a basin dam, submerged nozzle, and nozzle extension. The entrained air and inclusions from the gating system were significantly reduced using the new basin method. Near the end of the project, there has been close collaboration with Wescast Industries Inc., a company manufacturing automotive exhaust components. Both computer modeling using Magma software and melting/casting experiments on thin wall turbo-housing stainless steel castings were completed in this short period of time. Six gating designs were created, including the current gating on the pattern, non-pressurized, partially pressurized, naturally pressurized, naturally pressurized without filter, and radial choke gating without filter, for Magma modeling. The melt filling velocity and temperature were determined from the modeling. Based on the simulation results, three gating designs were chosen for further melting and casting experiments on the same casting pattern using the lip pouring method. It was observed again that gating designs greatly influenced the melt filling velocity and the number of inclusion defects. The radial choked gating showed improvements in casting cleanliness and yield over the other gatings, even though no mold filters were used in the gating system.« less

Failure analysis of an aluminum alloy material framework component induced by casting defects

NASA Astrophysics Data System (ADS)

Li, Bo; Hu, Weiye

2017-09-01

Failure analysis on a fractured radome framework component was carried out through visual observations, metallographic examination using optical microscope, fractog-raphy inspections using scanning electron microscope and chemical composition analysis. The failed frame was made of casting Al-Si7-Mg0.4 aluminum alloy. It had suffered a former vi-bration performance tests. It was indicated that the fractures were attributed to fatigue cracks which were induced by casting porosities at the outer surfaces of frame. Failure analysis was carefully conducted for the semi-penetrating crack appearing on the framework. According to the fractography inspected by scanning electron microscope, it was indicated that numerous casting porosities at the outer surface of the framework played the role of multiple fracture sources due to some applied stresses. Optical microstructure observations suggested that the dendrite-shaped casting porosities largely contributed to the crack-initiation. The groove-shaped structure at roots of spatial convex-bodies on the edge of casting porosities supplied the preferred paths of the crack-propagation. Besides, the brittle silicon eutectic particles distrib-uting along grain boundaries induced the intergranular fracture mode in the region of the over-load final fracture surface.

Probabilistic graphlet transfer for photo cropping.

PubMed

Zhang, Luming; Song, Mingli; Zhao, Qi; Liu, Xiao; Bu, Jiajun; Chen, Chun

2013-02-01

As one of the most basic photo manipulation processes, photo cropping is widely used in the printing, graphic design, and photography industries. In this paper, we introduce graphlets (i.e., small connected subgraphs) to represent a photo's aesthetic features, and propose a probabilistic model to transfer aesthetic features from the training photo onto the cropped photo. In particular, by segmenting each photo into a set of regions, we construct a region adjacency graph (RAG) to represent the global aesthetic feature of each photo. Graphlets are then extracted from the RAGs, and these graphlets capture the local aesthetic features of the photos. Finally, we cast photo cropping as a candidate-searching procedure on the basis of a probabilistic model, and infer the parameters of the cropped photos using Gibbs sampling. The proposed method is fully automatic. Subjective evaluations have shown that it is preferred over a number of existing approaches.

Interlocking multi-material components made of structured steel sheets and high-pressure die cast aluminium

NASA Astrophysics Data System (ADS)

Senge, S.; Brachmann, J.; Hirt, G.; Bührig-Polaczek, A.

2017-10-01

Lightweight design is a major driving force of innovation, especially in the automotive industry. Using hybrid components made of two or more different materials is one approach to reduce the vehicles weight and decrease fuel consumption. As a possible way to increase the stiffness of multi-material components, this paper presents a process chain to produce such components made of steel sheets and high-pressure die cast aluminium. Prior to the casting sequence the steel sheets are structured in a modified rolling process which enables continuous interlocking with the aluminium. Two structures manufactured by this rolling process are tested. The first one is a channel like structure and the second one is a channel like structure with undercuts. These undercuts enable the formation of small anchors when the molten aluminium fills them. The correlation between thickness reduction during rolling and the shape of the resulting structure was evaluated for both structures. It can be stated that channels with a depth of up to 0.5 mm and a width of 1 mm could be created. Undercuts with different size depending on the thickness reduction could be realised. Subsequent aluminium high-pressure die casting experiments were performed to determine if the surface structure can be filled gap-free with molten aluminium during the casting sequence and if a gap-free connection can be achieved after contraction of the aluminium. The casting experiments showed that both structures could be filled during the high-pressure die casting. The channel like structure results in a gap between steel and aluminium after contraction of the cast metal whereas the structure with undercuts leads to a good interlocking resulting in a gap-free connection.

Materials for Advanced Ultrasupercritical Steam Turbines Task 4: Cast Superalloy Development

DOE Office of Scientific and Technical Information (OSTI.GOV)

Thangirala, Mani

The Steam Turbine critical stationary structural components are high integrity Large Shell and Valve Casing heavy section Castings, containing high temperature steam under high pressures. Hence to support the development of advanced materials technology for use in an AUSC steam turbine capable of operating with steam conditions of 760°C (1400°F) and 35 Mpa (5000 psia), Casting alloy selection and evaluation of mechanical, metallurgical properties and castability with robust manufacturing methods are mandated. Alloy down select from Phase 1 based on producability criteria and creep rupture properties tested by NETL-Albany and ORNL directed the consortium to investigate cast properties of Haynesmore » 282 and Haynes 263. The goals of Task 4 in Phase 2 are to understand a broader range of mechanical properties, the impact of manufacturing variables on those properties. Scale up the size of heats to production levels to facilitate the understanding of the impact of heat and component weight, on metallurgical and mechanical behavior. GE Power & Water Materials and Processes Engineering for the Phase 2, Task 4.0 Castings work, systematically designed and executed casting material property evaluation, multiple test programs. Starting from 15 lbs. cylinder castings to world’s first 17,000 lbs. poured weight, heavy section large steam turbine partial valve Haynes 282 super alloy casting. This has demonstrated scalability of the material for steam Turbine applications. Activities under Task 4.0, Investigated and characterized various mechanical properties of Cast Haynes 282 and Cast Nimonic 263. The development stages involved were: 1) Small Cast Evaluation: 4 inch diam. Haynes 282 and Nimonic 263 Cylinders. This provided effects of liquidus super heat range and first baseline mechanical data on cast versions of conventional vacuum re-melted and forged Ni based super alloys. 2) Step block castings of 300 lbs. and 600 lbs. Haynes 282 from 2 foundry heats were evaluated which demonstrated the importance of proper heat treat cycles for Homogenization, and Solutionizing parameters selection and implementation. 3) Step blocks casting of Nimonic 263: Carried out casting solidification simulation analysis, NDT inspection methods evaluation, detailed test matrix for Chemical, Tensile, LCF, stress rupture, CVN impact, hardness and J1C Fracture toughness section sensitivity data and were reported. 4) Centrifugal Casting of Haynes 282, weighing 1400 lbs. with hybrid mold (half Graphite and half Chromite sand) mold assembly was cast using compressor casing production tooling. This test provided Mold cooling rates influence on centrifugally cast microstructure and mechanical properties. Graphite mold section out performs sand mold across all temperatures for 0.2% YS; %Elongation, %RA, UTS at 1400°F. Both Stress-LMP and conditional Fracture toughness plots data were in the scatter band of the wrought alloy. 5) Fundamental Studies on Cooling rates and SDAS test program. Evaluated the influence of 6 mold materials Silica, Chromite, Alumina, Silica with Indirect Chills, Zircon and Graphite on casting solidification cooling rates. Actual Casting cooling rates through Liquidus to Solidus phase transition were measured with 3 different locations based thermocouples placed in each mold. Compared with solidification simulation cooling rates and measurement of SDAS, microstructure features were reported. The test results provided engineered casting potential methods, applicable for heavy section Haynes 282 castings for optimal properties, with foundry process methods and tools. 6) Large casting of Haynes 282 Drawings and Engineering FEM models and supplemental requirements with applicable specifications were provided to suppliers for the steam turbine proto type feature valve casing casting. Molding, melting and casting pouring completed per approved Manufacturing Process Plan during 2014 Q4. The partial valve casing was successfully cast after casting methods were validated with solidification simulation analysis and the casting met NDT inspection and acceptance criteria. Heat treated and sectioned to extract trepan samples at different locations comparing with cast on coupons test data. Material properties requisite for design, such as tensile, creep/rupture, LCF, Fracture Toughness, Charpy V-notch chemical analysis testing were carried out. The test results will be presented in the final report. The typical Haynes 282 large size Steam Turbine production casting from Order to Delivery foundry schedule with the activity break up is shown in Figures 107 and 108. • From Purchase Order placement to Casting pouring ~ 26 weeks. 1. Sales and commercial review 3 2. Engineering Drawings/models review 4 3. Pattern and core box manufacturing 6 4. Casting process engineering review 4 5. FEM and solidification simulation analysis 4 6. Gating & Feeder Attachments, Ceramic tiling 2 7. Molding and coremaking production scheduling 6 8. Melting planning and schedule 3 9. Pouring, cooling and shake out 2 • From Pouring to casting Delivery ~ 29 weeks 10. Shot blast and riser cutting, gates removal 3 11. Homogenizing , solutionizing HT furnace prep 4 12. Grinding, Fettling 2 13. Aging HT Cycle, cooling 2 14. VT and LPT NDT inspections 2 15. Radiographic inspection 4 16. Mechanical testing, Chemical analysis test certs 4 17. Casting weld repair upgrades and Aging PWHT 4 18. NDT after weld repairs and casting upgrades 3 19. Casting Final Inspection and test certifications 3 20. Package and delivery 2 Hence the Total Lead time from P.O to Casting delivery is approximately 55 weeks. The Task 4.2 and Task 4.3 activities and reporting completed.« less

A Theoretical Analysis of the Interaction Between Pores and Inclusions During the Continuous Casting of Steel

NASA Astrophysics Data System (ADS)

Nick, Arash Safavi; Vynnycky, Michael; Fredriksson, Hasse

2016-06-01

A mathematical model is derived to predict the trajectories of pores and inclusions that are nucleated in the interdendritic region during the continuous casting of steel. Using basic fluid mechanics and heat transfer, scaling analysis, and asymptotic methods, the model accounts for the possible lateral drift of the pores as a result of the dependence of the surface tension on temperature and sulfur concentration. Moreover, the soluto-thermocapillary drift of such pores prior to final solidification, coupled to the fact that any inclusions present can only have a vertical trajectory, can help interpret recent experimental observations of pore-inclusion clusters in solidified steel castings.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ayala, Alicia; Corral, Erica L.; Loehman, Ronald E.

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,more » 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.« less

Treatment outcomes in 4 modes of orthodontic practice.

PubMed

Poulton, Donald; Vlaskalic, Vicki; Baumrind, Sheldon

2005-03-01

This study is a continuation of a previously published report on the outcome of orthodontic treatment provided in offices representing different modes of practice. The sample consisted of duplicate pretreatment (T1) and posttreatment (T2) dental casts of 348 patients from traditional private orthodontic practices (5 offices, 134 patients), company-owned practices (5 offices, 107 patients), offices associated with practice-management organizations (2 offices, 60 patients), and general dental practices (2 offices, 47 patients). Methods were used to obtain random, representative samples from each office, starting with lists of patients who were treated consecutively with full fixed orthodontic appliances. The dental casts were measured by 2 independent judges who used the unweighted PAR score. Good interjudge agreement was shown on the initial casts, but the agreement was not as strong on the final casts. The measurements showed that treatment outcomes were generally satisfactory, although some significant differences between offices and management modes were shown.

A Study of the Oscillation Marks' Characteristics of Continuously Cast Incoloy Alloy 825 Blooms

NASA Astrophysics Data System (ADS)

Saleem, Saud; Vynnycky, Michael; Fredriksson, Hasse

2016-08-01

A comprehensive experimental study of oscillation mark (OM) formation and its characteristics during the solidification of Incoloy alloy 825 in the continuous casting of blooms is investigated by plant trials and metallographic study. The experiments involved two heats with the same casting and mold conditions and sampling at different locations across the strand. The metallographic study combined macro/micro-examinations of OMs and segregation analysis of Cr, Mn, Mo, Ni, and Si by microprobe analysis. The results show that OMs have widely different characteristics, such as mark type, depth, segregation, and accompanying microstructure. Furthermore, the mark pitch can vary considerably even for the similar casting conditions, leading to different conditions for the marks' formation in relation to the mold's cyclic movement. Finally, a mechanism for the OM formation is discussed and proposed. Possible solutions for minimizing the observed defects by optimizing the mold conditions are suggested.

Further studies on gold alloys used in fabrication of porcelain-fused-to-metal restorations.

PubMed

Civjan, S; Huget, E F; Dvivedi, N; Cosner, H J

1975-03-01

Composition, microstructure, castability, mechanical properties, and heat treatment characteristics of two gold-palladium-silver-based alloys were studied. The materials exhibited compositional as well as microstructural differences. Clinically acceptable castings could not be obtained when manufacturers' recommended casting temperatures were used. Ultimate tensile strength, yield strength, modulus of elasticity, and Brinell hardness values for the alloys were comparable. The elastic limit of Cameo, however, was significantly higher than that of vivo-star. Maximum rehardening of annealed castings occurred on reheat treatment at temperatures between 1,200 and 1,300 F. As-cast specimens, however, were not heat hardenable. The sequence of heat treatments used in the application of porcelain reduced slightly the hardness of both alloys. Hardness of the metal substructures was not increased by return of porcelain-coated specimens to a 1,250 F oven for final heat treatment.

Slip casting and extruding shapes of rhenium with metal oxide additives. 1: Feasibility demonstration

NASA Technical Reports Server (NTRS)

Barr, F. A.; Page, R. J.

1986-01-01

The feasibility of fabricating small rhenium parts with metal oxide additives by means of slip casting and extrusion techniques is described. The metal oxides, ZrO2 and HfO2 were stabilized into the cubic phase with Y2O3. Additions of metal oxide to the rhenium of up to 15 weight percent were used. Tubes of 17 mm diameter with 0.5 mm walls were slip cast by adapting current ceramic oxide techniques. A complete cast double conical nozzle demonstrated the ability to meet shapes and tolerances. Extrusion of meter long tubing lengths of 3.9 mm o.d. x 2.3 mm i.d. final dimension is documented. Sintering schedules are presented to produce better than 95% of theoretical density parts. Finished machining was found possible were requried by electric discharge machining and diamond grinding.

An investigation of industrial molding compounds for use in 3D ultrasound, MRI, and CT imaging phantoms.

PubMed

Yunker, Bryan E; Cordes, Dietmar; Scherzinger, Ann L; Dodd, Gerald D; Shandas, Robin; Feng, Yusheng; Hunter, Kendall S

2013-05-01

This study investigated the ultrasound, MRI, and CT imaging characteristics of several industrial casting and molding compounds as a precursor to the future development of durable and anatomically correct flow phantoms. A set of usability and performance criteria was established for a proposed phantom design capable of supporting liquid flow during imaging. A literature search was conducted to identify the materials and methods previously used in phantom fabrication. A database of human tissue and casting material properties was compiled to facilitate the selection of appropriate materials for testing. Several industrial casting materials were selected, procured, and used to fabricate test samples that were imaged with ultrasound, MRI, and CT. Five silicones and one polyurethane were selected for testing. Samples of all materials were successfully fabricated. All imaging modalities were able to discriminate between the materials tested. Ultrasound testing showed that three of the silicones could be imaged to a depth of at least 2.5 cm (1 in.). The RP-6400 polyurethane exhibited excellent contrast and edge detail for MRI phantoms and appears to be an excellent water reference for CT applications. The 10T and 27T silicones appear to be usable water references for MRI imaging. Based on study data and the stated selection criteria, the P-4 silicone provided sufficient material contrast to water and edge detail for use across all imaging modalities with the benefits of availability, low cost, dimensional stability, nontoxic, nonflammable, durable, cleanable, and optical clarity. The physical and imaging differences of the materials documented in this study may be useful for other applications.

Electrochemical Study of Polymer and Ceramic-Based Nanocomposite Coatings for Corrosion Protection of Cast Iron Pipeline

PubMed Central

Ammar, Ameen Uddin; Shahid, Muhammad; Ahmed, Muhammad Khitab; Khan, Munawar; Khalid, Amir

2018-01-01

Coating is one of the most effective measures to protect metallic materials from corrosion. Various types of coatings such as metallic, ceramic and polymer coatings have been investigated in a quest to find durable coatings to resist electrochemical decay of metals in industrial applications. Many polymeric composite coatings have proved to be resistant against aggressive environments. Two major applications of ferrous materials are in marine environments and in the oil and gas industry. Knowing the corroding behavior of ferrous-based materials during exposure to these aggressive applications, an effort has been made to protect the material by using polymeric and ceramic-based coatings reinforced with nano materials. Uncoated and coated cast iron pipeline material was investigated during corrosion resistance by employing EIS (electrochemical impedance spectroscopy) and electrochemical DC corrosion testing using the “three electrode system”. Cast iron pipeline samples were coated with Polyvinyl Alcohol/Polyaniline/FLG (Few Layers Graphene) and TiO2/GO (graphene oxide) nanocomposite by dip-coating. The EIS data indicated better capacitance and higher impedance values for coated samples compared with the bare metal, depicting enhanced corrosion resistance against seawater and “produce water” of a crude oil sample from a local oil rig; Tafel scans confirmed a significant decrease in corrosion rate of coated samples. PMID:29495339

Electrochemical Study of Polymer and Ceramic-Based Nanocomposite Coatings for Corrosion Protection of Cast Iron Pipeline.

PubMed

Ammar, Ameen Uddin; Shahid, Muhammad; Ahmed, Muhammad Khitab; Khan, Munawar; Khalid, Amir; Khan, Zulfiqar Ahmad

2018-02-25

Coating is one of the most effective measures to protect metallic materials from corrosion. Various types of coatings such as metallic, ceramic and polymer coatings have been investigated in a quest to find durable coatings to resist electrochemical decay of metals in industrial applications. Many polymeric composite coatings have proved to be resistant against aggressive environments. Two major applications of ferrous materials are in marine environments and in the oil and gas industry. Knowing the corroding behavior of ferrous-based materials during exposure to these aggressive applications, an effort has been made to protect the material by using polymeric and ceramic-based coatings reinforced with nano materials. Uncoated and coated cast iron pipeline material was investigated during corrosion resistance by employing EIS (electrochemical impedance spectroscopy) and electrochemical DC corrosion testing using the "three electrode system". Cast iron pipeline samples were coated with Polyvinyl Alcohol/Polyaniline/FLG (Few Layers Graphene) and TiO₂/GO (graphene oxide) nanocomposite by dip-coating. The EIS data indicated better capacitance and higher impedance values for coated samples compared with the bare metal, depicting enhanced corrosion resistance against seawater and "produce water" of a crude oil sample from a local oil rig; Tafel scans confirmed a significant decrease in corrosion rate of coated samples.

75 FR 54596 - Final Results of Expedited Sunset Review: Heavy Iron Construction Castings from Brazil

Federal Register 2010, 2011, 2012, 2013, 2014

2010-09-08

... DEPARTMENT OF COMMERCE International Trade Administration [C-351-504] Final Results of Expedited... pursuant to section 751(c)(3)(B) of the Act and 19 CFR 351.218(e)(1)(ii)(B). As a result of this sunset... recurrence of a countervailable subsidy at the level indicated in the ``Final Results of Review'' section of...

The role of serial casting in early-onset scoliosis (EOS).

PubMed

Baulesh, David M; Huh, Jeannie; Judkins, Timothy; Garg, Sumeet; Miller, Nancy H; Erickson, Mark A

2012-01-01

Serial casting has demonstrated efficacy for idiopathic early-onset scoliosis (EOS). Results of casting in nonidiopathic (syndromic and congenital) EOS patients have not previously been well described. A total of 53 patients underwent serial casting for EOS from 2005 to 2010 at a single institution. Deformity was classified as idiopathic or nonidiopathic. Diagnosis, time in cast, number of casts, use of bracing, complications, and outcomes were recorded. Radiographic measures included Cobb angle and thoracic height (T1-T12). Thoracic height velocity was calculated and compared with established norms. A total of 36 patients, 19 idiopathic and 17 nonidiopathic (14 syndromic, 3 congenital), completed cast treatment and had >6-month follow-up and were therefore included. Of those, 17% (6/36) experienced resolution of their deformity, 53% (19/26) are currently in braces, and 31% (11/36) had undergone surgery. Surgery occurred on average at age 5.6 years and was delayed by an average of 2.1 years from time of first cast. A 19% complication was observed. There was no statistical difference in the rate of resolution of deformity between idiopathic (5/19) and nonidiopathic (1/17) patients (P=0.182), although there exists a trend toward greater curve correction in idiopathic patients. Surgery occurred in fewer patients (2/19) in the idiopathic group compared with the nonidiopathic group (9/17) (P=0.006). Significant improvements in Cobb angle was observed in the idiopathic group (12.2 degrees) during casting (P=0.003). Nonidiopathic patients did not maintain the correction gained during casting at the time of final follow-up. T1-T12 height increased across all study patients regardless of etiology during the period of casting at similar velocity to established norms of 1.4 cm/y for this age group. Serial casting offers modest deformity correction in idiopathic deformities compared with nonidiopathic deformities. Thoracic height growth continued throughout the casting period at normal velocity. Serial casting maintained normal longitudinal thoracic growth in all patients with EOS in this cohort. Although many required surgery, the increased thoracic height may have positive implications on ultimate pulmonary function. Therapeutic level III.

Tribological and Wear Performance of Nanocomposite PVD Hard Coatings Deposited on Aluminum Die Casting Tool

PubMed Central

Fox-Rabinovich, German; Locks Junior, Edinei; Stolf, Pietro; Matos Martins, Marcelo

2018-01-01

In the aluminum die casting process, erosion, corrosion, soldering, and die sticking have a significant influence on tool life and product quality. A number of coatings such as TiN, CrN, and (Cr,Al)N deposited by physical vapor deposition (PVD) have been employed to act as protective coatings due to their high hardness and chemical stability. In this study, the wear performance of two nanocomposite AlTiN and AlCrN coatings with different structures were evaluated. These coatings were deposited on aluminum die casting mold tool substrates (AISI H13 hot work steel) by PVD using pulsed cathodic arc evaporation, equipped with three lateral arc-rotating cathodes (LARC) and one central rotating cathode (CERC). The research was performed in two stages: in the first stage, the outlined coatings were characterized regarding their chemical composition, morphology, and structure using glow discharge optical emission spectroscopy (GDOES), scanning electron microscopy (SEM), and X-ray diffraction (XRD), respectively. Surface morphology and mechanical properties were evaluated by atomic force microscopy (AFM) and nanoindentation. The coating adhesion was studied using Mersedes test and scratch testing. During the second stage, industrial tests were carried out for coated die casting molds. In parallel, tribological tests were also performed in order to determine if a correlation between laboratory and industrial tests can be drawn. All of the results were compared with a benchmark monolayer AlCrN coating. The data obtained show that the best performance was achieved for the AlCrN/Si3N4 nanocomposite coating that displays an optimum combination of hardness, adhesion, soldering behavior, oxidation resistance, and stress state. These characteristics are essential for improving the die mold service life. Therefore, this coating emerges as a novelty to be used to protect aluminum die casting molds. PMID:29495620

Thermophysical property sensitivity effects in steel solidification

NASA Technical Reports Server (NTRS)

Overfelt, Tony

1993-01-01

The simulation of advanced solidification processes via digital computer techniques has gained widespread acceptance during the last decade or so. Models today can predict transient temperature fields, fluid flow fields, important microstructural parameters, and potential defects in castings. However, the lack of accurate thermophysical property data on important industrial alloys threatens to limit the ability of manufacturers to fully capitalize on the technology's benefits. A study of the sensitivity of one such numerical model of a steel plate casting to imposed variations in the data utilized for the thermal conductivity, specific heat, density, and heat of fusion is described. The sensitivity of the data's variability is characterized by its effects on the net solidification time of various points along the centerline of the plate casting. Recommendations for property measurements are given and the implications of data uncertainty for modelers are discussed.

Development of Thin Section Zinc Die Casting Technology

DOE Office of Scientific and Technical Information (OSTI.GOV)

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 formore » 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.« less

Effect of protective release coatings on the basis of superdispersersed zirconium oxide powder on the formation of gas defects in bronze casting

NASA Astrophysics Data System (ADS)

Martyushev, Nikita V.; Risto, Nikolay A.

2014-10-01

This paper investigates the use of nanopowders in the composition of foundry coatings when casting leaded tin bronzes. Influence of the composition of the applied protective coating on surface finish is studied. The effects of the coatings of the following compositions are compared: non-stick coating (a mixture of low-dispersed chromium oxide powder and heat-treated vegetable oil); non-stick lubricant ASPF-2/RgU on the basis of low- dispersed graphite powder and heat-treated vegetable oil; patent #2297300 (a mixture of superdispersed zirconium dioxide powder with industrial oil). It is demonstrated that application of foundry coatings containing superdispersed metal oxide powders with low thermal conductivity makes it possible to significantly reduce irregularities and eliminate gas porosity on the surface of tin-leaded bronze castings.

3D-printed coded apertures for x-ray backscatter radiography

NASA Astrophysics Data System (ADS)

Muñoz, André A. M.; Vella, Anna; Healy, Matthew J. F.; Lane, David W.; Jupp, Ian; Lockley, David

2017-09-01

Many different mask patterns can be used for X-ray backscatter imaging using coded apertures, which can find application in the medical, industrial and security sectors. While some of these patterns may be considered to have a self-supporting structure, this is not the case for some of the most frequently used patterns such as uniformly redundant arrays or any pattern with a high open fraction. This makes mask construction difficult and usually requires a compromise in its design by drilling holes or adopting a no two holes touching version of the original pattern. In this study, this compromise was avoided by 3D printing a support structure that was then filled with a radiopaque material to create the completed mask. The coded masks were manufactured using two different methods, hot cast and cold cast. Hot casting involved casting a bismuth alloy at 80°C into the 3D printed acrylonitrile butadiene styrene mould which produced an absorber with density of 8.6 g cm-3. Cold casting was undertaken at room temperature, when a tungsten/epoxy composite was cast into a 3D printed polylactic acid mould. The cold cast procedure offered a greater density of around 9.6 to 10 g cm-3 and consequently greater X-ray attenuation. It was also found to be much easier to manufacture and more cost effective. A critical review of the manufacturing procedure is presented along with some typical images. In both cases the 3D printing process allowed square apertures to be created avoiding their approximation by circular holes when conventional drilling is used.

Getters for improved technetium containment in cementitious waste forms

DOE PAGES

Asmussen, R. Matthew; Pearce, Carolyn I.; Miller, Brian W.; ...

2017-07-26

A cementitious waste form, Cast Stone, is a possible candidate technology for the immobilization of low activity nuclear waste (LAW) at the Hanford site. This paper focuses on the addition of getter materials to Cast Stone that can sequester Tc from the LAW, and in turn, lower Tc release from the Cast Stone. Two getters which produce different products upon sequestering Tc from LAW were tested: Sn(II) apatite (Sn-A) that removes Tc as a Tc(IV)-oxide and potassium metal sulfide (KMS-2) that removes Tc as a Tc(IV)-sulfide species, allowing for a comparison of stability of the form of Tc upon enteringmore » the waste form. The Cast Stone with KMS-2 getter had the best performance with addition equivalent to ~0.08 wt% of the total waste form mass. The observed diffusion (D obs) of Tc decreased from 4.6 ± 0.2 × 10 -12 cm 2/s for Cast Stone that did not contain a getter to 5.4 ± 0.4 × 10 -13 cm 2/s for KMS-2 containing Cast Stone. Finally, it was found that Tc-sulfide species are more stable against re-oxidation within getter containing Cast Stone compared with Tc-oxide and is the origin of the decrease in Tc D obs when using the KMS-2.« less

Distal femoral osteotomy in genovalgum: internal fixation with blade plate versus casting.

PubMed

Makhmalbaf, Hadi; Moradi, Ali; Ganji, Saeid

2014-10-01

To compare the results of two different ways of distal femoral osteotomy stabilization in patients suffering from genuvalgum: internal fixation with plate, and casting. In a non-randomized prospective study, after distal femoral osteotomy with the zigzag method, patients were divided into two groups: long leg casting, and internal fixation with blade plate. For all patients, questionnaires were filled to obtain data. Information such as range of motion, tibiofemoral anatomical angle and complications were recorded. 38 knees with valgus deformity underwent distal femoral supracondylar osteotomy. (8 with plaster cast and 30 with internal fixation using a blade plate). Preoperative range of motion was 129±6° and six months later it was 120±14°. The preoperative tibiofemoral angle was 32±6°; postoperative tibiofemoral angles were 3±3°, 6±2°, and 7±3° just after operation, six months, and two years later, respectively. Although this angle was greater among the group stabilized with a cast, this difference was not statistically significant. In postoperative complications, over-correction was found in five, recorvatom deformity in one, knee stiffness in three and superficial wound infection was recorded in three knees. There is no prominent difference in final range of motion and alignment whether fixation is done with casting or internal fixation. However, the complication rate seems higher in the casting method.

An innovative approach to sampling complex industrial emissions for use in animal toxicity tests: application to iron casting operations.

PubMed

Palmer, W G; Scholz, R C; Moorman, W J

1983-03-01

Sampling of complex mixtures of airborne contaminants for chronic animal toxicity tests often involves numerous sampling devices, requires extensive sampling time, and yields forms of collected materials unsuitable for administration to animals. A method is described which used a high volume, wet venturi scrubber for collection of respirable fractions of emissions from iron foundry casting operations. The construction and operation of the sampler are presented along with collection efficiency data and its application to the preparation of large quantities of samples to be administered to animals by intratracheal instillation.

Development of Thixomolded{reg_sign} magnesium products

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ghosh, D.; Fan, R.; Kang, K.

1995-10-01

Thixomolding{reg_sign} is a racial new process which merges the technologies of die-casting and plastic injection molding for the net shape molding of magnesium based alloys. Properties of Thixomolded{reg_sign} magnesium alloys are discussed and compared with those of traditional die casting. Magnesium alloys are of great interest to automobile manufacturers because of the potential weight savings and corresponding energy savings due to increased fuel economy. For this reason, one of the first target markets for Thixomolded{reg_sign} products is the automotive industry. The use of Thixomolding{reg_sign} in the production of an automobile part is examined.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

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. Toolmore » 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 retained as the exterior layer of the tooling, while commercially pure copper was chosen for the interior structure of the tooling. The tooling was fabricated by traditional machining of the copper substrate, and H13 powder was deposited on the copper via the Laser Engineered Net Shape (LENSTM) process. The H13 deposition layer was then final machined by traditional methods. Two tooling components were designed and fabricated; a thermal fatigue test specimen, and a core for a commercial aluminum high pressure die casting tool. The bimetallic thermal fatigue specimen demonstrated promising performance during testing, and the test results were used to improve the design and LENS TM deposition methods for subsequent manufacture of the commercial core. Results of the thermal finite element analysis for the thermal fatigue test specimen indicate that it has the ability to lose heat to the internal water cooling passages, and to external spray cooling, significantly faster than a monolithic H13 thermal fatigue sample. The commercial core is currently in the final stages of fabrication, and will be evaluated in an actual production environment at Shiloh Die casting. In this research, the feasibility of designing and fabricating copper/H13 bimetallic die casting tooling via LENS TM processing, for the purpose of improving die casting process efficiency, is demonstrated.« less

Study of twin-roll cast Aluminium alloys subjected to severe plastic deformation by equal channel angular pressing

NASA Astrophysics Data System (ADS)

Poková, M.; Cieslar, M.

2014-08-01

Aluminium alloys prepared by twin-roll casting method become widely used in industry applications. Their high solid solution supersaturation and finer grains ensure better mechanical properties when compared with the direct-chill cast ones. One of the possibilities how to enhance their thermal stability is the addition of zirconium. After heat treatment Al3Zr precipitates form and these pin moving grain boundaries when the material is exposed to higher temperatures. In the present work twin-roll cast aluminium alloys based on AA3003 with and without Zr addition were annealed for 8 hours at 450 °C to enable precipitation of Al3Zr phase. Afterwards they were subjected to severe plastic deformation by equal channel angular pressing, which led to the reduction of average grain size under 1 μm. During subsequent isochronal annealing recovery and recrystallization took place. These processes were monitored by microhardness measurements, light optical microscopy and in-situ transmission electron microscopy. The addition of Zr stabilizes the grain size and increases the recrystallization temperature by 100 °C.

Dimensional Stability of Grout-like Materials Used in Field-Cast Connections

DOT National Transportation Integrated Search

2016-12-01

The wide use of grouts and grout-like materials in the construction industry is seen in applications such as joint sealing, structural repair, and connections in prefabricated bridge elements (PBEs). Currently, different types of grouts are available...

Heavy Metals in ToxCast: Relevance to Food Safety (SOT)

EPA Science Inventory

Human exposure to heavy metals occurs through food contamination due to industrial processes, vehicle emissions and farming methods. Specific toxicity endpoints have been associated with metal exposures, e.g. lead and neurotoxicity; however, numerous varieties of heavy metals hav...

Knowledge Acquisition and Job Training for Advanced Technical Skills Using Immersive Virtual Environment

NASA Astrophysics Data System (ADS)

Watanuki, Keiichi; Kojima, Kazuyuki

The environment in which Japanese industry has achieved great respect is changing tremendously due to the globalization of world economies, while Asian countries are undergoing economic and technical development as well as benefiting from the advances in information technology. For example, in the design of custom-made casting products, a designer who lacks knowledge of casting may not be able to produce a good design. In order to obtain a good design and manufacturing result, it is necessary to equip the designer and manufacturer with a support system related to casting design, or a so-called knowledge transfer and creation system. This paper proposes a new virtual reality based knowledge acquisition and job training system for casting design, which is composed of the explicit and tacit knowledge transfer systems using synchronized multimedia and the knowledge internalization system using portable virtual environment. In our proposed system, the education content is displayed in the immersive virtual environment, whereby a trainee may experience work in the virtual site operation. Provided that the trainee has gained explicit and tacit knowledge of casting through the multimedia-based knowledge transfer system, the immersive virtual environment catalyzes the internalization of knowledge and also enables the trainee to gain tacit knowledge before undergoing on-the-job training at a real-time operation site.

Novel twin-roll-cast Ti/Al clad sheets with excellent tensile properties.

PubMed

Kim, Dae Woong; Lee, Dong Ho; Kim, Jung-Su; Sohn, Seok Su; Kim, Hyoung Seop; Lee, Sunghak

2017-08-14

Pure Ti or Ti alloys are recently spot-lighted in construction industries because they have excellent resistance to corrosions, chemicals, and climates as well as various coloring characteristics, but their wide applications are postponed by their expensiveness and poor formability. We present a new fabrication process of Ti/Al clad sheets by bonding a thin Ti sheet on to a 5052 Al alloy melt during vertical-twin-roll casting. This process has merits of reduced production costs as well as improved tensile properties. In the as-twin-roll-cast clad sheet, the homogeneously cast microstructure existed in the Al alloy substrate side, while the Ti/Al interface did not contain any reaction products, pores, cracks, or lateral delamination, which indicated the successful twin-roll casting. When this sheet was annealed at 350 °C~600 °C, the metallurgical bonding was expanded by interfacial diffusion, thereby leading to improvement in tensile properties over those calculated by a rule of mixtures. The ductility was also improved over that of 5052-O Al alloy (25%) or pure Ti (25%) by synergic effect of homogeneous deformation due to excellent Ti/Al bonding. This work provides new applications of Ti/Al clad sheets to lightweight-alloy clad sheets requiring excellent formability and corrosion resistance as well as alloy cost saving.

Molding of strength testing samples using modern PDCPD material for purpose of automotive industry

NASA Astrophysics Data System (ADS)

Grabowski, L.; Baier, A.; Sobek, M.

2017-08-01

The casting of metal materials is widely known but the molding of composite polymer materials is not well-known method still. The initial choice of method for producing composite bodies was the method of casting of PDCPD material. For purpose of performing casting of polymer composite material, a special mold was made. Firstly, the 3D printed, using PLA material, mold was used. After several attempts of casting PDCPD many problems were encountered. The second step was to use mold milled from a firm and dense isocyanate foam. After several attempts research shown that this solution is more resistant to high-temperature peak, but this material is too fragile to use it several times. This solution also prevents mold from using external heating, which can be necessary for performing correct molding process. The last process was to use the aluminum mold, which is dedicated to PDCPD polymer composite, because of low adhesiveness. This solution leads to perform correct PDCPD polymer composite material injection. After performing casting operation every PDCPD testing samples were tested. These results were compared together. The result of performed work was to archive correct properties of injection of composite material. Research and results were described in detail in this paper.

The Brazilian Aerospace Industry: A Cast Study of the Technological Impact of Offset Agreements in a Recipient Industry

DTIC Science & Technology

1989-12-01

Special Export Programs, Comissco de Beneficios Fiscais e Programas Especiais de Exportagdo - BEFIEX. This program allows the rebate of tariff and...development became a specific policy objective. The 1968-69 Development Plan, Programa Estrat6gico de Desenvolvimento (PED), defined an explicit...Comunicagdo de Programa de Aquisigdo - CPA) containing: object, quantity, delivery time, value, nature, and other basic elements of contracting. To comply

Fabrication process analysis and experimental verification for aluminum bipolar plates in fuel cells by vacuum die-casting

NASA Astrophysics Data System (ADS)

Jin, Chul Kyu; Kang, Chung Gil

2011-10-01

There are various methods for the fabrication of bipolar plates, but these are still limited to machining and stamping processes. High-pressure die casting (HPDC) is an ideal process for the manufacture of bipolar plates This study aims to investigate the formability of bipolar plates for polymer electrolyte membrane fuel cells (PEMFCs) fabricated by vacuum HPDC of an Al-Mg alloy (ALDC6). The cavity of the mold consisted of a thin-walled plate (200 mm × 200 mm × 0.8 mm) with a layer of serpentine channel (50 mm × 50 mm). The location and direction of the channel in the final mold design was determined by computational simulation (MAGMA soft). In addition, simulation results for different conditions of plunger stroke control were compared to those from actual die-casting experiments. Under a vacuum pressure of 35 kPa and for injection speeds of 0.3 and 2.5 m s-1 in the low and high speed regions, respectively, the samples had few casting defects. In addition, the hardness was higher and porosity in microstructure was less than those of the samples made under other injection speed conditions. In case of thin-walled plates, vacuum die casting is beneficial in terms of formability compared to conventional die casting.

Studying of influence of fiber reinforcing at fine-grained concrete applying in transport construction

NASA Astrophysics Data System (ADS)

Begunov, Oleg; Alexandrova, Olga; Solovyov, Vadim

2017-10-01

We observed causes of using fiber in nowadays construction industry and its influence on a final product properties, where the fine-grained concrete basing of repairing dry construction mix was used as a base. However, in Russia we do not have such experience. If we’re talking about changes occurring in the fine-grained concrete all of its are known about it, either in concrete, but in dry-construction mixes changes may have another purpose. Advantages and disadvantages of using fiber were oblieved also in that article. The main subject of this research is the influence of fiber on a mechanical properties of fine-grained concrete. The most attention is paid to estimate the influence of a concrete’s properties by metal fibers: casting time (initial and final), workability and strength (tensile strength and compressive strength) in this article. The most popular different type of metal fiber compares for its length and width and the optimum quantity of metal component chooses, which will indicate the maximum possible affirmative result of its using. Dependences comparing properties of fine-grained properties with fiber’s type, measurements and quantity which show the evident result of researching are discussed.

Cast Iron in The 19th Century Building Equipment

NASA Astrophysics Data System (ADS)

Kwasek, Michał; Piwek, Aleksander

2017-10-01

Cast iron is a material, characteristics of which enable to receive extremely artistic elements. It maintains good strength properties at the same time. That combination of these seemingly contrary traits makes it a commodity that was widely used in the 19th century industry and architecture. These usages were not only as decorative elements, technical and structural ones. The production of new household utilities started, which made people’s lives more comfortable. Cast iron allowed for fast and cheap production while maintaining high aesthetic qualities. Useful elements, which often were ornamental parts of buildings were created. The aim of the article is to characterise elements of interior equipment of the 19th century building that are made of cast iron. As it appears from performed bibliography, archival and field studies, the ways of exploitation are very broad. Some were mounted into the building; the others were a mobile equipment. As it occurred they were most commonly used as functional items. Cast iron was used to produce the minor elements, which were only parts of the bigger wooden or stone items. Notwithstanding, there were also bigger ones casted as a whole, and frequently ones that were assembled from many elements. Nowadays, elements of an interior feature are one of the subjects of study during the restoration work of the buildings. They can provide important information about the building and the way people lived and are considered as the essential part of historical objects.

Space Processing Applications Rocket project, SPAR 2

NASA Technical Reports Server (NTRS)

1977-01-01

Experiment objectives, design/operational concepts, and final results are summarized for six materials science experiments conducted during the second space processing applications rocket mission flown by NASA. The individual experiments discussed are: (1) solidification of Pb-Sb eutectic; (2) feasibility of producing closed-cell metal foams; (3) direct observation of dendrite remelting and macrosegregation in castings; (4) agglomeration in immiscible liquids; (5) casting dispersion - strengthened composites at zero gravity; and (6) solidification behavior of Al-In alloys under zero gravity conditions.

Manufacturing and Characterization of Ultra Pure Ferrous Alloys Final Report CRADA No. TC02069.0

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lesuer, D.; McGreevy, T. E.

This CRADA was a.collaborative effort between the Lawrence Livermore National Security LLC (formerly University of California)/Lawrence Livermore National Laboratory (LLNL),and Caterpillar Inc. (CaterpiHar), to further advance levitation casting techniques (developed at the Central Research Institute for Material (CRIM) in St. Petersburg, Russia) for use in manufacturing high purity metal alloys. This DOE Global Initiatives for Proliferation Prevention Program (IPP) project was to develop and demonstrate the levitation casting technology for producing ultra-pure alloys.

The Grain Structure of Castings: Some Aspects of Modelling

NASA Technical Reports Server (NTRS)

Hellawell, A.

1995-01-01

The efficacy of the modelling of the solidification of castings is typically tested against observed cooling curves and the final grain structures and sizes. Without thermo solutal convection, equiaxed grain formation is promoted by introduction of heterogeneous substrates into the melt, as grain refiners. With efficient thermo solutal convection, dendrite fragments from the mushy zone can act as an intrinsic source of equiaxed grains and resort to grain refining additions is unnecessary. The mechanisms of dendrite fragmentation and transport of these fragments are briefly considered.

Influence of Secondary Cooling Mode on Solidification Structure and Macro-segregation Behavior for High-carbon Continuous Casting Bloom

NASA Astrophysics Data System (ADS)

Dou, Kun; Yang, Zhenguo; Liu, Qing; Huang, Yunhua; Dong, Hongbiao

2017-07-01

A cellular automaton-finite element coupling model for high-carbon continuously cast bloom of GCr15 steel is established to simulate the solidification structure and to investigate the influence of different secondary cooling modes on characteristic parameters such as equiaxed crystal ratio, grain size and secondary dendrite arm spacing, in which the effect of phase transformation and electromagnetic stirring is taken into consideration. On this basis, evolution of carbon macro-segregation for GCr15 steel bloom is researched correspondingly via industrial tests. Based on above analysis, the relationship among secondary cooling modes, characteristic parameters for solidification structure as well as carbon macro-segregation is illustrated to obtain optimum secondary cooling strategy and alleviate carbon macro-segregation degree for GCr15 steel bloom in continuous casting process. The evaluating method for element macro-segregation is applicable in various steel types.

The fuzzy algorithm in the die casting mould for the application of multi-channel temperature control

NASA Astrophysics Data System (ADS)

Sun, Jin-gen; Chen, Yi; Zhang, Jia-nan

2017-01-01

Mould manufacturing is one of the most basic elements in the production chain of China. The mould manufacturing technology has become an important symbol to measure the level of a country's manufacturing industry. The die-casting mould multichannel intelligent temperature control method is studied by cooling water circulation, which uses fuzzy control to realize, aiming at solving the shortcomings of slow speed and big energy consumption during the cooling process of current die-casting mould. At present, the traditional PID control method is used to control the temperature, but it is difficult to ensure the control precision. While , the fuzzy algorithm is used to realize precise control of mould temperature in cooling process. The design is simple, fast response, strong anti-interference ability and good robustness. Simulation results show that the control method is completely feasible, which has higher control precision.

Application of superalloy powder metallurgy for aircraft engines

NASA Technical Reports Server (NTRS)

Dreshfield, R. L.; Miner, R. V., Jr.

1980-01-01

In the last decade, Government/Industry programs have advanced powder metallurgy-near-net-shape technology to permit the use of hot isostatic pressed (HIP) turbine disks in the commercial aircraft fleet. These disks offer a 30% savings of input weight and an 8% savings in cost compared in cast-and-wrought disks. Similar savings were demonstrated for other rotating engine components. A compressor rotor fabricated from hot-die-forged-HIP superalloy billets revealed input weight savings of 54% and cost savings of 35% compared to cast-and-wrought parts. Engine components can be produced from compositions such as Rene 95 and Astroloy by conventional casting and forging, by forging of HIP powder billets, or by direct consolidation of powder by HIP. However, each process produces differences in microstructure or introduces different defects in the parts. As a result, their mechanical properties are not necessarily identical. Acceptance methods should be developed which recognize and account for the differences.

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

2016-09-01

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.

Phosphorus Segregation in Meta-Rapidly Solidified Carbon Steels

NASA Astrophysics Data System (ADS)

Li, Na; Qiao, Jun; Zhang, Junwei; Sha, Minghong; Li, Shengli

2017-09-01

Twin-roll strip casters for near-net-shape manufacture of steels have received increased attention in the steel industry. Although negative segregation of phosphorus occurred in twin-roll strip casting (TRSC) steels in our prior work, its mechanism is still unclear. In this work, V-shaped molds were designed and used to simulate a meta-rapid solidification process without roll separating force during twin roll casting of carbon steels. Experimental results show that no obvious phosphorus segregation exist in the V-shaped mold casting (VMC) steels. By comparing TRSC and the VMC, it is proposed that the negative phosphorus segregation during TRSC results from phosphorus redistribution driven by recirculating and vortex flow in the molten pool. Meanwhile, solute atoms near the advancing interface are overtaken and incorporated into the solid because of the high solidification speed. The high rolling force could promote the negative segregation of alloying elements in TRSC.

Casting of weldable graphite/magnesium metal matrix composites with built-in metallic inserts

NASA Technical Reports Server (NTRS)

Lee, Jonathan A.; Kashalikar, Uday; Majkowski, Patricia

1994-01-01

Technology innovations directed at the advanced development of a potentially low cost and weldable graphite/magnesium metal matrix composites (MMC) through near net shape pressure casting are described. These MMC components uniquely have built-in metallic inserts to provide an innovative approach for joining or connecting other MMC components through conventional joining techniques such as welding, brazing, mechanical fasteners, etc. Moreover, the metallic inserts trapped within the MMC components can be made to transfer the imposed load efficiently to the continuous graphite fiber reinforcement thus producing stronger, stiffer, and more reliable MMC components. The use of low pressure near net shape casting is economical compared to other MMC fabrication processes. These castable and potentially weldable MMC components can provide great payoffs in terms of high strength, high stiffness, low thermal expansion, lightweight, and easily joinable MMC components for several future NASA space structural, industrial, and commercial applications.

Optimization of Squeeze Casting for Aluminum Alloy Parts

DOE Office of Scientific and Technical Information (OSTI.GOV)

David Schwam; John F. Wallace; Qingming Chang

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'' formore » 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 remain open until the casting is solidified and pressure is maintained on the solidifying casting. Fanned gates, particularly on the smaller section castings avoid jetting effects at the ingate end. The fan type ingate helps accomplish a rapid fill without high velocities. The molten metal has to fill the cavity before localized solidification occurs. This is best accomplished with a larger ingate to attain rapid filling without excessive velocity or jetting that occurs at high metal velocities. Straight gates are prone to case jetting of the metal stream even a low velocities. Fanned gates allow use of higher fill velocity without excessive jetting. A higher metal pressure provides a more complete fill of the die including improved compensation for solidification shrinkage. With the proper filling pattern, ingates, overflows and die temperature for a given die, very good tensile properties can be attained in squeeze casting. In general, the smaller squeeze castings require higher die temperatures. Computer models using the UES Procast and MagmaSoft finite element software can, after suitable adjustments, predict the flow pattern in the die cavity.« less

Recommendations for the use of precast deck panels at expansion joints

DOT National Transportation Integrated Search

2008-11-01

Prestressed concrete panels have been used by the bridge construction industry in the state of Texas for many : years to increase construction speed and improve safety and economy. At expansion joints, cast-in-place concrete : is used and requires te...

The Cooperative Infiltration of Science Education.

ERIC Educational Resources Information Center

Beder, Sharon

1998-01-01

Argues that educational materials produced by corporations and industry associations tend to give a corporate view of environmental problems, often casting doubt on the scientific basis for environmental regulation and promoting superficial solutions that have minimal impact on their operations. Contains 30 references. (Author/DDR)

Continuous Fiber Ceramic Composite (CFCC) Program: Gaseous Nitridation

DOE Office of Scientific and Technical Information (OSTI.GOV)

R. Suplinskas G. DiBona; W. Grant

2001-10-29

Textron has developed a mature process for the fabrication of continuous fiber ceramic composite (CFCC) tubes for application in the aluminum processing and casting industry. The major milestones in this project are System Composition; Matrix Formulation; Preform Fabrication; Nitridation; Material Characterization; Component Evaluation

76 FR 31936 - Non-Malleable Cast Iron Pipe Fittings From the People's Republic of China: Final Results of...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-06-02

... Fittings From the People's Republic of China: Final Results of Antidumping Duty Administrative Review... (``pipe fittings'') from the People's Republic of China (``PRC'').\\1\\ We gave interested parties an... Fittings From the People's Republic of China: Preliminary Results of Antidumping Duty Administrative Review...

Improved Virtual Planning for Bimaxillary Orthognathic Surgery.

PubMed

Hatamleh, Muhanad; Turner, Catherine; Bhamrah, Gurprit; Mack, Gavin; Osher, Jonas

2016-09-01

Conventional model surgery planning for bimaxillary orthognathic surgery can be laborious, time-consuming and may contain potential errors; hence three-dimensional (3D) virtual orthognathic planning has been proven to be an efficient, reliable, and cost-effective alternative. In this report, the 3D planning is described for a patient presenting with a Class III incisor relationship on a Skeletal III base with pan facial asymmetry complicated by reverse overjet and anterior open bite. A combined scan data of direct cone beam computer tomography and indirect dental scan were used in the planning. Additionally, a new method of establishing optimum intercuspation by scanning dental casts in final occlusion and positioning it to the composite-scans model was shown. Furthermore, conventional model surgery planning was carried out following in-house protocol. Intermediate and final intermaxillary splints were produced following the conventional method and 3D printing. Three-dimensional planning showed great accuracy and treatment outcome and reduced laboratory time in comparison with the conventional method. Establishing the final dental occlusion on casts and integrating it in final 3D planning enabled us to achieve the best possible intercuspation.

Developing high strength and ductility in biomedical Co-Cr cast alloys by simultaneous doping with nitrogen and carbon.

PubMed

Yamanaka, Kenta; Mori, Manami; Chiba, Akihiko

2016-02-01

There is a strong demand for biomedical Co-Cr-based cast alloys with enhanced mechanical properties for use in dental applications. We present a design strategy for development of Co-Cr-based cast alloys with very high strength, comparable to that of wrought Co-Cr alloys, without loss of ductility. The strategy consists of simultaneous doping of nitrogen and carbon, accompanied by increasing of the Cr content to increase the nitrogen solubility. The strategy was verified by preparing Co-33Cr-9W-0.35N-(0.01-0.31)C (mass%) alloys. We determined the carbon concentration dependence of the microstructures and their mechanical properties. Metal ion release of the alloys in an aqueous solution of 0.6% sodium chloride (NaCl) and 1% lactic acid was also evaluated to ensure their corrosion resistance. As a result of the nitrogen doping, the formation of a brittle σ-phase, a chromium-rich intermetallic compound, was significantly suppressed. Adding carbon to the alloys resulted in finer-grained microstructures and carbide precipitation; accordingly, the strength increased with increasing carbon concentration. The tensile ductility, on the other hand, increased with increasing carbon concentration only up to a point, reaching a maximum at a carbon concentration of ∼0.1mass% and decreasing with further carbon doping. However, the alloy with 0.31mass% of carbon exhibited 14% elongation and also possessed very high strength (725MPa in 0.2% proof stress). The addition of carbon did not significantly degrade the corrosion resistance. The results show that our strategy realizes a novel high-strength Co-Cr-based cast alloy that can be produced for advanced dental applications using a conventional casting procedure. The present study suggested a novel alloy design concept for realizing high-strength Co-Cr-based cast alloys. The proposed strategy is beneficial from the practical point of view because it uses conventional casting approach-a simpler, more cost-effective, industrially friendly manufacturing process than other manufacturing processes such as thermomechanical processing or powder metallurgy. The developed alloys showed the excellent strength-ductility balance and significantly high strength comparable to that of wrought Co-Cr-Mo alloys, while maintaining acceptable ductility and good corrosion resistance. We described the relationship between microstructures and mechanical and corrosion prosperities of the developed alloys; this provides the fundamental aspect of the proposed strategy and will be helpful for further investigations or industrial realization of the proposed strategy. Copyright © 2015 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

An investigation of industrial molding compounds for use in 3D ultrasound, MRI, and CT imaging phantoms

PubMed Central

Yunker, Bryan E.; Cordes, Dietmar; Scherzinger, Ann L.; Dodd, Gerald D.; Shandas, Robin; Feng, Yusheng; Hunter, Kendall S.

2013-01-01

Purpose: This study investigated the ultrasound, MRI, and CT imaging characteristics of several industrial casting and molding compounds as a precursor to the future development of durable and anatomically correct flow phantoms. Methods: A set of usability and performance criteria was established for a proposed phantom design capable of supporting liquid flow during imaging. A literature search was conducted to identify the materials and methods previously used in phantom fabrication. A database of human tissue and casting material properties was compiled to facilitate the selection of appropriate materials for testing. Several industrial casting materials were selected, procured, and used to fabricate test samples that were imaged with ultrasound, MRI, and CT. Results: Five silicones and one polyurethane were selected for testing. Samples of all materials were successfully fabricated. All imaging modalities were able to discriminate between the materials tested. Ultrasound testing showed that three of the silicones could be imaged to a depth of at least 2.5 cm (1 in.). The RP-6400 polyurethane exhibited excellent contrast and edge detail for MRI phantoms and appears to be an excellent water reference for CT applications. The 10T and 27T silicones appear to be usable water references for MRI imaging. Conclusions: Based on study data and the stated selection criteria, the P-4 silicone provided sufficient material contrast to water and edge detail for use across all imaging modalities with the benefits of availability, low cost, dimensional stability, nontoxic, nonflammable, durable, cleanable, and optical clarity. The physical and imaging differences of the materials documented in this study may be useful for other applications. PMID:23635298

Breaking through the strength-ductility trade-off dilemma in an Al-Si-based casting alloy.

PubMed

Dang, B; Zhang, X; Chen, Y Z; Chen, C X; Wang, H T; Liu, F

2016-08-09

Al-Si-based casting alloys have a great potential in various industrial applications. Common strengthening strategies on these alloys are accompanied inevitably by sacrifice of ductility, known as strength-ductility trade-off dilemma. Here, we report a simple route by combining rapid solidification (RS) with a post-solidification heat treatment (PHT), i.e. a RS + PHT route, to break through this dilemma using a commercial Al-Si-based casting alloy (A356 alloy) as an example. It is shown that yield strength and elongation to failure of the RS + PHT processed alloy are elevated simultaneously by increasing the cooling rate upon RS, which are not influenced by subsequent T6 heat treatment. Breaking through the dilemma is attributed to the hierarchical microstructure formed by the RS + PHT route, i.e. highly dispersed nanoscale Si particles in Al dendrites and nanoscale Al particles decorated in eutectic Si. Simplicity of the RS + PHT route makes it being suitable for industrial scaling production. The strategy of engineering microstructures offers a general pathway in tailoring mechanical properties of other Al-Si-based alloys. Moreover, the remarkably enhanced ductility of A356 alloy not only permits strengthening further the material by work hardening but also enables possibly conventional solid-state forming of the material, thus extending the applications of such an alloy.

Breaking through the strength-ductility trade-off dilemma in an Al-Si-based casting alloy

PubMed Central

Dang, B.; Zhang, X.; Chen, Y. Z.; Chen, C. X.; Wang, H. T.; Liu, F.

2016-01-01

Al-Si-based casting alloys have a great potential in various industrial applications. Common strengthening strategies on these alloys are accompanied inevitably by sacrifice of ductility, known as strength-ductility trade-off dilemma. Here, we report a simple route by combining rapid solidification (RS) with a post-solidification heat treatment (PHT), i.e. a RS + PHT route, to break through this dilemma using a commercial Al-Si-based casting alloy (A356 alloy) as an example. It is shown that yield strength and elongation to failure of the RS + PHT processed alloy are elevated simultaneously by increasing the cooling rate upon RS, which are not influenced by subsequent T6 heat treatment. Breaking through the dilemma is attributed to the hierarchical microstructure formed by the RS + PHT route, i.e. highly dispersed nanoscale Si particles in Al dendrites and nanoscale Al particles decorated in eutectic Si. Simplicity of the RS + PHT route makes it being suitable for industrial scaling production. The strategy of engineering microstructures offers a general pathway in tailoring mechanical properties of other Al-Si-based alloys. Moreover, the remarkably enhanced ductility of A356 alloy not only permits strengthening further the material by work hardening but also enables possibly conventional solid-state forming of the material, thus extending the applications of such an alloy. PMID:27502444

Atom Probe Tomography Unveils Formation Mechanisms of Wear-Protective Tribofilms by ZDDP, Ionic Liquid, and Their Combination

DOE PAGES

Guo, Wei; Zhou, Yan; Sang, Xiahan; ...

2017-06-20

The development of advanced lubricant additives has been a critical component in paving the way for increasing energy efficiency and durability for numerous industry applications. However, the formation mechanisms of additive-induced protective tribofilms are not yet fully understood because of the complex chemomechanical interactions at the contact interface and the limited spatial resolution of many characterizing techniques currently used. In this paper, the tribofilms on a gray cast iron surface formed by three antiwear additives are systematically studied; a phosphonium-phosphate ionic liquid (IL), a zinc dialkyldithiophosphate (ZDDP), and an IL+ZDDP combination. All three additives provide excellent wear protection, with themore » IL+ZDDP combination exhibiting a synergetic effect, resulting in further reduced friction and wear. Atom probe tomography (APT) and scanning transmission electron microscopy (STEM) imaging and electron energy loss spectroscopy (EELS) were used to interrogate the subnm chemistry and bonding states for each of the tribofilms of interest. The IL tribofilm appeared amorphous and was Fe, P, and O rich. Wear debris particles having an Fe-rich core and an oxide shell were present in this tribofilm and a transitional oxide (Fe 2O 3)-containing layer was identified at the interface between the tribofilm and the cast iron substrate. The ZDDP+IL tribofilm shared some of the characteristics found in the IL and ZDDP tribofilms. Finally, tribofilm formation mechanisms are proposed on the basis of the observations made at the atomic level.« less

Atom Probe Tomography Unveils Formation Mechanisms of Wear-Protective Tribofilms by ZDDP, Ionic Liquid, and Their Combination

DOE Office of Scientific and Technical Information (OSTI.GOV)

Guo, Wei; Zhou, Yan; Sang, Xiahan

The development of advanced lubricant additives has been a critical component in paving the way for increasing energy efficiency and durability for numerous industry applications. However, the formation mechanisms of additive-induced protective tribofilms are not yet fully understood because of the complex chemomechanical interactions at the contact interface and the limited spatial resolution of many characterizing techniques currently used. In this paper, the tribofilms on a gray cast iron surface formed by three antiwear additives are systematically studied; a phosphonium-phosphate ionic liquid (IL), a zinc dialkyldithiophosphate (ZDDP), and an IL+ZDDP combination. All three additives provide excellent wear protection, with themore » IL+ZDDP combination exhibiting a synergetic effect, resulting in further reduced friction and wear. Atom probe tomography (APT) and scanning transmission electron microscopy (STEM) imaging and electron energy loss spectroscopy (EELS) were used to interrogate the subnm chemistry and bonding states for each of the tribofilms of interest. The IL tribofilm appeared amorphous and was Fe, P, and O rich. Wear debris particles having an Fe-rich core and an oxide shell were present in this tribofilm and a transitional oxide (Fe 2O 3)-containing layer was identified at the interface between the tribofilm and the cast iron substrate. The ZDDP+IL tribofilm shared some of the characteristics found in the IL and ZDDP tribofilms. Finally, tribofilm formation mechanisms are proposed on the basis of the observations made at the atomic level.« less

Occupational noise-induced hearing loss in Indian steel industry workers: an exploratory study.

PubMed

Singh, Lakhwinder Pal; Bhardwaj, Arvind; Deepak, Kishore Kumar

2013-04-01

The present study focused on exploring the current level of hearing protection and subsequently determined the prevalence of occupational noise-induced hearing loss among casting and forging industry workers. The casting and forging industry provides employment to a significant portion of the population. The level of hearing protection was assessed through questionnaire survey of 572 workers. Out of these workers, 165 and another control group of 57 participants were assessed by formal audiometry. Audiometric tests were conducted at frequencies of 1.0 KHz to 8.0 KHz.The occurrence of hearing loss was determined on the basis of a hearing threshold level with a low fence of 25 dB. Student's test and ANOVA were used to compare the various groups; a p value < .05 was considered statistically significant. More than 90% of the workers sampled showed significant hearing loss at medium and high frequencies. The analyses revealed a higher prevalence of significant hearing loss among the forging workers compared with the workers associated with the other activities. The workers of the Indian steel industry are highly exposed to occupational noise. The majority of workers are not protected from noise-induced hearing loss. There is a need to provide special ear protectors for workers engaged in forging. A complete hearing protection program, including training, audiometry, job rotation, and the use of hearing protection devices, needs to be introduced.

Effect of Tunable Surface Potential on the Structure of Spin-Cast Polymeric Blend Films

NASA Astrophysics Data System (ADS)

Hawker, C.; Huang, E.; Russell, T. P.

1998-03-01

The demixing of binary polymeric mixtures has been studied with various surface potentials. This was performed by spin casting polystyrene/poly(methyl methacrylate) mixtures on to silicon substrates that had been modified with an end-grafted random copolymer brush layer. The composition of the random copolymer brush, containing the same monomeric components as the homopolymers can be varied in a precise manner over the entire concentration range. Atomic force and optical microscopy were used to study the morphology formed during spin casting and after annealing. Further insight into the structure was gained by rinsing these films with preferential solvents to remove one of the constituents and by performing the microscopy measurements. Finally, x-ray photoelectron spectroscopy, XPS, was used to elucidate the composition of the film near the air/polymer interface. Our data show that the resulting thin film structure depends strongly on the composition of the end grafted random copolymer film. Furthermore, the effect of thickness, solvent used in casting, and annealing conditions will be addressed.

Fabrication of low cost soft tissue prostheses with the desktop 3D printer

NASA Astrophysics Data System (ADS)

He, Yong; Xue, Guang-Huai; Fu, Jian-Zhong

2014-11-01

Soft tissue prostheses such as artificial ear, eye and nose are widely used in the maxillofacial rehabilitation. In this report we demonstrate how to fabricate soft prostheses mold with a low cost desktop 3D printer. The fabrication method used is referred to as Scanning Printing Polishing Casting (SPPC). Firstly the anatomy is scanned with a 3D scanner, then a tissue casting mold is designed on computer and printed with a desktop 3D printer. Subsequently, a chemical polishing method is used to polish the casting mold by removing the staircase effect and acquiring a smooth surface. Finally, the last step is to cast medical grade silicone into the mold. After the silicone is cured, the fine soft prostheses can be removed from the mold. Utilizing the SPPC method, soft prostheses with smooth surface and complicated structure can be fabricated at a low cost. Accordingly, the total cost of fabricating ear prosthesis is about $30, which is much lower than the current soft prostheses fabrication methods.

Fabrication of low cost soft tissue prostheses with the desktop 3D printer

PubMed Central

He, Yong; Xue, Guang-huai; Fu, Jian-zhong

2014-01-01

Soft tissue prostheses such as artificial ear, eye and nose are widely used in the maxillofacial rehabilitation. In this report we demonstrate how to fabricate soft prostheses mold with a low cost desktop 3D printer. The fabrication method used is referred to as Scanning Printing Polishing Casting (SPPC). Firstly the anatomy is scanned with a 3D scanner, then a tissue casting mold is designed on computer and printed with a desktop 3D printer. Subsequently, a chemical polishing method is used to polish the casting mold by removing the staircase effect and acquiring a smooth surface. Finally, the last step is to cast medical grade silicone into the mold. After the silicone is cured, the fine soft prostheses can be removed from the mold. Utilizing the SPPC method, soft prostheses with smooth surface and complicated structure can be fabricated at a low cost. Accordingly, the total cost of fabricating ear prosthesis is about $30, which is much lower than the current soft prostheses fabrication methods. PMID:25427880

Fabrication of low cost soft tissue prostheses with the desktop 3D printer.

PubMed

He, Yong; Xue, Guang-huai; Fu, Jian-zhong

2014-11-27

Soft tissue prostheses such as artificial ear, eye and nose are widely used in the maxillofacial rehabilitation. In this report we demonstrate how to fabricate soft prostheses mold with a low cost desktop 3D printer. The fabrication method used is referred to as Scanning Printing Polishing Casting (SPPC). Firstly the anatomy is scanned with a 3D scanner, then a tissue casting mold is designed on computer and printed with a desktop 3D printer. Subsequently, a chemical polishing method is used to polish the casting mold by removing the staircase effect and acquiring a smooth surface. Finally, the last step is to cast medical grade silicone into the mold. After the silicone is cured, the fine soft prostheses can be removed from the mold. Utilizing the SPPC method, soft prostheses with smooth surface and complicated structure can be fabricated at a low cost. Accordingly, the total cost of fabricating ear prosthesis is about $30, which is much lower than the current soft prostheses fabrication methods.

Evaluation and comparison of bisphenol A analog activity using ToxCast data (SOT)

EPA Science Inventory

Bisphenol A (BPA) is used in consumer products and industrial applications, primarily in plastics, and has been detected in the environment, human urine, blood, and breast milk. Mainly studied as an endocrine disruptor, other toxicities, including obesity, metabolic conditions s...

Enhancing Manufacturing Process Education via Computer Simulation and Visualization

ERIC Educational Resources Information Center

Manohar, Priyadarshan A.; Acharya, Sushil; Wu, Peter

2014-01-01

Industrially significant metal manufacturing processes such as melting, casting, rolling, forging, machining, and forming are multi-stage, complex processes that are labor, time, and capital intensive. Academic research develops mathematical modeling of these processes that provide a theoretical framework for understanding the process variables…

Characterization of process air emissions in automotive production plants.

PubMed

D'Arcy, J B; Dasch, J M; Gundrum, A B; Rivera, J L; Johnson, J H; Carlson, D H; Sutherland, J W

2016-01-01

During manufacturing, particles produced from industrial processes become airborne. These airborne emissions represent a challenge from an industrial hygiene and environmental standpoint. A study was undertaken to characterize the particles associated with a variety of manufacturing processes found in the auto industry. Air particulates were collected in five automotive plants covering ten manufacturing processes in the areas of casting, machining, heat treatment and assembly. Collection procedures provided information on air concentration, size distribution, and chemical composition of the airborne particulate matter for each process and insight into the physical and chemical processes that created those particles.

Equations of State and High-Pressure Phases of Explosives

NASA Astrophysics Data System (ADS)

Peiris, Suhithi M.; Gump, Jared C.

Energetic materials, being the collective name for explosives, propellants, pyrotechnics, and other flash-bang materials, span a wide range of composite chemical formulations. Most militarily used energetics are solids composed of particles of the pure energetic material held together by a binder. Commonly used binders include various oils, waxes, and polymers or plasticizers, and the composite is melt cast, cured, or pressed to achieve the necessary mechanical properties (gels, putties, sheets, solid blocks, etc.) of the final energetic material. Mining, demolition, and other industries use liquid energetics that are similarly composed of an actual energetic material or oxidizer together with a fuel, that is to be mixed and poured for detonation. Pure energetic materials that are commonly used are nitroglycerine, ammonium nitrate, ammonium or sodium perchlorate, trinitrotoluene (TNT), HMX, RDX, and TATB. All of them are molecular materials or molecular ions that when initiated or insulted undergoes rapid decomposition with excessive liberation of heat resulting in the formation of stable final products. When the final products are gases, and they are rapidly produced, the sudden pressure increase creates a shock wave. When decomposition is so rapid that the reaction moves through the explosive faster than the speed of sound in the unreacted explosive, the material is said to detonate. Typically, energetic materials that undergo detonation are known as high explosives (HEs) and energetic materials that burn rapidly or deflagrate are known as low explosives and/or propellants.

Direct chill casting of aluminium alloys under electromagnetic interaction by permanent magnet assembly

NASA Astrophysics Data System (ADS)

Bojarevičs, Andris; Kaldre, Imants; Milgrāvis, Mikus; Beinerts, Toms

2018-05-01

Direct chill casting is one of the methods used in industry to obtain good microstructure and properties of aluminium alloys. Nevertheless, for some alloys grain structure is not optimal. In this study, we offer the use of electromagnetic interaction to modify melt convection near the solidification interface. Solidification under various electromagnetic interactions has been widely studied, but usually at low solidification velocity and high thermal gradient. This type of interaction may succeed fragmentation of dendrite arms and transport of solidification nuclei thus leading to improved material structure and properties. Realization of experimental small-scale crystallizer and electromagnetic system has been described in this article.

Effect of Starting As-cast Structure on the Microstructure-Texture Evolution During Subsequent Processing and Finally Ridging Behavior of Ferritic Stainless Steel

NASA Astrophysics Data System (ADS)

Modak, Pranabananda; Patra, Sudipta; Mitra, Rahul; Chakrabarti, Debalay

2018-03-01

Effect of the initial as-cast structure on the microstructure-texture evolution during thermomechanical processing of 409L grade ferritic stainless steel was studied. Samples from the regions of cast slab having `columnar,' `equiaxed,' and a mixture of `columnar' and `equiaxed' grains were subjected to two different processing schedules: one with intermediate hot-band annealing before cold-rolling followed by final annealing, and another without any hot-band annealing. EBSD study reveals that large columnar crystals with cube orientation are very difficult to deform and recrystallize uniformly. Resultant variations in ferrite grain structure and retention of cube-textured band in cold-rolled and annealed sheet contribute to ridging behavior during stretch forming. Initial equiaxed grain structure is certainly beneficial to reduce or even eliminate ridging defect by producing uniform ferrite grain structure, free from any texture banding. Application of hot-band annealing treatment is also advantageous as it can maximize the evolution of beneficial gamma-fiber texture and eliminate the ridging defect in case of completely `equiaxed' starting structure. Such treatment reduces the severity of ridging even if the initial structure contains typically mixed `columnar-equiaxed' grains.

Effect of Starting As-cast Structure on the Microstructure-Texture Evolution During Subsequent Processing and Finally Ridging Behavior of Ferritic Stainless Steel

NASA Astrophysics Data System (ADS)

Modak, Pranabananda; Patra, Sudipta; Mitra, Rahul; Chakrabarti, Debalay

2018-06-01

Effect of the initial as-cast structure on the microstructure-texture evolution during thermomechanical processing of 409L grade ferritic stainless steel was studied. Samples from the regions of cast slab having `columnar,' `equiaxed,' and a mixture of `columnar' and `equiaxed' grains were subjected to two different processing schedules: one with intermediate hot-band annealing before cold-rolling followed by final annealing, and another without any hot-band annealing. EBSD study reveals that large columnar crystals with cube orientation are very difficult to deform and recrystallize uniformly. Resultant variations in ferrite grain structure and retention of cube-textured band in cold-rolled and annealed sheet contribute to ridging behavior during stretch forming. Initial equiaxed grain structure is certainly beneficial to reduce or even eliminate ridging defect by producing uniform ferrite grain structure, free from any texture banding. Application of hot-band annealing treatment is also advantageous as it can maximize the evolution of beneficial gamma-fiber texture and eliminate the ridging defect in case of completely `equiaxed' starting structure. Such treatment reduces the severity of ridging even if the initial structure contains typically mixed `columnar-equiaxed' grains.

Software Computes Tape-Casting Parameters

NASA Technical Reports Server (NTRS)

deGroh, Henry C., III

2003-01-01

Tcast2 is a FORTRAN computer program that accelerates the setup of a process in which a slurry containing metal particles and a polymeric binder is cast, to a thickness regulated by a doctor blade, onto fibers wound on a rotating drum to make a green precursor of a metal-matrix/fiber composite tape. Before Tcast2, setup parameters were determined by trial and error in time-consuming multiple iterations of the process. In Tcast2, the fiber architecture in the final composite is expressed in terms of the lateral distance between fibers and the thickness-wise distance between fibers in adjacent plies. The lateral distance is controlled via the manner of winding. The interply spacing is controlled via the characteristics of the slurry and the doctor-blade height. When a new combination of fibers and slurry is first cast and dried to a green tape, the shrinkage from the wet to the green condition and a few other key parameters of the green tape are measured. These parameters are provided as input to Tcast2, which uses them to compute the doctor-blade height and fiber spacings needed to obtain the desired fiber architecture and fiber volume fraction in the final composite.

Application of a Pore Fraction Hot Tearing Model to Directionally Solidified and Direct Chill Cast Aluminum Alloys

NASA Astrophysics Data System (ADS)

Dou, Ruifeng; Phillion, A. B.

2016-08-01

Hot tearing susceptibility is commonly assessed using a pressure drop equation in the mushy zone that includes the effects of both tensile deformation perpendicular to the thermal gradient as well as shrinkage feeding. In this study, a Pore Fraction hot tearing model, recently developed by Monroe and Beckermann (JOM 66:1439-1445, 2014), is extended to additionally include the effect of strain rate parallel to the thermal gradient. The deformation and shrinkage pore fractions are obtained on the basis of the dimensionless Niyama criterion and a scaling variable method. First, the model is applied to the binary Al-Cu system under conditions of directional solidification. It is shown that for the same Niyama criterion, a decrease in the cooling rate increases both the deformation and shrinkage pore fractions because of an increase in the time spent in the brittle temperature region. Second, the model is applied to the industrial aluminum alloy AA5182 as part of a finite element simulation of the Direct Chill (DC) casting process. It is shown that an increase in the casting speed during DC casting increases the deformation and shrinkage pore fractions, causing the maximum point of pore fraction to move towards the base of the casting. These results demonstrate that including the strain rate parallel to the thermal gradient significantly improves the predictive quality of hot tearing criteria based on the pressure drop equation.

Data-Driven Neural Network Model for Robust Reconstruction of Automobile Casting

NASA Astrophysics Data System (ADS)

Lin, Jinhua; Wang, Yanjie; Li, Xin; Wang, Lu

2017-09-01

In computer vision system, it is a challenging task to robustly reconstruct complex 3D geometries of automobile castings. However, 3D scanning data is usually interfered by noises, the scanning resolution is low, these effects normally lead to incomplete matching and drift phenomenon. In order to solve these problems, a data-driven local geometric learning model is proposed to achieve robust reconstruction of automobile casting. In order to relieve the interference of sensor noise and to be compatible with incomplete scanning data, a 3D convolution neural network is established to match the local geometric features of automobile casting. The proposed neural network combines the geometric feature representation with the correlation metric function to robustly match the local correspondence. We use the truncated distance field(TDF) around the key point to represent the 3D surface of casting geometry, so that the model can be directly embedded into the 3D space to learn the geometric feature representation; Finally, the training labels is automatically generated for depth learning based on the existing RGB-D reconstruction algorithm, which accesses to the same global key matching descriptor. The experimental results show that the matching accuracy of our network is 92.2% for automobile castings, the closed loop rate is about 74.0% when the matching tolerance threshold τ is 0.2. The matching descriptors performed well and retained 81.6% matching accuracy at 95% closed loop. For the sparse geometric castings with initial matching failure, the 3D matching object can be reconstructed robustly by training the key descriptors. Our method performs 3D reconstruction robustly for complex automobile castings.

Analysis of Pfizer compounds in EPA's ToxCast chemicals-assay space.

PubMed

Shah, Falgun; Greene, Nigel

2014-01-21

The U.S. Environmental Protection Agency (EPA) launched the ToxCast program in 2007 with the goal of evaluating high-throughput in vitro assays to prioritize chemicals that need toxicity testing. Their goal was to develop predictive bioactivity signatures for toxic compounds using a set of in vitro assays and/or in silico properties. In 2009, Pfizer joined the ToxCast initiative by contributing 52 compounds with preclinical and clinical data for profiling across the multiple assay platforms available. Here, we describe the initial analysis of the Pfizer subset of compounds within the ToxCast chemical (n = 1814) and in vitro assay (n = 486) space. An analysis of the hit rate of Pfizer compounds in the ToxCast assay panel allowed us to focus our mining of assays potentially most relevant to the attrition of our compounds. We compared the bioactivity profile of Pfizer compounds to other compounds in the ToxCast chemical space to gain insights into common toxicity pathways. Additionally, we explored the similarity in the chemical and biological spaces between drug-like compounds and environmental chemicals in ToxCast and compared the in vivo profiles of a subset of failed pharmaceuticals having high similarity in both spaces. We found differences in the chemical and biological spaces of pharmaceuticals compared to environmental chemicals, which may question the applicability of bioactivity signatures developed exclusively based on the latter to drug-like compounds if used without prior validation with the ToxCast Phase-II chemicals. Finally, our analysis has allowed us to identify novel interactions for our compounds in particular with multiple nuclear receptors that were previously not known. This insight may help us to identify potential liabilities with future novel compounds.

Secondary Waste Cast Stone Waste Form Qualification Testing Plan

DOE Office of Scientific and Technical Information (OSTI.GOV)

Westsik, Joseph H.; Serne, R. Jeffrey

2012-09-26

The Hanford Tank Waste Treatment and Immobilization Plant (WTP) is being constructed to treat the 56 million gallons of radioactive waste stored in 177 underground tanks at the Hanford Site. The WTP includes a pretreatment facility to separate the wastes into high-level waste (HLW) and low-activity waste (LAW) fractions for vitrification and disposal. The LAW will be converted to glass for final disposal at the Integrated Disposal Facility (IDF). Cast Stone – a cementitious waste form, has been selected for solidification of this secondary waste stream after treatment in the ETF. The secondary-waste Cast Stone waste form must be acceptablemore » for disposal in the IDF. This secondary waste Cast Stone waste form qualification testing plan outlines the testing of the waste form and immobilization process to demonstrate that the Cast Stone waste form can comply with the disposal requirements. Specifications for the secondary-waste Cast Stone waste form have not been established. For this testing plan, Cast Stone specifications are derived from specifications for the immobilized LAW glass in the WTP contract, the waste acceptance criteria for the IDF, and the waste acceptance criteria in the IDF Permit issued by the State of Washington. This testing plan outlines the testing needed to demonstrate that the waste form can comply with these waste form specifications and acceptance criteria. The testing program must also demonstrate that the immobilization process can be controlled to consistently provide an acceptable waste form product. This testing plan also outlines the testing needed to provide the technical basis for understanding the long-term performance of the waste form in the disposal environment. These waste form performance data are needed to support performance assessment analyses of the long-term environmental impact of the secondary-waste Cast Stone waste form in the IDF« less

Effect of sociocultural cleavage on genetic differentiation: a study from North India.

PubMed

Khan, Faisal; Pandey, Atul Kumar; Borkar, Meenal; Tripathi, Manorma; Talwar, Sudha; Bisen, P S; Agrawal, Suraksha

2008-06-01

Indian populations possess an exclusive genetic profile primarily due to the many migratory events, which caused an extensive range of genetic diversity, and also due to stringent and austere sociocultural barriers that structure these populations into different endogamous groups. In the present study we attempt to explore the genetic relationships between various endogamous North Indian populations and to determine the effect of stringent social regulations on their gene pool. Twenty STR markers were genotyped in 1,800 random North Indians from 9 endogamous populations belonging to upper-caste and middle-caste Hindus and Muslims. All nine populations had high allelic diversity (176 alleles) and average observed heterozygosity (0.742 +/- 0.06), suggesting strong intrapopulation diversity. The average F(ST) value over all loci was as low as 0.0084. However, within-group F(ST) and genetic distance analysis showed that populations of the same group were genetically closer to each other. The genetic distance of Muslims from middle castes (F(ST) = 0.0090; DA = 0.0266) was significantly higher than that of Muslims from upper castes (F(ST) = 0.0050; DA = 0.0148). Phylogenetic trees (neighbor-joining and maximum-likelihood) show the basal cluster pattern of three clusters corresponding to Muslims, upper-caste, and middle-caste populations, with Muslims clustered with upper-caste populations. Based on the results, we conclude that the extensive gene flow through a series of migrations and invasions has created an enormous amount of genetic diversity. The interpopulation differences are minimal but have a definite pattern, in which populations of different socioreligious groups have more genetic similarity within the same group and are genetically more distant from populations of other groups. Finally, North Indian Muslims show a differential genetic relationship with upper- and middle-caste populations.

In vivo wear. Part I: The Michigan computer-graphic measuring system.

PubMed

McDowell, G C; Bloem, T J; Lang, B R; Asgar, K

1988-07-01

Three-dimensional coordinate measuring machines for examining the quality of industrial castings were reviewed. The concept was modified and successfully converted to examine the minute geometric configurations of the surfaces of dental materials. The wear of composites has undoubtedly precipitated this perceptive, thorough study.

Utilization of Space Shuttle External Tank materials by melting and powder metallurgy

NASA Technical Reports Server (NTRS)

Chern, T. S.

1985-01-01

The Crucible Melt Extraction Process was demonstrated to convert scraps of aluminum alloy 2219, used in the Space Shuttle External Tank, into fibers. The cast fibers were then consolidated by cold welding. The X-ray diffraction test of the cast fibers was done to examine the crystallinity and oxide content of the fibers. The compressive stress-strain behavior of the consolidated materials was also examined. Two conceptual schemes which would adapt the as-developed Crucible Melt Extraction Process to the microgravity condition in space were finally proposed.

Physical metallurgy of BATMAN II Ti-bearing martensitic steels

NASA Astrophysics Data System (ADS)

Pilloni, L.; Attura, F.; Calza-Bini, A.; De Santis, G.; Filacchioni, G.; Carosi, A.; Amato, S.

1998-10-01

Seven laboratory experimental casts of 7-9% Cr Ti-bearing martensitic steels were obtained via VIM process. Plates of 25 mm thickness were produced by hot rolling. On each cast CCT diagrams and critical temperatures were determined. Several austenitizing treatments were performed to study the grain size evolution. The effect of microstructure on impact properties were finally investigated. This paper discusses the role of chemical composition on microstructural and physical properties and shows the beneficial effect either of low-temperature austenitizing or double-austenitizing steps on impact properties.

Utilization of space shuttle external tank materials by melting and powder metallurgy

NASA Astrophysics Data System (ADS)

Chern, Terry S.

The Crucible Melt Extraction Process was demonstrated to convert scraps of aluminum alloy 2219, used in the Space Shuttle External Tank, into fibers. The cast fibers were then consolidated by cold welding. The X-ray diffraction test of the cast fibers was done to examine the crystallinity and oxide content of the fibers. The compressive stress-strain behavior of the consolidated materials was also examined. Two conceptual schemes which would adapt the as-developed Crucible Melt Extraction Process to the microgravity condition in space were finally proposed.

Materials for advanced ultrasupercritical steam turbines

DOE Office of Scientific and Technical Information (OSTI.GOV)

Purgert, Robert; Shingledecker, John; Saha, Deepak

The U.S. Department of Energy (DOE) and the Ohio Coal Development Office (OCDO) have sponsored a project aimed at identifying, evaluating, and qualifying the materials needed for the construction of the critical components of coal-fired power plants capable of operating at much higher efficiencies than the current generation of supercritical plants. This increased efficiency is expected to be achieved principally through the use of advanced ultrasupercritical (A-USC) steam conditions. A limiting factor in this can be the materials of construction for boilers and for steam turbines. The overall project goal is to assess/develop materials technology that will enable achieving turbinemore » throttle steam conditions of 760°C (1400°F)/35MPa (5000 psi). This final technical report covers the research completed by the General Electric Company (GE) and Electric Power Research Institute (EPRI), with support from Oak Ridge National Laboratory (ORNL) and the National Energy Technology Laboratory (NETL) – Albany Research Center, to develop the A-USC steam turbine materials technology to meet the overall project goals. Specifically, this report summarizes the industrial scale-up and materials property database development for non-welded rotors (disc forgings), buckets (blades), bolting, castings (needed for casing and valve bodies), casting weld repair, and casting to pipe welding. Additionally, the report provides an engineering and economic assessment of an A-USC power plant without and with partial carbon capture and storage. This research project successfully demonstrated the materials technology at a sufficient scale and with corresponding materials property data to enable the design of an A-USC steam turbine. The key accomplishments included the development of a triple-melt and forged Haynes 282 disc for bolted rotor construction, long-term property development for Nimonic 105 for blading and bolting, successful scale-up of Haynes 282 and Nimonic 263 castings using traditional sand foundry practices, and a techno-economic study of an A-USC plant including cost estimates for an A-USC turbine which showed A-USC to be economically attractive for partial carbon and capture compared to today’s USC technology. Based on this successful materials research and a review with U.S. utility stakeholders, a new project to develop a component test facility (ComTest) including the world’s first A-USC turbine has been proposed to continue the technology development.« less

High temperature oxidation of alumina forming cast austenitic stainless steels within an environment of pure steam

NASA Astrophysics Data System (ADS)

Prenzlow, Elmer A.

Steam cracking of hydrocarbons in the petrochemical industry is a multibillion dollar industry. The processes performed in these plants create byproducts that negatively affect the integrity of stainless steel piping through high temperature corrosion. Alloys used presently in industry rely on the formation of chromium oxide (chromia) as a protective layer between the bulk metal pipe and chemical byproducts. However, chromia can become susceptible to attack from aggressive species such as carbon, water vapor, and sulfur compounds, thus creating a need for a better protection method. A new series of austenitic stainless steels have been developed in recent years that, rather than forming chromia, create a protective layer of aluminum oxide (alumina) under oxidative conditions. These alloys have high nickel content for the stabilization of the austenitic phase, and a more thermodynamically stable oxide layer relative to the traditional chromia formers. Consequently, alumina forming alloys have been proposed as replacements for chromia forming alloys in the petrochemical industry. General oxidation testing has been performed on alumina forming alloys under dry and 10% water vapor conditions. However, oxidation conditions in industry resemble a 100% steam environment. Therefore, test methods to mimic such conditions are needed so that alloys can be tested and developed further for these applications. Four alloys with aluminum contents ranging from 2.6 to 3.9 wt% were cut from centrifugally cast pipes and subjected to oxidation in an environment of pure steam for up to 30 hours, at temperatures of 800 °C and 950 °C. Samples were analyzed using Raman, SEM, and EDS and showed a continuous alumina layer free of cracks. The alumina layer thickness increased with time. Additionally, larger thicknesses were observed in samples oxidized at 950 °C from those of 800 °C. Thickness measurements were used to calculate parabolic and non-parabolic oxidation rate constants. Samples were compared using calculated parabolic and modified parabolic rates of oxidation. Plots for the prediction of oxide layer thickness were generated both for the Wagner model of parabolic oxidation, and an experimentally determined modification to said model. Oxide scale thickness as formed in pure steam was shown to be related to the aluminum content of the alloy and the temperature and time of exposure. Further testing of alumina forming stainless steels in other concentrations of steam would allow for the determination of steam's effect on alumina formation kinetics. In addition, tests at additional temperatures between 800 and 950 °C would allow for the calculation of activation energies and full understanding of the oxide layer. Finally, the analysis of alumina layer thickness effects on coking performance in a petrochemical application would allow for the potential transition of these alloys into the commercial market.

Evaluation of particulate matter emissions from manganese alloy production using life-cycle assessment.

PubMed

Davourie, Julia; Westfall, Luke; Ali, Mohammed; McGough, Doreen

2017-01-01

Life-cycle assessments (LCAs) provide a wealth of industry data to assist in evaluating the environmental impacts of industrial processes and product supply chains. In this investigation, data from a recent LCA covering global manganese alloy production was used to evaluate sources of particulate matter (PM) emissions associated with the manganese alloy supply chain. The analysis is aimed at providing an empirical, industry-averaged breakdown of the contribution that processes and emissions controls have on total emissions, manganese releases and occupational exposure. The assessment shows that 66% of PM emissions associated with manganese production occur beyond manganese facilities. Direct or on-site emissions represent 34% of total PM and occur predominantly as disperse sources during mineral extraction and hauling, and as primary furnace emissions. The largest contribution of manganese-bearing PM at ground-level is associated with fugitive emissions from metal and slag tapping, casting, crushing and screening. The evaluation provides a high-level ranking of emissions by process area, to assist in identifying priority areas for industry-wide initiatives to reduce emissions and occupational exposure of manganese. The range of PM emission levels in industry indicate that further enhancements in PM emissions can be achieved by sharing of best practices in emissions controls, limiting furnace conditions which lead to by-passing of emissions controls and application of secondary emission controls to capture fugitive emissions during tapping and casting. The LCA approach to evaluating PM emissions underscores the important role that process optimization and resource efficiency have on reducing PM emissions throughout the manganese supply chain. Copyright © 2016. Published by Elsevier B.V.

Selection enhanced estimates of marker effects on means and variances of beef tenderness

USDA-ARS?s Scientific Manuscript database

Genetic marker associations from surveys of industry cattle populations have low frequencies of rare homozygous animals. Selection for calpain (CAPN1) and calpastatin (CAST) genetic markers was replicated in two cattle populations (Angus and MARC III) at the U.S. Meat Animal Research Center. These...

Directing 101.

ERIC Educational Resources Information Center

Pintoff, Ernest

Providing an introduction to anyone considering directing as a field of study or career, this book takes a broad look at the process of directing and encourages students and professionals alike to look outside of the movie industry for inspiration. Chapters in the book discuss selecting and acquiring material; budgeting and financing; casting and…

Telecommunications Reform: A High-Stakes Debate

ERIC Educational Resources Information Center

Luker, Mark A.

2005-01-01

The last major overhaul of U.S. federal telecommunications laws occurred nine years ago, with the Telecommunications Act of 1996. Now Congress--along with the Federal Communications Commission (FCC), state and local governments, and a cast of thousands representing the interests of the telecommunications industry, its customers, and many other…

EPA’s ToxCast Program for Predicting Toxicity and Prioritizing Chemicals for Further Screening and Testing

EPA Science Inventory

Testing of environmental and industrial chemicals for toxicity potential is a daunting task because of the wide range of possible toxicity mechanisms. Although animal testing is one means of achieving broad toxicity coverage, evaluation of large numbers of chemicals is challengin...

Alaskan Fish Gelatin Films: Thermal, Tensile, and Barrier Properties and Effects of Cross-linking

USDA-ARS?s Scientific Manuscript database

Gelatin was extracted from the skins of Alaska pollock (Theragra chalcogramma) and Alaska pink salmon (Oncorhynchus gorbuscha). These skins were by-products generated from the Alaskan fishing industry. Films were then cast from the fish gelatin and their thermal, tensile, water vapor permeability, o...

EPAs ToxCast Program for Predicting Toxcity and Prioritizing Chemicals for Further Screening and Testing

EPA Science Inventory

Testing of environmental and industrial chemicals for toxicity potential is a daunting task because of the wide range of possible toxicity mechanisms. Although animal testing is one means of achieving broad toxicity coverage, evaluation of large numbers of chemicals is challengin...

Microstructure and physical properties of nano-biocomposite films based on cassava starch and laponite.

PubMed

Valencia, Germán Ayala; Luciano, Carla Giovana; Lourenço, Rodrigo Vinicius; do Amaral Sobral, Paulo José

2018-02-01

The aim of this research was to study the effects of laponite concentrations on some properties of nano-biocomposite films based on cassava starch, focusing mainly the relation between the properties of the surface microstructure and roughness, water contact angle and gloss. Nano-biocomposite films were produced by casting. We analyzed gloss, color, opacity, water contact angle, crystallinity by X-ray diffraction, and microstructure by scanning electron microscopy and atomic force microscopy. Texture parameters (energy, entropy and fractal dimension) were extracted from micrographs. We observed a great impact of laponite in the morphology of nano-biocomposite films. Texture parameters correlated with surface heterogeneity and roughness. Finally, surface roughness affected the surface hydrophilicity of nano-biocomposite films. Laponite platelets were exfoliated and/or intercalated with amylose and amylopectin chains. This research reports new information on the effects of laponite concentrations on the morphological, optical and wetting properties of nano-biocomposite films aiming future industrial applications. Copyright © 2017 Elsevier B.V. All rights reserved.

Mapping the global flow of steel: from steelmaking to end-use goods.

PubMed

Cullen, Jonathan M; Allwood, Julian M; Bambach, Margarita D

2012-12-18

Our society is addicted to steel. Global demand for steel has risen to 1.4 billion tonnes a year and is set to at least double by 2050, while the steel industry generates nearly a 10th of the world's energy related CO₂ emissions. Meeting our 2050 climate change targets would require a 75% reduction in CO₂ emissions for every tonne of steel produced and finding credible solutions is proving a challenge. The starting point for understanding the environmental impacts of steel production is to accurately map the global steel supply chain and identify the biggest steel flows where actions can be directed to deliver the largest impact. In this paper we present a map of global steel, which for the first time traces steel flows from steelmaking, through casting, forming, and rolling, to the fabrication of final goods. The diagram reveals the relative scale of steel flows and shows where efforts to improve energy and material efficiency should be focused.

Industrial applications of automated X-ray inspection

NASA Astrophysics Data System (ADS)

Shashishekhar, N.

2015-03-01

Many industries require that 100% of manufactured parts be X-ray inspected. Factors such as high production rates, focus on inspection quality, operator fatigue and inspection cost reduction translate to an increasing need for automating the inspection process. Automated X-ray inspection involves the use of image processing algorithms and computer software for analysis and interpretation of X-ray images. This paper presents industrial applications and illustrative case studies of automated X-ray inspection in areas such as automotive castings, fuel plates, air-bag inflators and tires. It is usually necessary to employ application-specific automated inspection strategies and techniques, since each application has unique characteristics and interpretation requirements.

Epoxy hydantoins as matrix resins

NASA Technical Reports Server (NTRS)

Weiss, J.

1983-01-01

Tensile strength and fracture toughness of castings of the hydantoin resins cured with methylenedianiline are significantly higher than MY 720 control castings. Water absorption of an ethyl, amyl hydantoin formulation is 2.1 percent at equilibrium and Tg's are about 160 C, approximately 15 deg below the final cure temperature. Two series of urethane and ester-extended hydantoin epoxy resins were synthesized to determine the effect of crosslink density and functional groups on properties. Castings cured with methylenedianiline or with hexahydrophthalic anhydride were made from these compounds and evaluated. The glass transition temperatures, tensile strengths and moduli, and fracture toughness values were all much lower than that of the simple hydantoin epoxy resins. Using a methylene bishydantoin epoxy with a more rigid structure gave brittle, low-energy fractures, while a more flexible, ethoxy-extended hydantoin epoxy resin gave a very low Tg.

Automated flaw detection scheme for cast austenitic stainless steel weld specimens using Hilbert-Huang transform of ultrasonic phased array data

DOE Office of Scientific and Technical Information (OSTI.GOV)

Khan, Tariq; Majumdar, Shantanu; Udpa, Lalita

2012-05-17

The objective of this work is to develop processing algorithms to detect and localize flaws using ultrasonic phased-array data. Data was collected on cast austenitic stainless stell (CASS) weld specimens onloan from the U.S. nuclear power industry' Pressurized Walter Reactor Owners Group (PWROG) traveling specimen set. Each specimen consists of a centrifugally cast stainless stell (CCSS) pipe section welded to a statically cst(SCSS) or wrought (WRSS) section. The paper presents a novel automated flaw detection and localization scheme using low frequency ultrasonic phased array inspection singals from the weld and heat affected zone of the based materials. The major stepsmore » of the overall scheme are preprocessing and region of interest (ROI) detection followed by the Hilbert-Huang transform (HHT) of A-scans in the detected ROIs. HHT offers time-frequency-energy distribution for each ROI. The Accumulation of energy in a particular frequency band is used as a classification feature for the particular ROI.« less

Mortality among hourly motor vehicle manufacturing workers.

PubMed

Delzell, Elizabeth; Brown, David A; Matthews, Robert

2003-08-01

We evaluated mortality among 198,245 motor vehicle industry workers during the period of 1973 to 1995. Workers' mortality rates were lower than expected overall (40,131 observed/43,859 expected deaths, standardized mortality ratio [SMR] = 92, CI = 91-92) and for all major cause of death categories except cancer (SMR = 100, CI = 98-102). Mortality rates were higher than expected for lung cancer overall (SMR = 110, CI = 107-113) and among employees in transmission/gear manufacturing (SMR = 121, CI = 112-130), casting operations (SMR = 122, CI = 110-135), engine manufacturing (SMR = 111, CI = 101-123), and vehicle assembly (SMR = 111, CI = 105-117); for stomach cancer in engine manufacturing (SMR = 147, CI = 110-192); and for prostate cancer in casting operations (SMR = 128, CI = 102-158). Excesses of lung cancer in transmission, vehicle assembly, and casting operations and of stomach cancer in engine manufacturing have been observed in other investigations. Further information on employees' occupational exposures and personal attributes is required to clarify the interpretation of these results.

Factors related to tooth loss due to dental caries among workers in an industrial estates in Thailand.

PubMed

Chatrchaiwiwatana, Supaporn; Ratanasiri, Amornrat; Jaidee, Jeeratip; Soontorn, Surasak

2012-11-01

The present study aimed to evaluate the prevalence and factors related to tooth loss due to dental caries among workers in industrial estates in Pathumthani and Phranakhorn Si Ayutthaya provinces in central Thailand. The present study utilized quantitative and qualitative methodologies. A quantitative study was done using a cross-sectional analytic method with a sample group of 457 adults (283 males; 174 females) between 19 and 53 years. Data were obtained through an oral examination and oral health behavior questionnaire. Data analyses were done using descriptive, bivariate and multivariable logistic regression statistics. In-depth interviews were used to collect qualitative data from 11 subjects. Most (62.2%) participants had tooth loss due to caries and findings from the final multivariable logistic regression model revealed that such loss was associated with education, residency, use of social security welfare, decayed teeth and filled teeth. Relatedly, the in-depth interview confirmed that tooth loss due to dental caries was related to (1) lack of time to visit a dentist (2) have a negative attitude toward or a phobia regarding dental treatment (3) inability to afford the high cast of dental treatment (4) lack of knowledge in regarding dental caries prevention, root canal treatment and the harmful effects of losing teeth (5) choosing to get an extraction upon having caries exposed pulp and (6) lack of oral health promotion programs provided by either the government or private sectors. The government and non-government organizations should promote oral health in an industrial estates and provide services and welfare for dental health of workers in an industrial estate appropriate to their socio-economic needs.

Physiological variation as a mechanism for developmental caste-biasing in a facultatively eusocial sweat bee.

PubMed

Kapheim, Karen M; Smith, Adam R; Ihle, Kate E; Amdam, Gro V; Nonacs, Peter; Wcislo, William T

2012-04-07

Social castes of eusocial insects may have arisen through an evolutionary modification of an ancestral reproductive ground plan, such that some adults emerge from development physiologically primed to specialize on reproduction (queens) and others on maternal care expressed as allo-maternal behaviour (workers). This hypothesis predicts that variation in reproductive physiology should emerge from ontogeny and underlie division of labour. To test these predictions, we identified physiological links to division of labour in a facultatively eusocial sweat bee, Megalopta genalis. Queens are larger, have larger ovaries and have higher vitellogenin titres than workers. We then compared queens and workers with their solitary counterparts-solitary reproductive females and dispersing nest foundresses-to investigate physiological variation as a factor in caste evolution. Within dyads, body size and ovary development were the best predictors of behavioural class. Queens and dispersers are larger, with larger ovaries than their solitary counterparts. Finally, we raised bees in social isolation to investigate the influence of ontogeny on physiological variation. Body size and ovary development among isolated females were highly variable, and linked to differences in vitellogenin titres. As these are key physiological predictors of social caste, our results provide evidence for developmental caste-biasing in a facultatively eusocial bee.

Physiological variation as a mechanism for developmental caste-biasing in a facultatively eusocial sweat bee

PubMed Central

Kapheim, Karen M.; Smith, Adam R.; Ihle, Kate E.; Amdam, Gro V.; Nonacs, Peter; Wcislo, William T.

2012-01-01

Social castes of eusocial insects may have arisen through an evolutionary modification of an ancestral reproductive ground plan, such that some adults emerge from development physiologically primed to specialize on reproduction (queens) and others on maternal care expressed as allo-maternal behaviour (workers). This hypothesis predicts that variation in reproductive physiology should emerge from ontogeny and underlie division of labour. To test these predictions, we identified physiological links to division of labour in a facultatively eusocial sweat bee, Megalopta genalis. Queens are larger, have larger ovaries and have higher vitellogenin titres than workers. We then compared queens and workers with their solitary counterparts—solitary reproductive females and dispersing nest foundresses—to investigate physiological variation as a factor in caste evolution. Within dyads, body size and ovary development were the best predictors of behavioural class. Queens and dispersers are larger, with larger ovaries than their solitary counterparts. Finally, we raised bees in social isolation to investigate the influence of ontogeny on physiological variation. Body size and ovary development among isolated females were highly variable, and linked to differences in vitellogenin titres. As these are key physiological predictors of social caste, our results provide evidence for developmental caste-biasing in a facultatively eusocial bee. PMID:22048951

Segmentation of images for gingival growth measurement

NASA Astrophysics Data System (ADS)

Kim, Dong-Il; Wilson, Joseph N.

1992-12-01

The ability to measure gingival volume growth from dental casts would provide a valuable resource for periodontists. This problem is attractive from a computer vision standpoint due to the complexities of data acquisition, segmentation of gingival and tooth surfaces and boundaries, and extraction of features (such as tooth axes) to help solve the correspondence problem for multiple casts. In this paper, a structured light 3-D range finder is used to collect raw data. The most complicated subtask is that of detecting discontinuities such as the gingival margin. Discontinuity detection is hindered both by cast anomalies (such as bubbles and holes generated during the process of dental impression) and by the subtle nature of the discontinuities themselves. First, we discuss an approach to segmenting a dental cast into tooth and gingival units using depth and orientation discontinuities. The visible cast surface is reconstructed by obtaining the minimum of a parameterized functional. The first derivative of the energy functional (which corresponds to the Euler-Lagrange equation) is solved using the multigrid methods. both orientation and depth discontinuities are detected by adding a discrete discontinuity functional to the energy functional. The principal axes and boundaries of the teeth provide the information necessary to determine the region to be measured in estimating gingival growth. Finally, voxels corresponding to growth regions are counted to measure the target volume.

Modeling the Homogenization Kinetics of As-Cast U-10wt% Mo alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Xu, Zhijie; Joshi, Vineet; Hu, Shenyang Y.

2016-01-15

Low-enriched U-22at% Mo (U-10Mo) alloy has been considered as an alternative material to replace the highly enriched fuels in research reactors. For the U-10Mo to work effectively and replace the existing fuel material, a thorough understanding of the microstructure development from as-cast to the final formed structure is required. The as-cast microstructure typically resembles an inhomogeneous microstructure with regions containing molybdenum-rich and -lean regions, which may affect the processing and possibly the in-reactor performance. This as-cast structure must be homogenized by thermal treatment to produce a uniform Mo distribution. The development of a modeling capability will improve the understanding ofmore » the effect of initial microstructures on the Mo homogenization kinetics. In the current work, we investigated the effect of as-cast microstructure on the homogenization kinetics. The kinetics of the homogenization was modeled based on a rigorous algorithm that relates the line scan data of Mo concentration to the gray scale in energy dispersive spectroscopy images, which was used to generate a reconstructed Mo concentration map. The map was then used as realistic microstructure input for physics-based homogenization models, where the entire homogenization kinetics can be simulated and validated against the available experiment data at different homogenization times and temperatures.« less

A novel ultra-low carbon grain oriented silicon steel produced by twin-roll strip casting

NASA Astrophysics Data System (ADS)

Wang, Yang; Zhang, Yuan-Xiang; Lu, Xiang; Fang, Feng; Xu, Yun-Bo; Cao, Guang-Ming; Li, Cheng-Gang; Misra, R. D. K.; Wang, Guo-Dong

2016-12-01

A novel ultra-low carbon grain oriented silicon steel was successfully produced by strip casting and two-stage cold rolling method. The microstructure, texture and precipitate evolution under different first cold rolling reduction were investigated. It was shown that the as-cast strip was mainly composed of equiaxed grains and characterized by very weak Goss texture ({110}<001>) and λ-fiber (<001>//ND). The coarse sulfides of size 100 nm were precipitated at grain boundaries during strip casting, while nitrides remained in solution in the as-cast strip and the fine AlN particles of size 20-50 nm, which were used as grain growth inhibitors, were formed in intermediate annealed sheet after first cold rolling. In addition, the suitable Goss nuclei for secondary recrystallization were also formed during intermediate annealing, which is totally different from the conventional process that the Goss nuclei originated in the subsurface layer of the hot rolled sheet. Furthermore, the number of AlN inhibitors and the intensity of desirable Goss texture increased with increasing first cold rolling reduction. After secondary recrystallization annealing, very large grains of size 10-40 mm were formed and the final magnetic induction, B8, was as high as 1.9 T.

Solid State Characterizations of Long-Term Leached Cast Stone Monoliths

DOE Office of Scientific and Technical Information (OSTI.GOV)

Asmussen, Robert M.; Pearce, Carolyn I.; Parker, Kent E.

This report describes the results from the solid phase characterization of six Cast Stone monoliths from the extended leach tests recently reported on (Serne et al. 2016),that were selected for characterization using multiple state-of-the-art approaches. The Cast Stone samples investigated were leached for > 590 d in the EPA Method 1315 test then archived for > 390 d in their final leachate. After reporting the long term leach behavior of the monoliths (containing radioactive 99Tc and stable 127I spikes and for original Westsik et al. 2013 fabricated monoliths, 238U), it was suggested that physical changes to the waste forms andmore » a depleting inventory of contaminants of potential concern may mean that effective diffusivity calculations past 63 d should not be used to accurately represent long-term waste form behavior. These novel investigations, in both length of leaching time and application of solid state techniques, provide an initial arsenal of techniques which can be utilized to perform such Cast Stone solid phase characterization work, which in turn can support upcoming performance assessment maintenance. The work was performed at Pacific Northwest National Laboratory (PNNL) for Washington River Protection Solutions (WRPS) to characterize several properties of the long- term leached Cast Stone monolith samples.« less

Simulation of the as-cast structure of Al-4.0wt.%Cu ingots with a 5-phase mixed columnar-equiaxed solidification model

NASA Astrophysics Data System (ADS)

Wu, M.; Ahmadein, M.; Kharicha, A.; Ludwig, A.; Li, J. H.; Schumacher, P.

2012-07-01

Empirical knowledge about the formation of the as-cast structure, mostly obtained before 1980s, has revealed two critical issues: one is the origin of the equiaxed crystals; one is the competing growth of the columnar and equiaxed structures, and the columnar-to-equiaxed transition (CET). Unfortunately, the application of empirical knowledge to predict and control the as-cast structure was very limited, as the flow and crystal transport were not considered. Therefore, a 5-phase mixed columnar-equiaxed solidification model was recently proposed by the current authors based on modeling the multiphase transport phenomena. The motivation of the recent work is to determine and evaluate the necessary modeling parameters, and to validate the mixed columnar-equiaxed solidification model by comparison with laboratory castings. In this regard an experimental method was recommended for in-situ determination of the nucleation parameters. Additionally, some classical experiments of the Al-Cu ingots were conducted and the as-cast structural information including distinct columnar and equiaxed zones, macrosegregation, and grain size distribution were analysed. The final simulation results exhibited good agreement with experiments in the case of high pouring temperature, whereas disagreement in the case of low pouring temperature. The reasons for the disagreement are discussed.

Experimental processing and the effects of cenosphere on some mechanical properties of Al6061-SiC composites

NASA Astrophysics Data System (ADS)

Ashoka, E.; Sharanaprabhu, C. M.; Krishnaraja, G. Kodancha; Kudari, S. K.

2018-04-01

In this paper, stir casting technique was utilized to fabricate the hybrid Aluminium alloy (Al 6061) metal matrix reinforced with silicon carbide (SiC) and cenosphere particulates. An Al6061-SiC-Cenosphere hybrid composite is selected with 3wt% of silicon carbide and 3wt%, 6wt% and 9wt% proportions of cenosphere particulates. The uniform distribution of these two reinforcement particulates in Al6061matrix was achieved by stirring and pouring the hybrid composite mixture into the steel mould to accomplish the rectangular shaped casting. These various hybrid composites were studied with respect to its microstructure and some mechanical properties. The rectangular shaped casting of various hybrid composites was machined according to ASTM tensile specimens standards to estimate some mechanical properties. For various cast hybrid composites a comparative study is done with respect to modulus of elasticity, yield stress, percentage elongation and microhardness. Finally, the distribution of particulates and the nature of the tensile specimen fractured surface of various hybrid composites were understood using scanning electron microscope.

Experimental Study On Flexural Behaviour Of Beams Reinforced With GFRP Rebars

NASA Astrophysics Data System (ADS)

Naveen Kumar, G.; Sundaravadivelu, Karthik

2017-07-01

In saline, moisture and cold conditions corrosion of steel is inevitable and the lot of economy is used for rehabilitation works. Corrosion of steel is nothing but oxidation of iron in moisture conditions and this corrosion leads to the spalling of concrete which intern reduces the strength of the structure. To reduce this corrosion effects, new materials with resistance against corrosion have to be introduced. Many experiments are going on using Glass Fiber Reinforced Polymer (GFRP) as alternate material for steel due to its non-corrosive nature, weight of GFRP is nearly one third of steel and ultimate tensile strength is higher than steel. In this paper, six beams are casted in which three beams are casted with steel as main and shear reinforcement and another three beams are casted with GFRP as main reinforcement with steel as shear reinforcing material. All beams casted are of same dimensions with variation in reinforcement percentage. The size of the beams casted is of length 1200 mm, breadth 100 mm and depth 200 mm. The clear cover of 25 mm is provided on top and bottom of the beam. Beams are tested under two-point loading with constant aspect ratio (a/d) and comparing the flexural strength, load deflection curves and types of failures of beams reinforced with GFRP as main reinforcement and beams reinforced with conventional steel. The final experimental results are compared with numerical results. M30 grade concrete with Conplast as a superplasticizer is used for casting beams.

Development of volume deposition on cast iron by additive manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sridharan, Niyanth; Dehoff, Ryan R.; Jordan, Brian H.

2016-11-10

ORNL partnered with Cummins to demonstrate the feasibility of using additive manufacturing techniques to help develop repair techniques for refurbished cast iron engine blocks. Cummins is interested in the refurbished engine business due to the increased cost savings and reduced emissions. It is expected that by refurbishing engines could help reduce the green house gas emissions by as much as 85%. Though such repair techniques are possible in principle there has been no major industry in the automotive sector that has deployed this technology. Therefore phase-1 would seek to evaluate the feasibility of using the laser directed energy deposition techniquemore » to repair cast iron engine blocks. The objective of the phase-1 would be to explore various strategies and understand the challenges involved. During phase-1 deposits were made using Inconel-718, Nickel, Nr-Cr-B braze filler. Inconel 718 builds showed significant cracking in the heat-affected zone in the cast iron. Nickel was used to reduce the cracking in the cast iron substrate, however the Ni builds did not wet the substrate sufficiently resulting in poor dimensional tolerance. In order to increase wetting the Ni was alloyed with the Ni-Cr-B braze to decrease the surface tension of Ni. This however resulted in significant cracks in the build due to shrinkage stresses associated with multiple thermal cycling. Hence to reduce the residual stresses in the builds the DMD-103D equipment was modified and the cast iron block was pre heated using cartridge heaters. Inconel-718 alloyed with Ni was deposited on the engine block. The pre-heated deposits showed a reduced susceptibility to cracking. If awarded the phase-2 of the project would aim to develop process parameters to achieve a crack free deposit engine block.« less

Water research program final report, March 15, 1970 to October 31, 1972. Separations processes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Minturn, R. E.

A summary article on separation by filtration is reprinted, and research is reported in the following areas: dynamic membranes, cast film membranes, concentration polarization, economic analysis; and enhanced heat transfer. (DHM)

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.

78 FR 72639 - Non-Malleable Cast Iron Pipe Fittings From the People's Republic of China: Final Results of the...

Federal Register 2010, 2011, 2012, 2013, 2014

2013-12-03

... dumping margins likely to prevail is indicated in the ``Final Results of Sunset Review'' section of this... likelihood of continuation or recurrence of dumping and the magnitude of the margins likely to prevail if the... dumping margin likely to prevail [FR Doc. 2013-28952 Filed 12-2-13; 8:45 am] BILLING CODE 3510-DS-P ...

75 FR 62110 - Notice of Petitions by Firms for Determination of Eligibility To Apply for Trade Adjustment...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-10-07

... passive and electro- mechanical component parts. Knickerbocker Machine Shop, Inc. dba 611 Union Boulevard... manufactures Memphis, TX 79245. components of cast steel products. Pequea Machine, Inc 200 Jalyn Drive, P.O..., Warren, PA 16365. manufacturer of solid polyurethane and rubber industrial wear products. Any party...

Manufacturing Materials and Processes. Grade 11-12. Course #8165 (Semester). Technology Education Course Guide. Industrial Arts/Technology Education.

ERIC Educational Resources Information Center

North Carolina State Dept. of Public Instruction, Raleigh. Div. of Vocational Education.

This guide is intended for use in teaching an introductory course in manufacturing materials and processes. The course centers around four basic materials--metallics, polymers, ceramics, and composites--and seven manufacturing processes--casting, forming, molding, separating, conditioning, assembling, and finishing. Concepts and classifications of…

Robotic Water Blast Cleaner

NASA Technical Reports Server (NTRS)

Sharpe, M. H.; Roberts, M. L.; Hill, W. E.; Jackson, C. H.

1983-01-01

Water blasting system under development removes hard, dense, extraneous material from surfaces. High pressure pump forces water at supersonic speed through nozzle manipulated by robot. Impact of water blasts away unwanted material from workpiece rotated on air bearing turntable. Designed for removing thermal-protection material, system is adaptable to such industrial processes as cleaning iron or steel castings.

Transitional flow in thin tubes for space station freedom radiator

NASA Technical Reports Server (NTRS)

Loney, Patrick; Ibrahim, Mounir

1995-01-01

A two dimensional finite volume method is used to predict the film coefficients in the transitional flow region (laminar or turbulent) for the radiator panel tubes. The code used to perform this analysis is CAST (Computer Aided Simulation of Turbulent Flows). The information gathered from this code is then used to augment a Sinda85 model that predicts overall performance of the radiator. A final comparison is drawn between the results generated with a Sinda85 model using the Sinda85 provided transition region heat transfer correlations and the Sinda85 model using the CAST generated data.

CASTING DEFECT MODELING IN AN INTEGRATED COMPUTATIONAL MATERIALS ENGINEERING APPROACH

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sabau, Adrian S

2015-01-01

To accelerate the introduction of new cast alloys, the simultaneous modeling and simulation of multiphysical phenomena needs to be considered in the design and optimization of mechanical properties of cast components. The required models related to casting defects, such as microporosity and hot tears, are reviewed. Three aluminum alloys are considered A356, 356 and 319. The data on calculated solidification shrinkage is presented and its effects on microporosity levels discussed. Examples are given for predicting microporosity defects and microstructure distribution for a plate casting. Models to predict fatigue life and yield stress are briefly highlighted here for the sake ofmore » completion and to illustrate how the length scales of the microstructure features as well as porosity defects are taken into account for modeling the mechanical properties. Thus, the data on casting defects, including microstructure features, is crucial for evaluating the final performance-related properties of the component. ACKNOWLEDGEMENTS This work was performed under a Cooperative Research and Development Agreement (CRADA) with the Nemak Inc., and Chrysler Co. for the project "High Performance Cast Aluminum Alloys for Next Generation Passenger Vehicle Engines. The author would also like to thank Amit Shyam for reviewing the paper and Andres Rodriguez of Nemak Inc. Research sponsored by the U. S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Office, as part of the Propulsion Materials Program under contract DE-AC05-00OR22725 with UT-Battelle, LLC. Part of this research was conducted through the Oak Ridge National Laboratory's High Temperature Materials Laboratory User Program, which is sponsored by the U. S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Program.« less

Thermodynamic Behavior Research Analysis of Twin-roll Casting Lead Alloy Strip Process

NASA Astrophysics Data System (ADS)

Jiang, Chengcan; Rui, Yannian

2017-03-01

The thermodynamic behavior of twin-roll casting (TRC) lead alloy strip process directly affects the forming of the lead strip, the quality of the lead strip and the production efficiency. However, there is little research on the thermodynamics of lead alloy strip at home and abroad. The TRC lead process is studied in four parameters: the pouring temperature of molten lead, the depth of molten pool, the roll casting speed, and the rolling thickness of continuous casting. Firstly, the thermodynamic model for TRC lead process is built. Secondly, the thermodynamic behavior of the TRC process is simulated with the use of Fluent. Through the thermodynamics research and analysis, the process parameters of cast rolling lead strip can be obtained: the pouring temperature of molten lead: 360-400 °C, the depth of molten pool: 250-300 mm, the roll casting speed: 2.5-3 m/min, the rolling thickness: 8-9 mm. Based on the above process parameters, the optimal parameters(the pouring temperature of molten lead: 375-390 °C, the depth of molten pool: 285-300 mm, the roll casting speed: 2.75-3 m/min, the rolling thickness: 8.5-9 mm) can be gained with the use of the orthogonal experiment. Finally, the engineering test of TRC lead alloy strip is carried out and the test proves the thermodynamic model is scientific, necessary and correct. In this paper, a detailed study on the thermodynamic behavior of lead alloy strip is carried out and the process parameters of lead strip forming are obtained through the research, which provide an effective theoretical guide for TRC lead alloy strip process.

Silicon-based Porous Ceramics via Freeze Casting of Preceramic Polymers

NASA Astrophysics Data System (ADS)

Naviroj, Maninpat

Freeze casting is a technique for processing porous materials that has drawn significant attention for its effectiveness in producing a variety of tailorable pore structures for ceramics, metals, and polymers. With freeze casting, pores are generated based on a solidification process where ice crystals act as a sacrificial template which can eventually be sublimated to create pores. While the majority of freeze-casting studies have been performed using conventional ceramic suspensions, this work explores an alternative processing route by freeze casting with preceramic polymer solutions. Significant differences exist between freeze casting of a particulate suspension and a polymeric solution. These changes affect the processing method, solidification behavior, and pore structure, thereby introducing new challenges and possibilities for the freeze-casting technique. The first part of this study explored the processing requirements involved with freeze casting of preceramic polymers, along with methods to control the resulting pore structure. Solvent choice, freezing front velocity, and polymer concentration were used as processing variables to manipulate the pore structures. A total of seven organic solvents were freeze cast with a polymethylsiloxane preceramic polymer to produce ceramics with isotropic, dendritic, prismatic, and lamellar pore morphologies. Changes in freezing front velocity and polymer concentration were shown to influence pore size, shape, and connectivity. Differences between suspension- and solution-based samples freeze cast under equivalent conditions were also investigated. Certain solidification microstructures were strongly affected by the presence of suspended particles, creating differences between pore structures generated from the same solvents. Additionally, processing of solution-based samples were found to be the more facile technique. Compressive strength and water permeability of dendritic and lamellar structures were analyzed to determine functional differences between the pore structures. Results show that dendritic structures were up to 30 times stronger, while lamellar structures provided higher permeability constants. A change in freezing front velocity was shown to significantly affect permeability but not compressive strength. Finally, improved pore alignment along the freezing direction was achieved by controlling the nucleation and growth of solvent crystals through the use of a grain-selection template. Dendritic samples freeze cast with a template showed substantial increase in pore alignment, as determined by image analysis and permeability tests, with the permeability constant increasing by up to 6-fold when compared to a control sample.

A prospective study on the effectiveness of cotton versus waterproof cast padding in maintaining the reduction of pediatric distal forearm fractures.

PubMed

Robert, Christopher E; Jiang, Jimmy J; Khoury, Joseph G

2011-03-01

Distal forearm fractures, one of the most common fractures seen in the pediatric population, are regularly treated by closed reduction and casting. Our study investigates the effectiveness of Gore-Tex-lined casting in maintaining the reduction of 100% displaced distal forearm fractures compared with traditional cotton-lined casts. We screened all patients from February 2007 to July 2009 who presented to Children's Hospital in Birmingham, AL with a distal radius fracture. Only patients with 100% displaced distal radius fractures were eligible to be assigned to either the cotton-lined or Gore-Tex-lined cast groups. Power analysis was performed to identify an adequate patient sample size. The mean maximum change between initial post-reduction x-rays and follow-up x-rays for anterior-posterior (AP) angulation, AP displacement, lateral angulation, and lateral displacement of the radius were calculated for both cotton and Gore-Tex groups. The rate of subsequent intervention and/or unacceptable results for each group was also analyzed. Seven hundred and twenty-two patients were treated with distal radius fractures at our hospital with 59 patients eligible for inclusion in our study. Thirty-six of our patients were treated with cotton-lined casts, and 23 patients were treated with Gore-Tex-lined cast. The mean maximum change in AP angulation, AP displacement, lateral angulation, and lateral displacement of the radius after initial reduction was 9.2 degrees, 6.9%, 13.9 degrees, and 13.6%, respectively, for the cotton-lined cast group and 7.7 degrees, 6.1%, 14.6 degrees, and 9.6%, respectively, for the Gore-Tex-lined cast group. There were no statistical differences between the means of the 4 measurements (P=0.33, 0.69, 0.73, and 0.10, respectively). There were also no significant differences between groups for final AP and lateral angulation and displacement. Subgroup analysis showed no significant differences in all measurements between cotton and Gore-Tex groups. Gore-Tex and cotton-lined casts are equally effective in their ability to maintain the reduction of 100% displaced distal forearm fractures. Thus, Gore-Tex-lined casts can be offered to pediatric patients immediately after closed reduction of distal radius fractures of any severity. Therapeutic level II.

Modeling of the Coupling of Microstructure and Macrosegregation in a Direct Chill Cast Al-Cu Billet

NASA Astrophysics Data System (ADS)

Heyvaert, Laurent; Bedel, Marie; Založnik, Miha; Combeau, Hervé

2017-10-01

The macroscopic multiphase flow and the growth of the solidification microstructures in the mushy zone of a direct chill (DC) casting are closely coupled. These couplings are the key to the understanding of the formation of the macrosegregation and of the non-uniform microstructure of the casting. In the present paper we use a multiphase and multiscale model to provide a fully coupled picture of the links between macrosegregation and microstructure in a DC cast billet. The model describes nucleation from inoculant particles and growth of dendritic and globular equiaxed crystal grains, fully coupled with macroscopic transport phenomena: fluid flow induced by natural convection and solidification shrinkage, heat, mass, and solute mass transport, motion of free-floating equiaxed grains, and of grain refiner particles. We compare our simulations to experiments on grain-refined and non-grain-refined industrial size billets from literature. We show that a transition between dendritic and globular grain morphology triggered by the grain refinement is the key to the explanation of the differences between the macrosegregation patterns in the two billets. We further show that the grain size and morphology are strongly affected by the macroscopic transport of free-floating equiaxed grains and of grain refiner particles.

Influence of macromolecular architecture on necking in polymer extrusion film casting process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pol, Harshawardhan; Banik, Sourya; Azad, Lal Busher

2015-05-22

Extrusion film casting (EFC) is an important polymer processing technique that is used to produce several thousand tons of polymer films/coatings on an industrial scale. In this research, we are interested in understanding quantitatively how macromolecular chain architecture (for example long chain branching (LCB) or molecular weight distribution (MWD or PDI)) influences the necking and thickness distribution of extrusion cast films. We have used different polymer resins of linear and branched molecular architecture to produce extrusion cast films under controlled experimental conditions. The necking profiles of the films were imaged and the velocity profiles during EFC were monitored using particlemore » tracking velocimetry (PTV) technique. Additionally, the temperature profiles were captured using an IR thermography and thickness profiles were calculated. The experimental results are compared with predictions of one-dimensional flow model of Silagy et al{sup 1} wherein the polymer resin rheology is modeled using molecular constitutive equations such as the Rolie-Poly (RP) and extended Pom Pom (XPP). We demonstrate that the 1-D flow model containing the molecular constitutive equations provides new insights into the role of macromolecular chain architecture on film necking.{sup 1}D. Silagy, Y. Demay, and J-F. Agassant, Polym. Eng. Sci., 36, 2614 (1996)« less

Thermal analysis on Al7075/Al2O3 metal matrix composites fabricated by stir casting process

NASA Astrophysics Data System (ADS)

Jacob, S.; Shajin, S.; Gnanavel, C.

2017-03-01

Metal matrix Composites (MMC’s) have evoked a keen interest in recent times for various applications in aerospace, renewable energy and automotive industries due to their superior strength, low cost, easy availability and high temperature resistance [1]. The crack and propagation occurs in conventional materials without any appreciable indication in a short span. Hence composite materials are preferred nowadays to overcome this problem [2]. The process of metal matrix composites (MMC’s) is to unite the enviable attributes of metals and ceramics. The Stir casting method is used for producing aluminium metal matrix composites (AMC’s). A key challenge of the process is to spread the ceramic particles to achieve a defect free microstructure [2]. By carefully selecting stir casting processing specification, such as stirring time, temperature of the melt and blade angle, the desired microstructure can be obtained. The focus of this work is to develop a high strength particulate strengthen aluminium metal matrix composites, and Al7075 was selected which can offer high strength without much disturbing ductility of metal matrix [4]. The composites will be examined using standard metallurgical and mechanical tests. The cast composites are analysed to Laser flash analysis (LFA) to determine Thermal conductivity [5]. Also changes in microstructure are determined by using SEM analysis.

Novel casting processes for single-crystal turbine blades of superalloys

NASA Astrophysics Data System (ADS)

Ma, Dexin

2018-03-01

This paper presents a brief review of the current casting techniques for single-crystal (SC) blades, as well as an analysis of the solidification process in complex turbine blades. A series of novel casting methods based on the Bridgman process were presented to illustrate the development in the production of SC blades from superalloys. The grain continuator and the heat conductor techniques were developed to remove geometry-related grain defects. In these techniques, the heat barrier that hinders lateral SC growth from the blade airfoil into the extremities of the platform is minimized. The parallel heating and cooling system was developed to achieve symmetric thermal conditions for SC solidification in blade clusters, thus considerably decreasing the negative shadow effect and its related defects in the current Bridgman process. The dipping and heaving technique, in which thinshell molds are utilized, was developed to enable the establishment of a high temperature gradient for SC growth and the freckle-free solidification of superalloy castings. Moreover, by applying the targeted cooling and heating technique, a novel concept for the three-dimensional and precise control of SC growth, a proper thermal arrangement may be dynamically established for the microscopic control of SC growth in the critical areas of large industrial gas turbine blades.

The cavitation erosion of ultrasonic sonotrode during large-scale metallic casting: Experiment and simulation.

PubMed

Tian, Yang; Liu, Zhilin; Li, Xiaoqian; Zhang, Lihua; Li, Ruiqing; Jiang, Ripeng; Dong, Fang

2018-05-01

Ultrasonic sonotrodes play an essential role in transmitting power ultrasound into the large-scale metallic casting. However, cavitation erosion considerably impairs the in-service performance of ultrasonic sonotrodes, leading to marginal microstructural refinement. In this work, the cavitation erosion behaviour of ultrasonic sonotrodes in large-scale castings was explored using the industry-level experiments of Al alloy cylindrical ingots (i.e. 630 mm in diameter and 6000 mm in length). When introducing power ultrasound, severe cavitation erosion was found to reproducibly occur at some specific positions on ultrasonic sonotrodes. However, there is no cavitation erosion present on the ultrasonic sonotrodes that were not driven by electric generator. Vibratory examination showed cavitation erosion depended on the vibration state of ultrasonic sonotrodes. Moreover, a finite element (FE) model was developed to simulate the evolution and distribution of acoustic pressure in 3-D solidification volume. FE simulation results confirmed that significant dynamic interaction between sonotrodes and melts only happened at some specific positions corresponding to severe cavitation erosion. This work will allow for developing more advanced ultrasonic sonotrodes with better cavitation erosion-resistance, in particular for large-scale castings, from the perspectives of ultrasonic physics and mechanical design. Copyright © 2018 Elsevier B.V. All rights reserved.

Enhancement of Efficiency and Reduction of Grid Thickness Variation on Casting Process with Lean Six Sigma Method

NASA Astrophysics Data System (ADS)

Witantyo; Setyawan, David

2018-03-01

In a lead acid battery industry, grid casting is a process that has high defect and thickness variation level. DMAIC (Define-Measure-Analyse-Improve-Control) method and its tools will be used to improve the casting process. In the Define stage, it is used project charter and SIPOC (Supplier Input Process Output Customer) method to map the existent problem. In the Measure stage, it is conducted a data retrieval related to the types of defect and the amount of it, also the grid thickness variation that happened. And then the retrieved data is processed and analyzed by using 5 Why’s and FMEA method. In the Analyze stage, it is conducted a grid observation that experience fragile and crack type of defect by using microscope showing the amount of oxide Pb inclusion in the grid. Analysis that is used in grid casting process shows the difference of temperature that is too high between the metal fluid and mold temperature, also the corking process that doesn’t have standard. The Improve stage is conducted a fixing process which generates the reduction of grid variation thickness level and defect/unit level from 9,184% to 0,492%. In Control stage, it is conducted a new working standard determination and already fixed control process.

Straighttalk. Creating a climate of innovation: the healthcare industry's biggest challenge. Panel discussion.

PubMed

Chin, David; Rosenblatt, Alice; Simon, Greg; Lauer, Charles

2007-10-29

The U.S. health system is not sustainable as currently structured--innovation is necessary to fuel reform, according to PricewaterhouseCoopers' report, HealthCast 2020: Creating a Sustainable Health System. But wide-scale innovation--which requires diverse players within the industry to collaborate--is difficult to achieve. In this installment of Straight Talk, leaders from WellPoint, Inc., one of the nation's largest health benefits companies, and FasterCures/The Center for Accelerating Medical Solutions, a think-tank based in Washington, talk about what they're doing to nurture innovation.

Improved quality truck castings : final report.

DOT National Transportation Integrated Search

2016-06-01

A review of the car repair billing database shows that many bolsters and side frames are removed from service each year due to : cracking or breaking. Derailment-related costs due to bolster and side frame failures total approximately $9 million per ...

Application of self-consolidating concrete in bridge structures : final report.

DOT National Transportation Integrated Search

2011-05-01

The objectives of this research were to evaluate the feasibility and performance of self-consolidating concrete (SCC) made with local aggregates for use in cast-in-place and precast concrete applications and to develop draft specifications, acceptanc...

ScienceCast 99: A Whiff of Dark Matter on the ISS

NASA Image and Video Library

2013-04-12

An advanced particle detector onboard the International Space Station may have recorded its first whiff of Dark Matter. Researchers are excited about the possibility of finally understanding what this mysterious substance is made of.

High-Strength Aluminum Casting Alloy for High-Temperature Applications (MSFC Center Director's Discretionary Fund Final Project No. 97-10)

NASA Technical Reports Server (NTRS)

Lee, J. A.

1998-01-01

A new aluminum-silicon alloy has been successfully developed at Marshall Space Flight Center that has a significant improvement in tensile strength at elevated temperatures (550 to 700 F). For instance, the new alloy shows in average tensile strength of at least 90 percent higher than the current 390 aluminum piston alloy tested at 500 F. Compared to conventional aluminum alloys, automotive engines using the new piston alloy will have improved gas mileage, and may produce less air pollution in order to meet the future U.S. automotive legislative requirements for low hydrocarbon emissions. The projected cost for this alloy is less than $0.95/lb, and it readily allows the automotive components to be cast at a high production volume with a low, fully accounted cost. It is economically produced by pouring molten metal directly into conventional permanent steel molds or die casting.

Sequencing of Dust Filter Production Process Using Design Structure Matrix (DSM)

NASA Astrophysics Data System (ADS)

Sari, R. M.; Matondang, A. R.; Syahputri, K.; Anizar; Siregar, I.; Rizkya, I.; Ursula, C.

2018-01-01

Metal casting company produces machinery spare part for manufactures. One of the product produced is dust filter. Most of palm oil mill used this product. Since it is used in most of palm oil mill, company often have problems to address this product. One of problem is the disordered of production process. It carried out by the job sequencing. The important job that should be solved first, least implement, while less important job and could be completed later, implemented first. Design Structure Matrix (DSM) used to analyse and determine priorities in the production process. DSM analysis is sort of production process through dependency sequencing. The result of dependency sequences shows the sequence process according to the inter-process linkage considering before and after activities. Finally, it demonstrates their activities to the coupled activities for metal smelting, refining, grinding, cutting container castings, metal expenditure of molds, metal casting, coating processes, and manufacture of molds of sand.

Cast iron-base alloy for cylinder/regenerator housing

NASA Technical Reports Server (NTRS)

Witter, Stewart L.; Simmons, Harold E.; Woulds, Michael J.

1985-01-01

NASACC-1 is a castable iron-base alloy designed to replace the costly and strategic cobalt-base X-40 alloy used in the automotive Stirling engine cylinder/generator housing. Over 40 alloy compositions were evaluated using investment cast test bars for stress-rupture testing. Also, hydrogen compatibility and oxygen corrosion resistance tests were used to determine the optimal alloy. NASACC-1 alloy was characterized using elevated and room temperature tensile, creep-rupture, low cycle fatigue, heat capacity, specific heat, and thermal expansion testing. Furthermore, phase analysis was performed on samples with several heat treated conditions. The properties are very encouraging. NASACC-1 alloy shows stress-rupture and low cycle fatigue properties equivalent to X-40. The oxidation resistance surpassed the program goal while maintaining acceptable resistance to hydrogen exposure. The welding, brazing, and casting characteristics are excellent. Finally, the cost of NASACC-1 is significantly lower than that of X-40.

Improving the collection of knowledge, attitude and practice data with community surveys: a comparison of two second-stage sampling methods.

PubMed

Davis, Rosemary H; Valadez, Joseph J

2014-12-01

Second-stage sampling techniques, including spatial segmentation, are widely used in community health surveys when reliable household sampling frames are not available. In India, an unresearched technique for household selection is used in eight states, which samples the house with the last marriage or birth as the starting point. Users question whether this last-birth or last-marriage (LBLM) approach introduces bias affecting survey results. We conducted two simultaneous population-based surveys. One used segmentation sampling; the other used LBLM. LBLM sampling required modification before assessment was possible and a more systematic approach was tested using last birth only. We compared coverage proportions produced by the two independent samples for six malaria indicators and demographic variables (education, wealth and caste). We then measured the level of agreement between the caste of the selected participant and the caste of the health worker making the selection. No significant difference between methods was found for the point estimates of six malaria indicators, education, caste or wealth of the survey participants (range of P: 0.06 to >0.99). A poor level of agreement occurred between the caste of the health worker used in household selection and the caste of the final participant, (Κ = 0.185), revealing little association between the two, and thereby indicating that caste was not a source of bias. Although LBLM was not testable, a systematic last-birth approach was tested. If documented concerns of last-birth sampling are addressed, this new method could offer an acceptable alternative to segmentation in India. However, inter-state caste variation could affect this result. Therefore, additional assessment of last birth is required before wider implementation is recommended. Published by Oxford University Press in association with The London School of Hygiene and Tropical Medicine © The Author 2013; all rights reserved.

The Economic Effect of Competition in the Air Transportation Industry

NASA Technical Reports Server (NTRS)

Hubbard, H. B.

1972-01-01

The air transportation industry has been described as a highly-competitive, regulated oligopoly or as a price-regulated cartel with blocked entry, resulting in excessive service and low load factors. The current structure of the industry has been strongly influenced by the hypotheses that increased levels of competition are desirable per se, and that more competing carriers can be economically supported in larger markets, in longer haul markets, with lower unit costs, and with higher fare levels. An elementary application of competition/game theory casts doubt on the validity of these hypotheses, but rather emphasizes the critical importance of the short-term non-variable costs in determining economic levels of competition.

Using special additions to preparation of the moulding mixture for casting steel parts of drive wheel type

NASA Astrophysics Data System (ADS)

Josan, A.; Pinca Bretotean, C.

2015-06-01

The paper presents the possibility of using special additions to the execution of moulding mixtures for steel castings, drive wheel type. Critical analysis of moulding technology leads to the idea that most defects appear due to using improper moulding mixture. Using a improper moulding mixture leads to penetration of steel in moulding mixture, resulting in the formation of adherences, due to inadequate refractarity of the mould and core mixtures. Using only the unique mixture to the moulding leads to increasing consumption of new sand, respectively to the increase of price of piece. Acording to the dates registered in the industrial practice is necessary to use the special additions to obtain the moulding mixtures, carbonaceous materials respectively.

Posterior Temporary Fixation Versus Nonoperative Treatment for Anderson-D'Alonzo Type III Odontoid Fractures: Functional Computed Tomography Evaluation of C1-C2 Rotation.

PubMed

Guo, Qunfeng; Wang, Liang; Lu, Xuhua; Guo, Xiang; Ni, Bin

2017-04-01

To evaluate differences in radiologic and functional outcomes between C1-C2 posterior temporary fixation (PTF) and cephalocervicothoracic cast fixation for type III odontoid fractures. Data from 13 patients who underwent PTF and 13 cases who underwent cephalocervicothoracic cast fixation due to fresh type III odontoid fractures were reviewed retrospectively. All patients with fracture healing underwent a functional computed tomography scan at the final follow-up to evaluate the range of motion in C1-C2 rotation. Functional outcomes were evaluated in the form of visual analog scale for neck pain, neck stiffness, patient satisfaction, and Neck Disability Index. The outcomes were compared between the 2 groups. At the final follow up, all 26 patients achieved healing of their fractures. There were no complications associated with either treatment. The left-to-right ranges of motion of C1-C2 rotation were 41.9° ± 11.9° in the PTF group and 43.5° ± 12.0° in the cephalocervicothoracic cast fixation group. There was no statistical difference between the 2 groups regarding the C1-C2 rotation angle (P > 0.05). There also were no significant differences between 2 groups in functional outcomes evaluated by visual analog scale for neck pain, neck stiffness, Neck Disability Index, and patient satisfaction (all P > 0.05). The outcomes of PTF and cephalocervicothoracic cast fixation were comparable in the treatment of type III odontoid fractures. For type III odontoid fractures that cannot be managed by nonoperative fixation or anterior screw fixation, PTF may be the treatment of choice, because it spares the motion of the C1-C2 complex. Copyright © 2016 Elsevier Inc. All rights reserved.

Comparison of Dimensional Accuracy between Open-Tray and Closed-Tray Implant Impression Technique in 15° Angled Implants

PubMed Central

Balouch, F; Jalalian, E; Nikkheslat, M; Ghavamian, R; Toopchi, Sh; Jallalian, F; Jalalian, S

2013-01-01

Statement of Problem: Various impression techniques have different effects on the accuracy of final cast dimensions. Meanwhile; there are some controversies about the best technique. Purpose: This study was performed to compare two kinds of implant impression methods (open tray and closed tray) on 15 degree angled implants. Materials and Method: In this experimental study, a steel model with 8 cm in diameter and 3 cm in height were produced with 3 holes devised inside to stabilize 3 implants. The central implant was straight and the other two implants were 15° angled. The two angled implants had 5 cm distance from each other and 3.5 cm from the central implant. Dental stone, high strength (type IV) was used for the main casts. Impression trays were filled with poly ether, and then the two impression techniques (open tray and closed tray) were compared. To evaluate positions of the implants, each cast was analyzed by CMM device in 3 dimensions (x,y,z). Differences in the measurements obtained from final casts and laboratory model were analyzed using t-Test. Results: The obtained results indicated that closed tray impression technique was significantly different in dimensional accuracy when compared with open tray method. Dimensional changes were 129 ± 37μ and 143.5 ± 43.67μ in closed tray and open tray, while coefficient of variation in closed- tray and open tray were reported to be 27.2% and 30.4%, respectively. Conclusion: Closed impression technique had less dimensional changes in comparison with open tray method, so this study suggests that closed tray impression technique is more accurate. PMID:24724130

Aging and Curing Temperature Effects on Compressive Strength of Mortar Containing Lime Stone Quarry Dust and Industrial Granite Sludge.

PubMed

Amin, Muhammad Nasir; Khan, Kaffayatullah; Saleem, Muhammad Umair; Khurram, Nauman; Niazi, Muhammad Umar Khan

2017-06-11

In this study, the researchers investigated the potential use of locally available waste materials from the lime stone quarry and the granite industry as a partial replacement of cement. Quarry sites and granite industry in the eastern province of Saudi Arabia produces tons of powder wastes in the form of quarry dust (QD) and granite sludge (GS), respectively, causing serious environmental problems along with frequent dust storms in the area. According to ASTM C109, identical 50-mm3 specimens were cast throughout this study to evaluate the compressive strength development of mortars (7, 28 and 91 days) containing these waste materials. Experimental variables included different percentage replacement of cement with waste materials (GS, QD), fineness of GS, various curing temperatures (20, 40 and 60 °C as local normal and hot environmental temperatures) and curing moisture (continuously moist and partially moist followed by air curing). Finally, the results of mortar containing waste materials were compared to corresponding results of control mortar (CM) and mortar containing fly ash (FA). The test results indicated that under normal curing (20 °C, moist cured), the compressive strength of mortar containing the different percentage of waste materials (QD, GS, FA and their combinations) remained lower than that of CM at all ages. However, the compressive strength of mortar containing waste materials slightly increased with increased fineness of GS and significantly increased under high curing temperatures. It was recommended that more fineness of GS be achieved to use its high percentage replacement with cement (30% or more) incorporating local environmental conditions.

Aging and Curing Temperature Effects on Compressive Strength of Mortar Containing Lime Stone Quarry Dust and Industrial Granite Sludge

PubMed Central

Amin, Muhammad Nasir; Khan, Kaffayatullah; Saleem, Muhammad Umair; Khurram, Nauman; Niazi, Muhammad Umar Khan

2017-01-01

In this study, the researchers investigated the potential use of locally available waste materials from the lime stone quarry and the granite industry as a partial replacement of cement. Quarry sites and granite industry in the eastern province of Saudi Arabia produces tons of powder wastes in the form of quarry dust (QD) and granite sludge (GS), respectively, causing serious environmental problems along with frequent dust storms in the area. According to ASTM C109, identical 50-mm3 specimens were cast throughout this study to evaluate the compressive strength development of mortars (7, 28 and 91 days) containing these waste materials. Experimental variables included different percentage replacement of cement with waste materials (GS, QD), fineness of GS, various curing temperatures (20, 40 and 60 °C as local normal and hot environmental temperatures) and curing moisture (continuously moist and partially moist followed by air curing). Finally, the results of mortar containing waste materials were compared to corresponding results of control mortar (CM) and mortar containing fly ash (FA). The test results indicated that under normal curing (20 °C, moist cured), the compressive strength of mortar containing the different percentage of waste materials (QD, GS, FA and their combinations) remained lower than that of CM at all ages. However, the compressive strength of mortar containing waste materials slightly increased with increased fineness of GS and significantly increased under high curing temperatures. It was recommended that more fineness of GS be achieved to use its high percentage replacement with cement (30% or more) incorporating local environmental conditions. PMID:28772999

Modeling injury rates as a function of industrialized versus on-site construction techniques.

PubMed

Rubio-Romero, J C; Suárez-Cebador, M; Abad, Jesús

2014-05-01

It is often predicted that the industrialization of building activities will lead to a reduction of accident rates in the construction sector, particularly as a result of switching activities from building sites to factories. However, to date no scientific research has provided objective quantitative results to back up this claim. The aim of this paper is to evaluate how industrialization affects the accident rate in different industrialized building systems in Spain. Our results revealed that the industrialized steel modular system presents the lowest accident rate, while the highest accident rate was recorded in the construction method with cast-in-place concrete. The lightweight construction system also presents a high accident rate. Accordingly, industrialized building systems cannot claim to be safer than traditional ones. The different types of "on-site work" seem to be the main variable which would explain the accident rates recorded in industrialized construction systems. Copyright © 2014 Elsevier Ltd. All rights reserved.

Differential gene expression in response to juvenile hormone analog treatment in the damp-wood termite Hodotermopsis sjostedti (Isoptera, Archotermopsidae).

PubMed

Cornette, Richard; Hayashi, Yoshinobu; Koshikawa, Shigeyuki; Miura, Toru

2013-04-01

Termite societies are characterized by a highly organized division of labor among conspicuous castes, groups of individuals with various morphological specializations. Termite caste differentiation is under control of juvenile hormone (JH), but the molecular mechanism underlying the response to JH and early events triggering caste differentiation are still poorly understood. In order to profile candidate gene expression during early soldier caste differentiation of the damp-wood termite, Hodotermopsis sjostedti, we treated pseudergates (workers) with a juvenile hormone analog (JHA) to induce soldier caste differentiation. We then used Suppressive Subtractive Hybridization to create two cDNA libraries enriched for transcripts that were either up- or downregulated at 24h after treatment. Finally, we used quantitative PCR to confirm temporal expression patterns. Hexamerins represent a large proportion of the genes upregulated following JHA treatment and have an expression pattern that shows roughly an inverse correlation to intrinsic JH titers. This data is consistent with the role of a JH "sink", which was demonstrated for hexamerins in another termite, Reticulitermes flavipes. A putative nuclear protein was also upregulated a few hours after JHA treatment, which suggests a role in the early response to JH and subsequent regulation of transcriptional events associated with soldier caste differentiation. Some digestive enzymes, such as endogenous beta-endoglucanase and chymotrypsin, as well as a protein associated to digestion were identified among genes downregulated after JHA treatment. This suggests that JH may directly influence the pseudergate-specific digestive system. Copyright © 2013 Elsevier Ltd. All rights reserved.

Training Next-Gen Data Superheroes

ERIC Educational Resources Information Center

Waters, John K.

2013-01-01

The latest data alert: By 2020, the amount of data generated daily will reach 40 zettabytes, or roughly 5,247 gigabytes for every person on earth. That's one of the findings in a new report published by IT industry analysts at IDC. The study casts doubt on the ability to capture the value of all this data, especially since schools barely tapped…

Microstructural characterization of as-cast biocompatible Co-Cr-Mo alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Giacchi, J.V., E-mail: jgiacchi@exa.unicen.edu.ar; Instituto de Fisica de Materiales Tandil; Morando, C.N.

2011-01-15

The microstructure of a cobalt-base alloy (Co-Cr-Mo) obtained by the investment casting process was studied. This alloy complies with the ASTM F75 standard and is widely used in the manufacturing of orthopedic implants because of its high strength, good corrosion resistance and excellent biocompatibility properties. This work focuses on the resulting microstructures arising from samples poured under industrial environment conditions, of three different Co-Cr-Mo alloys. For this purpose, we used: 1) an alloy built up from commercial purity constituents, 2) a remelted alloy and 3) a certified alloy for comparison. The characterization of the samples was achieved by using opticalmore » microscopy (OM) with a colorant etchant to identify the present phases and scanning electron microscopy (SE-SEM) and energy dispersion spectrometry (EDS) techniques for a better identification. In general the as-cast microstructure is a Co-fcc dendritic matrix with the presence of a secondary phase, such as the M{sub 23}C{sub 6} carbides precipitated at grain boundaries and interdendritic zones. These precipitates are the main strengthening mechanism in this type of alloys. Other minority phases were also reported and their presence could be linked to the cooling rate and the manufacturing process variables and environment. - Research Highlights: {yields}The solidification microstructure of an ASTM-F75 type alloy were studied. {yields}The alloys were poured under an industrial environment. {yields}Carbides and sigma phase identified by color metallography and scanning microscopy (SEM and EDS). {yields}Two carbide morphologies were detected 'blocky type' and 'pearlite type'. {yields}Minority phases were also detected.« less

Effect of forging on mechanical properties of rice husk ash-silicon carbide reinforced Al1100 hybrid composites

NASA Astrophysics Data System (ADS)

Ghanaraja, S.; Gireesha, B. L.; Ravikumar, K. S.; Likith, P.

2018-04-01

During the past few years, material design has changed prominence to pursue light weight, environment friendliness, low cost, quality, higher service temperature, higher elastic modulus, improved wear resistance and performance. Straight monolithic materials have limitations in achieving the above decisive factors. To overcome these limitations and to convince the ever increasing demand of modern day technology, Attention has been shifted towards Metal Matrix Composites (MMC). Stir casting route is most hopeful for synthesizing discontinuous reinforcement aluminium matrix composites because of its relative simplicity and easy adaptability with all shape casting process used in metal casting industry. Hybridization of metal matrix composites is the introduction of more than one type/kind, size and shape of reinforcement during processing of composites. It is carried out to obtain synergistic properties of different reinforcements and matrix used, which may not be rea1ised in monolithic alloy or in conventional monocomposites. The present study involves synthesis of hybrid composites by addition of the desired amount of Silicon Carbide (SiC) and Rice Husk Ash (RHA) particles in to the molten Al 1100-Mg alloy through stir casting technique fallowed by hot forging of the cast composites. The influence of increasing in the wt% (3, 6, 9, 12 and 15 wt%) of SiC particles addition (3 wt% Rice husk ash kept constant) on evolution of microstructure is studied through XRD and SEM and their impact on the mechanical properties like hardness and tensile strength of the resulting forged hybrid composites has been investigated.

Engineering scale demonstration of a prospective Cast Stone process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cozzi, A.; Fowley, M.; Hansen, E.

2014-09-30

This report documents an engineering-scale demonstration with non-radioactive simulants that was performed at SRNL using the Scaled Continuous Processing Facility (SCPF) to fill an 8.5 ft container with simulated Cast Stone grout. The Cast Stone formulation was chosen from the previous screening tests. Legacy salt solution from previous Hanford salt waste testing was adjusted to correspond to the average composition generated from the Hanford Tank Waste Operation Simulator (HTWOS). The dry blend materials, ordinary portland cement (OPC), Class F fly ash, and ground granulated blast furnace slag (GGBFS or BFS), were obtained from Lafarge North America in Pasco, WA. Overmore » three days, the SCPF was used to fill a 1600 gallon container, staged outside the facility, with simulated Cast Stone grout. The container, staged outside the building approximately 60 ft from the SCPF, was instrumented with x-, y-, and z-axis thermocouples to monitor curing temperature. The container was also fitted with two formed core sampling vials. For the operation, the targeted grout production rate was 1.5 gpm. This required a salt solution flow rate of approximately 1 gpm and a premix feed rate of approximately 580 lb/h. During the final day of operation, the dry feed rate was increased to evaluate the ability of the system to handle increased throughput. Although non-steady state operational periods created free surface liquids, no bleed water was observed either before or after operations. The final surface slope at a fill height of 39.5 inches was 1-1.5 inches across the 8.5 foot diameter container, highest at the final fill point and lowest diametrically opposed to the fill point. During processing, grout was collected in cylindrical containers from both the mixer discharge and the discharge into the container. These samples were stored in a humid environment either in a closed box proximal to the container or inside the laboratory. Additional samples collected at these sampling points were analyzed for rheological properties and density. Both the rheological properties (plastic viscosity and yield strength) and density were consistent with previous and later SCPF runs.« less

Thelytokous parthenogenesis, male clonality and genetic caste determination in the little fire ant: new evidence and insights from the lab.

PubMed

Foucaud, J; Estoup, A; Loiseau, A; Rey, O; Orivel, J

2010-08-01

Previous studies indicate that some populations of the little fire ant, Wasmannia auropunctata, display an unusual reproduction system polymorphism. Although some populations have a classical haplodiploid reproduction system, in other populations queens are produced by thelytokous parthenogenesis, males are produced by a male clonality system and workers are produced sexually. An atypical genetic caste determination system was also suggested. However, these conclusions were indirectly inferred from genetic studies on field population samples. Here we set up experimental laboratory nests that allow the control of the parental relationships between individuals. The queens heading those nests originated from either putatively clonal or sexual populations. We characterized the male, queen and worker offspring they produced at 12 microsatellite loci. Our results unambiguously confirm the unique reproduction system polymorphism mentioned above and that male clonality is strictly associated with thelytokous parthenogenesis. We also observed direct evidence of the rare production of sexual gynes and arrhenotokous males in clonal populations. Finally, we obtained evidence of a genetic basis for caste determination. The evolutionary significance of the reproduction system polymorphism and genetic caste determination as well as future research opportunities are discussed.

Microstructures, Mechanical Properties, and Wear Resistances of Thixoextruded SiCp/WE43 Magnesium Matrix Composites

NASA Astrophysics Data System (ADS)

Chen, Qiang; Chen, Gang; Han, Fei; Xia, Xiangsheng; Wu, Yang

2017-07-01

Near-net shaping of Mg-RE alloy matrix composites has received increasing attention. In this work, stir casting followed by extrusion was adopted to fabricate Mg-RE alloy (WE43) matrix composites reinforced by micron-sized SiC particles. The microstructural evolutions of SiCp/WE43 composites partially remelted from as-cast and extruded states were studied. Furthermore, the thixoformability of SiCp/WE43 composites in different states was evaluated by thixoextruding a type of double-cup component. The microstructures of as-cast SiCp/WE43 composites were optimized under the comprehensive effects of SiC particles and RE elements. The SiCp/WE43 composite was fully recrystallized during hot extrusion, and the α-Mg matrix consisted of fine equiaxed grains. Although the as-cast SiCp/WE43 composite consisted of satisfactory structures and can be successfully thixoextruded into the final component with good surface quality and no evidence of internal defects, the microstructures, Vickers hardness, tensile mechanical properties, and wear resistance were still inferior to those of the component thixoextruded from extruded composite. Moreover, the thixoextrusion process was analyzed schematically, and an ideal thixoforming process that should contain two stages was proposed.

A comparison of the fatigue behavior of cast Ti-7.5Mo with c.p. titanium, Ti-6Al-4V and Ti-13Nb-13Zr alloys.

PubMed

Lin, Chia-Wei; Ju, Chien-Ping; Chern Lin, Jiin-Huey

2005-06-01

The purpose of the present study is to compare the high-cycle fatigue behavior of newly developed Ti-7.5Mo alloy with that of c.p. Ti, Ti-13Nb-13Zr and Ti-6Al-4V alloys in their as-cast state. Experimental results indicate that Ti-6Al-4V and c.p. Ti have higher stress-controlled fatigue resistance but lower strain-controlled fatigue resistance than Ti-7.5Mo and Ti-13Nb-13Zr. Among four materials Ti-7.5Mo demonstrates the best strain-controlled fatigue performance. The fracture surfaces of the present materials are comprised of three morphologically distinct zones: crack initiation zone, crack propagation zone, and the final-stage overload zone. The fatigue cracks almost always initiate from casting-induced surface/subsurface pores. A river pattern is observed in the propagation zone. In the overload zone dimples are typically observed. Three factors most significantly affecting the fatigue performance of the present materials are the presence of the casting-induced surface/subsurface pores; the location of the pores; and the inherent mechanical properties of the materials.

Geologic continuous casting below continental and deep-sea detachment faults and at the striated extrusion of Sacsayhuaman, Peru

USGS Publications Warehouse

Spencer, J.E.

1999-01-01

In the common type of industrial continuous casting, partially molten metal is extruded from a vessel through a shaped orifice called a mold in which the metal assumes the cross-sectional form of the mold as it cools and solidifies. Continuous casting can be sustained as long as molten metal is supplied and thermal conditions are maintained. I propose that a similar process produced parallel sets of grooves in three geologic settings, as follows: (1) corrugated metamorphic core complexes where mylonized mid-crustal rocks were exhumed by movement along low-angle normal faults known as detachment faults; (2) corrugated submarine surfaces where ultramafic and mafic rocks were exhumed by normal faulting within oceanic spreading centers; and (3) striated magma extrusions exemplified by the famous grooved outcrops at the Inca fortress of Sacsayhuaman in Peru. In each case, rocks inferred to have overlain the corrugated surface during corrugation genesis molded and shaped a plastic to partially molten rock mass as it was extruded from a moderate- to high-temperature reservoir.

Novel strip-cast Mg/Al clad sheets with excellent tensile and interfacial bonding properties

PubMed Central

Kim, Jung-Su; Lee, Dong Ho; Jung, Seung-Pill; Lee, Kwang Seok; Kim, Ki Jong; Kim, Hyoung Seop; Lee, Byeong-Joo; Chang, Young Won; Yuh, Junhan; Lee, Sunghak

2016-01-01

In order to broaden industrial applications of Mg alloys, as lightest-weight metal alloys in practical uses, many efforts have been dedicated to manufacture various clad sheets which can complement inherent shortcomings of Mg alloys. Here, we present a new fabrication method of Mg/Al clad sheets by bonding thin Al alloy sheet on to Mg alloy melt during strip casting. In the as-strip-cast Mg/Al clad sheet, homogeneously distributed equi-axed dendrites existed in the Mg alloy side, and two types of thin reaction layers, i.e., γ (Mg17Al12) and β (Mg2Al3) phases, were formed along the Mg/Al interface. After post-treatments (homogenization, warm rolling, and annealing), the interfacial layers were deformed in a sawtooth shape by forming deformation bands in the Mg alloy and interfacial layers, which favorably led to dramatic improvement in tensile and interfacial bonding properties. This work presents new applications to multi-functional lightweight alloy sheets requiring excellent formability, surface quality, and corrosion resistance as well as tensile and interfacial bonding properties. PMID:27245687

The Coupling of Macrosegregation with Grain Nucleation, Growth and Motion in DC Cast Aluminum Alloy Ingots

NASA Astrophysics Data System (ADS)

Založnik, Miha; Kumar, Arvind; Combeau, Hervé; Bedel, Marie; Jarry, Philippe; Waz, Emmanuel

The phenomena responsible for the formation of macrosegregations, and grain structures during solidification are closely intertwined. We present a model study of the formation of macrosegregation and grain structure in an industrial sized (350 mm thick) direct chill (DC) cast aluminum alloy slab. The modeling of these phenomena in DC casting is a challenging problem mainly due to the size of the products, the variety of the phenomena to be accounted for, and the non-linearities involved. We used a volume-averaged multiscale model that describes nucleation on grain refiner particles and grain growth, coupled with macroscopic transport: fluid flow driven by natural convection and shrinkage, transport of free-floating globular equiaxed grains, heat transfer, and solute transport. We analyze the heat and mass transfer in the slurry moving-grain zone that is a result of the coupling of the fluid flow and of the grain nucleation, growth and motion. We discuss the impact of the flow structure in the slurry zone and of the grain packing fraction on the macrosegregation.

Novel strip-cast Mg/Al clad sheets with excellent tensile and interfacial bonding properties.

PubMed

Kim, Jung-Su; Lee, Dong Ho; Jung, Seung-Pill; Lee, Kwang Seok; Kim, Ki Jong; Kim, Hyoung Seop; Lee, Byeong-Joo; Chang, Young Won; Yuh, Junhan; Lee, Sunghak

2016-06-01

In order to broaden industrial applications of Mg alloys, as lightest-weight metal alloys in practical uses, many efforts have been dedicated to manufacture various clad sheets which can complement inherent shortcomings of Mg alloys. Here, we present a new fabrication method of Mg/Al clad sheets by bonding thin Al alloy sheet on to Mg alloy melt during strip casting. In the as-strip-cast Mg/Al clad sheet, homogeneously distributed equi-axed dendrites existed in the Mg alloy side, and two types of thin reaction layers, i.e., γ (Mg17Al12) and β (Mg2Al3) phases, were formed along the Mg/Al interface. After post-treatments (homogenization, warm rolling, and annealing), the interfacial layers were deformed in a sawtooth shape by forming deformation bands in the Mg alloy and interfacial layers, which favorably led to dramatic improvement in tensile and interfacial bonding properties. This work presents new applications to multi-functional lightweight alloy sheets requiring excellent formability, surface quality, and corrosion resistance as well as tensile and interfacial bonding properties.

Remaining life of reinforced concrete beams with diagonal-tension cracks : final report.

DOT National Transportation Integrated Search

2004-04-01

This report covers the initial efforts of a research study investigating the remaining capacity and life of cast-in-place reinforced concrete deck-girder (RCDG) bridges with diagonal tension cracks. A database of 442 bridges constructed from 1947 to ...

Addressing the issue of insufficient information in data-based bridge health monitoring : final report.

DOT National Transportation Integrated Search

2015-11-01

One of the most efficient ways to solve the damage detection problem using the statistical pattern recognition : approach is that of exploiting the methods of outlier analysis. Cast within the pattern recognition framework, : damage detection assesse...

Evaluation of catch basin grates : final report.

DOT National Transportation Integrated Search

1972-10-01

The Louisiana Department of Highways has adopted new designs for the Standard Plans for the RCB 22X catch basin to replace the old standard cast iron grate with either a welded bar steel grate or an alternate riveted steel reticuline grate. This revi...

Precast alternative for flat slab bridges : final report.

DOT National Transportation Integrated Search

2013-10-26

The cast-in-place (CIP) concrete slab bridge and the hollow core flat slab bridge are two very common bridge types utilized by the : South Carolina Department of Transportation (SCDOT). The CIP bridge is durable but has a long construction time while...

Thermal Stress and Heat Transfer Coefficient for Ceramics Stalk Having Protuberance Dipping into Molten Metal

NASA Astrophysics Data System (ADS)

Noda, Nao-Aki; Hendra; Li, Wenbin; Takase, Yasushi; Ogura, Hiroki; Higashi, Yusuke

Low pressure die casting is defined as a net shape casting technology in which the molten metal is injected at high speeds and pressure into a metallic die. The low pressure die casting process plays an increasingly important role in the foundry industry as a low-cost and high-efficiency precision forming technique. In the low pressure die casting process is that the permanent die and filling systems are placed over the furnace containing the molten alloy. The filling of the cavity is obtained by forcing the molten metal, by means of a pressurized gas, to rise into a ceramic tube having protuberance, which connects the die to the furnace. The ceramics tube, called stalk, has high temperature resistance and high corrosion resistance. However, attention should be paid to the thermal stress when the stalk having protuberance is dipped into the molten aluminum. It is important to reduce the risk of fracture that may happen due to the thermal stresses. In this paper, thermo-fluid analysis is performed to calculate surface heat transfer coefficient. The finite element method is applied to calculate the thermal stresses when the stalk having protuberance is dipped into the crucible with varying dipping speeds. It is found that the stalk with or without protuberance should be dipped into the crucible slowly to reduce the thermal stress.

Real-time measurement system for tracking birefringence, weight, thickness, and surface temperature during drying of solution cast coatings and films

NASA Astrophysics Data System (ADS)

Unsal, E.; Drum, J.; Yucel, O.; Nugay, I. I.; Yalcin, B.; Cakmak, M.

2012-02-01

This paper describes the design and performance of a new instrument to track temporal changes in physical parameters during the drying behavior of solutions, as well as curing of monomers. This real-time instrument follows in-plane and out-of-plane birefringence, weight, thickness, and surface temperature during the course of solidification of coatings and films through solvent evaporation and thermal or photocuring in a controlled atmosphere. It is specifically designed to simulate behavior of polymer solutions inside an industrial size, continuous roll-to-roll solution casting line and other coating operations where resins are subjected to ultraviolet (UV) curing from monomer precursors. Controlled processing parameters include air speed, temperature, initial cast thickness, and solute concentration, while measured parameters are thickness, weight, film temperature, in-plane and out-of-plane birefringence. In this paper, we illustrate the utility of this instrument with solution cast and dried poly (amide-imide)/DMAc (Dimethylacetamide) solution, water based black paint, and organo-modified clay/NMP (N-Methylpyrrolidone) solution. In addition, the physical changes that take place during UV photo polymerization of a monomer are tracked. This instrument is designed to be generic and it can be used for tracking any drying/swelling/solidification systems including paper, foodstuffs such as; grains, milk as well as pharmaceutical thin paste and slurries.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nick Cannell; Adrian S. Sabau

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 phasemore » 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 the shell mold. A model for thermal radiation within the shell mold was developed, and the thermal model was successfully validated using ProCAST. Since the fused silica shells had the lowest thermal expansion properties in the industry, the dewaxing phase, including the coupling between wax-shell systems, was neglected. The prefiring of the empty shell mold was considered in the model, and the shell mold was limited to a pure elastic material. The alloy dimensions were obtained from numerical simulations only with coupled shell-alloy systems. The alloy dimensions were in excellent quantitative agreement with experimental data, validating the deformation module. For actual parts, however, the creep properties of the shell molds must also be obtained, modeled, and validated.« less

Continuous flight auger pile bridge foundation : Implementation Phase I : Texas Gulf Coast Region : final report.

DOT National Transportation Integrated Search

2004-01-01

Continuous flight auger (CFA) piles better known as Augered, Cast In-Place (ACIP) piles have been widely used in the United States for several decades because of relatively rapid installation and minimum environmental impact during installation with ...

Economic Security: Neglected Dimension of National Security?

DTIC Science & Technology

2011-01-01

passenger liner Lusitania with great loss of life finally prompted action. The Navy thereupon invited inventor Thomas Alva Edison to chair the...anchor fabrication to forging cast gun casings and polished liner tubes, becoming fully operational in 1892. The Army got funding to upgrade Watervliet

Austempered ductile iron (ADI) for railroad wheels : final report.

DOT National Transportation Integrated Search

2017-01-31

The purpose of this project is to investigate the potential for austempered ductile iron (ADI) to be used as an alternative material for the production of rail wheels, which are currently cast or forged steel which is commonly heat treated. ADI has s...

The Advanced Industrial Materials (AIM) program office of industrial technologies fiscal year 1995

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sorrell, C.A.

1997-04-01

In many ways, the Advanced Industrial Materials (AIM) Program underwent a major transformation in FY95 and these changes have continued to the present. When the Program was established in 1990 as the Advanced Industrial Concepts (AIC) Materials Program, the mission was to conduct applied research and development to bring materials and processing technologies from the knowledge derived from basic research to the maturity required for the end use sectors for commercialization. In 1995, the Office of Industrial Technologies (OIT) made radical changes in structure and procedures. All technology development was directed toward the seven `Vision Industries` that use about 80%more » of industrial energy and generated about 90% of industrial wastes. These are: aluminium; chemical; forest products; glass; metal casting; refineries; and steel. OIT is working with these industries, through appropriate organizations, to develop Visions of the desired condition of each industry some 20 to 25 years in the future and then to prepare Road Maps and Implementation Plans to enable them to reach their goals. The mission of AIM has, therefore, changed to `Support development and commercialization of new or improved materials to improve productivity, product quality, and energy efficiency in the major process industries.`« less

Real-Time Investigation of Solidification of Metal Matrix Composites

NASA Technical Reports Server (NTRS)

Kaukler, William; Sen, Subhayu

1999-01-01

Casting of metal matrix composites can develop imperfections either as non- uniform distributions of the reinforcement phases or as outright defects such as porosity. The solidification process itself initiates these problems. To identify or rectify the problems, one must be able to detect and to study how they form. Until, recently this was only possible by experiments that employed transparent metal model organic materials with glass beads to simulate the reinforcing phases. Recent results obtained from a Space Shuttle experiment (using transparent materials) will be used to illustrate the fundamental physics that dictates the final distribution of agglomerates in a casting. We have further extended this real time investigation to aluminum alloys using X-ray microscopy. A variety of interface-particle interactions will be discussed and how they alter the final properties of the composite. A demonstration of how a solid-liquid interface is distorted by nearby voids or particles, particle pushing or engulfment by the interface, formations of wormholes, Aggregation of particles, and particle-induced segregation of alloying elements will be presented.

Utilisation of Waste Marble Dust as Fine Aggregate in Concrete

NASA Astrophysics Data System (ADS)

Vigneshpandian, G. V.; Aparna Shruthi, E.; Venkatasubramanian, C.; Muthu, D.

2017-07-01

Concrete is the important construction material and it is used in the construction industry due to its high compressive strength and its durability. Now a day’s various studies have been conducted to make concrete with waste material with the intention of reducing cost and unavailability of conventional materials. This paper investigates the strength properties of concrete specimens cast using waste marble dust as replacement of fine aggregate. The marble pieces are finely crushed to powdered and the gradation is compared with conventional fine aggregate. Concrete specimen were cast using wmd in the laboratory with different proportion (25%, 50% and 100%) by weight of cement and from the studies it reveals that addition of waste marble dust as a replacement of fine aggregate marginally improves compressive, tensile and flexural strength in concrete.

Rapid manufacturing of metallic Molds for parts in Automobile

NASA Astrophysics Data System (ADS)

Zhang, Renji; Xu, Da; Liu, Yuan; Yan, Xudong; Yan, Yongnian

1998-03-01

The recent research of RPM (Rapid Prototyping Manufacturing) in our lab has been focused on the rapid creation of alloyed cast iron (ACI) molds. There are a lot of machinery parts in an automobile, so a lot of mettallic molds are needed in automobile industry. A new mold manufacturing technology has been proposed. A new large scale RP machine has been set up in our lab now. Then rapid prototypes could be manufactured by means of laminated object manufacturing (LOM) technology. The molds for parts in automobile have been produced by ceramic shell precision casting. An example is a drawing mold for cover parts in automobile. Sufficient precision and surface roughness have been obtained. Itis proved that this is a vew kind of technology. Work supported by the Mational Science Foundation of China.

A Simplified Three-Phase Model of Equiaxed Solidification for the Prediction of Microstructure and Macrosegregation in Castings

NASA Astrophysics Data System (ADS)

Tveito, Knut Omdal; Pakanati, Akash; M'Hamdi, Mohammed; Combeau, Hervé; Založnik, Miha

2018-04-01

Macrosegregation is a result of the interplay of various transport mechanisms, including natural convection, solidification shrinkage, and grain motion. Experimental observations also indicate the impact of grain morphology, ranging from dendritic to globular, on macrosegregation formation. To avoid the complexity arising due to modeling of an equiaxed dendritic grain, we present the development of a simplified three-phase, multiscale equiaxed dendritic solidification model based on the volume-averaging method, which accounts for the above-mentioned transport phenomena. The validity of the model is assessed by comparing it with the full three-phase model without simplifications. It is then applied to qualitatively analyze the impact of grain morphology on macrosegregation formation in an industrial scale direct chill cast aluminum alloy ingot.

Corrosion protection of low-carbon steel using exopolysaccharide coatings from Leuconostoc mesenteroides.

PubMed

Finkenstadt, Victoria L; Côté, Gregory L; Willett, J L

2011-06-01

Corrosion of metals is a serious and challenging problem faced worldwide by industry. Purified Leuconostoc mesenteroides exopolysaccharide (EPS) coatings, cast from aqueous solution, inhibited the corrosion of low-carbon steel as determined by electrochemical impedance spectroscopy (EIS). There were two different corrosion behaviors exhibited when EPS films from different strains were cast onto the steel. One EPS coating reacted immediately with the steel substrate to form an iron (III) oxide layer ("rust") during the drying process while another did not. The samples that did not flash corrode had higher corrosion inhibition and formed an iron (II) passivation layer during EIS testing that persisted after the cells were disassembled. Corrosion inhibition was strain-specific as polysaccharides with similar structure did not have the same corrosion potential.

Longwy: Higher Education and Health Mobilised in the Process of Regeneration

ERIC Educational Resources Information Center

Hardouin, Magali; le Goff, Erwan

2013-01-01

For almost a century, Longwy has been one of the most important industrial areas of France, contributing the majority of the national production of cast iron and steel. The objective of this paper is to analyse how higher education, then health and well-being were mobilised in the process of regeneration of Longwy, which had been very harshly…

Castings Airworthiness

DTIC Science & Technology

1989-05-01

also drawn up by Vereinigte Flugtech- nischen Werken as a technoeconomic analysis . The aerospace industry will be looking for the following...ultimate load without rupture. These conditions are verified by analysis and test. The limit load is the maximum load the vehicle is expected to see...the uncertainty factor (formerly known as the factor of safety) which accounts for variations in manufacture, defects not assumed in analysis but

Exploring As-Cast PbCaSn-Mg Anodes for Improved Performance in Copper Electrowinning

NASA Astrophysics Data System (ADS)

Yuwono, Jodie A.; Clancy, Marie; Chen, Xiaobo; Birbilis, Nick

2018-06-01

Lead calcium tin (PbCaSn) alloys are the common anodes used in copper electrowinning (Cu EW). Given a large amount of energy consumed in Cu EW process, anodes with controlled oxygen evolution reaction (OER) kinetics and a lower OER overpotential are advantageous for reducing the energy consumption. To date, magnesium (Mg) has never been studied as an alloying element for EW anodes. As-cast PbCaSn anodes with the addition of Mg were examined herein, revealing an improved performance compared to that of the industrial standard PbCaSn anode. The alloy performances in the early stages of anode life and passivation were established from electrochemical studies which were designed to simulate industrial Cu EW process. The 24-hour polarization testing revealed that the Mg alloying depolarizes the anode potential up to 80 mV; thus, resulting in a higher Cu EW efficiency. In addition, scanning electron microscopy and X-ray photoelectron spectroscopy revealed that the alteration of the alloy microstructure and the corresponding interfacial reactions contribute to the changes of the anode electrochemical performances. The present study reveals for the first time the potency of Mg alloying in reducing the overpotential of PbCaSn anode.

Effect of iron-intermetallics and porosity on tensile and impact properties of aluminum-silicon-copper and aluminum-silicon-magnesium cast alloys

NASA Astrophysics Data System (ADS)

Ma, Zheyuan

Aluminum-silicon (Al-Si) alloys are an important class of materials that constitute the majority of aluminum cast parts produced, due to their superior properties and excellent casting characteristics. Within this family of alloys, Al-Si-Cu and Al-Si-Mg cast alloys are frequently employed in automotive applications. The commercially popular 319 and 356 alloys, representing these two alloy systems, were selected for study in the present work, with the aim of investigating the effect of iron intermetallics and porosity on the alloy performance. This was carried out through a study of the tensile and impact properties, these being two of the important mechanical properties used in design calculations. Iron, through the precipitation of second phase intermetallic constituents, in particular the platelike beta-Al5FeSi phase, is harmful to the alloy properties. Likewise, gas- or shrinkage porosity in castings is also detrimental to the mechanical properties. By determining the optimum alloying, melt processing and solidification parameters (viz., Fe content, Sr modification and cooling rate) required to minimize the harmful effects of porosity and iron intermetallics, and studying their role on the fracture behavior, the fracture mechanism in the alloys could be determined. Castings were prepared from both industrial and experimental 319.2, B319.2 and A356.2 alloy melts, containing Fe levels of 0.2--1.0 wt%. Sr-modified (˜200 ppm) melts were also prepared for each alloy Fe level. The end-chilled refractory mold used provided directional solidification and a range of cooling rates (or dendrite arm spacings, DAS) within the same casting. Tensile and impact test samples machined from specimen blanks sectioned from the castings at various heights above the chill end provided DASs of 23--85mum. All samples were T6-heat-treated before testing. Tests were carried out employing Instron Universal and Instrumented Charpy testing machines. Optical microscopy, image analysis, SEM and EPMA techniques were used for microstructural and fracture analysis. The results show that the highest cooling rate (23 mum DAS) is the most significant parameter controlling the size and distribution of the beta-Al 5FeSi phase and porosity in the unmodified 319.2 and A356.2 alloys. (Abstract shortened by UMI.)

Fabrication and Properties of polyacrylic acid by ionic surfactant disturbance method

NASA Astrophysics Data System (ADS)

Lawan, S.; Osotchan, T.; Chuajiw, W.; Subannajui, K.

2017-09-01

The formation of polymeric materials can be achieved by several methods such as melting and casting, screw extrusion, cross-linking of resin or rubber in a mold, and so on. In this work, the polyacrylic acid is formed by using the emulsion disturbance method. Despite extensively used in the colour painting and coating industries, acrylic emulsion can be processed into a foam and powder configuration by a reaction between acrylic emulsion and salt. The solidification hardly changes the volume between liquid emulsion and solidified polymer which means the final structure of polyacrylic acid is filled with opened air cells. The opened air cell structure is confirmed by the result from scanning electron microscopy. The chemical analysis and crystallography of acrylic powder and foam are examined by Fourier-transform infrared spectroscopy and X-ray diffraction respectively. The phase transformation and Thermal stability are studied by differential scanning calorimetry and thermo gravimetric analysis. Moreover, the mechanical properties of acrylic foam were observed by tensile, compressive and hardness test. In addition to the basic property analysis, acrylic foam was also used in the particle filtration application.

Aggregate Effect on the Concrete Cone Capacity of an Undercut Anchor under Quasi-Static Tensile Load

PubMed Central

Marcon, Marco; Ninčević, Krešimir; Boumakis, Ioannis; Czernuschka, Lisa-Marie

2018-01-01

In the last decades, fastening systems have become an essential part of the construction industry. Post-installed mechanical anchors are frequently used in concrete members to connect them with other load bearing structural members, or to attach appliances. Their performance is limited by the concrete related failure modes which are highly influenced by the concrete mix design. This paper aims at investigating the effect that different aggregates used in the concrete mix have on the capacity of an undercut anchor under tensile quasi-static loading. Three concrete batches were cast utilising three different aggregate types. For two concrete ages (28 and 70 days), anchor tensile capacity and concrete properties were obtained. Concrete compressive strength, fracture energy and elastic modulus are used to normalize and compare the undercut anchor concrete tensile capacity employing some of the most widely used prediction models. For a more insightful comparison, a statistical method that yields also scatter information is introduced. Finally, the height and shape of the concrete cones are compared by highly precise and objective photogrammetric means. PMID:29723972

Aggregate Effect on the Concrete Cone Capacity of an Undercut Anchor under Quasi-Static Tensile Load.

PubMed

Marcon, Marco; Ninčević, Krešimir; Boumakis, Ioannis; Czernuschka, Lisa-Marie; Wan-Wendner, Roman

2018-05-01

In the last decades, fastening systems have become an essential part of the construction industry. Post-installed mechanical anchors are frequently used in concrete members to connect them with other load bearing structural members, or to attach appliances. Their performance is limited by the concrete related failure modes which are highly influenced by the concrete mix design. This paper aims at investigating the effect that different aggregates used in the concrete mix have on the capacity of an undercut anchor under tensile quasi-static loading. Three concrete batches were cast utilising three different aggregate types. For two concrete ages (28 and 70 days), anchor tensile capacity and concrete properties were obtained. Concrete compressive strength, fracture energy and elastic modulus are used to normalize and compare the undercut anchor concrete tensile capacity employing some of the most widely used prediction models. For a more insightful comparison, a statistical method that yields also scatter information is introduced. Finally, the height and shape of the concrete cones are compared by highly precise and objective photogrammetric means.

Extended Ponseti method for failed tenotomy in idiopathic clubfeet: a pilot study.

PubMed

Agarwal, Anil; Agrawal, Nargesh; Barik, Sitanshu; Gupta, Neeraj

2018-01-29

We evaluated the outcome of a new protocol of an extended Ponseti method in the management of idiopathic club foot with residual equinus following failed Achilles tenotomy. We also compared the failed with a successful tenotomy group to analyze the parameters for failure. The Ponseti technique-treated idiopathic club foot patients with failed percutaneous Achilles tenotomy (failure to achieve <15° dorsiflexion) were treated by continued stretching casts, with a weekly change for a further 3 weeks. Final dorsiflexion more than 15° if achieved with the above protocol was recorded as a success. Twenty-six (16%) patients with failed Achilles tenotomy and residual equinus out of a total of 161 patients with primary idiopathic club foot were tested with the protocol. Ten (38.5%) failed patients had bilateral foot involvement and 16 (61.5%) had unilateral foot involvement. A total of seven (26.9%) patients achieved the end point dorsiflexion of more than 15° in one further cast, 10 (38.5%) in two casts, and four (15.4%) in three casts, respectively. Overall success of the extended Ponseti protocol was achieved in 21/26 (80.8%) patients. The patient's age, precasting initial Pirani score, number of Ponseti casts, pretenotomy Pirani score, and pretenotomy ankle joint dorsiflexion were statistically different in the failed compared with the successful tenotomy group. The tested extended Ponseti protocol showed a success rate of 80.8% in salvaging failed tenotomy cases. The failed tenotomy group was relatively older at presentation, had high precasting and pretenotomy Pirani scores, received extra number of Ponseti casts, and less pretenotomy ankle joint dorsiflexion compared with successful feet.

Building the Sun4Cast System: Improvements in Solar Power Forecasting

DOE PAGES

Haupt, Sue Ellen; Kosovic, Branko; Jensen, Tara; ...

2017-06-16

The Sun4Cast System results from a research-to-operations project built on a value chain approach, and benefiting electric utilities’ customers, society, and the environment by improving state-of-the-science solar power forecasting capabilities. As integration of solar power into the national electric grid rapidly increases, it becomes imperative to improve forecasting of this highly variable renewable resource. Thus, a team of researchers from public, private, and academic sectors partnered to develop and assess a new solar power forecasting system, Sun4Cast. The partnership focused on improving decision-making for utilities and independent system operators, ultimately resulting in improved grid stability and cost savings for consumers.more » The project followed a value chain approach to determine key research and technology needs to reach desired results. Sun4Cast integrates various forecasting technologies across a spectrum of temporal and spatial scales to predict surface solar irradiance. Anchoring the system is WRF-Solar, a version of the Weather Research and Forecasting (WRF) numerical weather prediction (NWP) model optimized for solar irradiance prediction. Forecasts from multiple NWP models are blended via the Dynamic Integrated Forecast (DICast) System, the basis of the system beyond about 6 h. For short-range (0-6 h) forecasts, Sun4Cast leverages several observation-based nowcasting technologies. These technologies are blended via the Nowcasting Expert System Integrator (NESI). The NESI and DICast systems are subsequently blended to produce short to mid-term irradiance forecasts for solar array locations. The irradiance forecasts are translated into power with uncertainties quantified using an analog ensemble approach, and are provided to the industry partners for real-time decision-making. The Sun4Cast system ran operationally throughout 2015 and results were assessed. As a result, this paper analyzes the collaborative design process, discusses the project results, and provides recommendations for best-practice solar forecasting.« less

Exposure and inhalation risk assessment in an aluminium cast-house.

PubMed

Godderis, L; Vanderheyden, W; Van Geel, J; Moens, G; Masschelein, R; Veulemans, H

2005-12-01

To date the exposure, absorption and respiratory health effects of cast-house workers have not been described since most studies performed in the aluminium industry are focused on exposure and health effects of potroom personnel. In the present study, we assessed the external exposure and the absorbed dose of metals in personnel from the aluminium cast house. This was combined with an evaluation of respiratory complaints and the lung function of the personnel. 30 workers from an aluminium casting plant participated and 17 individuals of the packaging and distribution departments were selected as controls. The exposure was assessed by the quantification of total inhalable fume with metal fraction and by the determination of urinary aluminium, chromium, beryllium, manganese and lead concentration. Carbon monoxide (CO), carbon dioxide (CO2), aldehydes and polyaromatic hydrocarbons and man-made mineral fibres concentration were assessed as well. In order to evaluate their respiratory status each participant filled out a questionnaire and their lung function was tested by forced spirometry. Total inhalable fume exposure was maximum 4.37 mg m(-3). Exposure to the combustion gases, man-made mineral fibres and metal fume was well below the exposure limits. Beryllium could not be detected in the urine. The values of aluminium, manganese and lead in the urine were all under the respective reference value. One individual had a urinary chromium excretion above the ACGIH defined biological exposure index (BEI) of 30 microg g(-1) creatinine. There was no significant difference in any of the categories of the respiratory questionnaire and in the results of the spirometry between cast house personnel and referents (Chi-square, all p > 0.05). Exposure in cast houses seem to be acceptable under these conditions. However, peak exposure to fumes cannot be excluded and the potential risk of chromium and beryllium exposure due to the recycling of aluminium requires further attention.

Improvement of food packaging related properties in whey protein isolate‑based nanocomposite films and coatings by addition of montmorillonite nanoplatelets

NASA Astrophysics Data System (ADS)

Schmid, Markus; Merzbacher, Sarah; Brzoska, Nicola; Müller, Kerstin; Jesdinszki, Marius

2017-11-01

In the present study the effects of the addition of montmorillonite (MMT) nanoplatelets on whey protein isolate (WPI)-based nanocomposite films and coatings were investigated. The main objective was the development of WPI-based MMT-nanocomposites with enhanced barrier and mechanical properties. WPI-based nanocomposite cast-films and coatings were prepared by dispersing 0 % (reference sample), 3 %, 6 %, 9 % (w/w protein) MMT, or, depending on the protein concentration, also 12 % and 15 % (w/w protein) MMT into native WPI-based dispersions, followed by subsequent denaturation during the drying and curing process. The natural MMT nanofillers could be randomly dispersed into film-forming WPI-based nanodispersions, displaying good compatibility with the hydrophilic biopolymer matrix. As a result, by addition of 15 % (w/w protein) MMT into 10 % (w/w dispersion) WPI-based cast-films or coatings, the oxygen permeability (OP) was reduced by 91 % for glycerol-plasticized and 84 % for sorbitol-plasticized coatings, water vapor transmission rate (WVTR) was reduced by 58 % for sorbitol-plasticized cast-films. Due to the addition of MMT- nanofillers the Young’s modulus and tensile strength improved by 315 % and 129 %, respectively, whereas elongation at break declined by 77 % for glycerol-plasticized cast-films. In addition, comparison of plasticizer type revealed that sorbitol-plasticized cast-films were generally stiffer and stronger, but less flexible compared glycerol-plasticized cast-films. Viscosity measurements demonstrated good processability and suitability for up-scaled industrial processes of native WPI-based nanocomposite dispersions, even at high nanofiller-loadings. These results suggest that the addition of natural MMT- nanofillers into native WPI-based matrices to form nanocomposite films and coatings holds great potential to replace well-established, fossil-based packaging materials for at least certain applications such as oxygen barriers as part of multilayer flexible packaging films.

Building the Sun4Cast System: Improvements in Solar Power Forecasting

DOE Office of Scientific and Technical Information (OSTI.GOV)

Haupt, Sue Ellen; Kosovic, Branko; Jensen, Tara

The Sun4Cast System results from a research-to-operations project built on a value chain approach, and benefiting electric utilities’ customers, society, and the environment by improving state-of-the-science solar power forecasting capabilities. As integration of solar power into the national electric grid rapidly increases, it becomes imperative to improve forecasting of this highly variable renewable resource. Thus, a team of researchers from public, private, and academic sectors partnered to develop and assess a new solar power forecasting system, Sun4Cast. The partnership focused on improving decision-making for utilities and independent system operators, ultimately resulting in improved grid stability and cost savings for consumers.more » The project followed a value chain approach to determine key research and technology needs to reach desired results. Sun4Cast integrates various forecasting technologies across a spectrum of temporal and spatial scales to predict surface solar irradiance. Anchoring the system is WRF-Solar, a version of the Weather Research and Forecasting (WRF) numerical weather prediction (NWP) model optimized for solar irradiance prediction. Forecasts from multiple NWP models are blended via the Dynamic Integrated Forecast (DICast) System, the basis of the system beyond about 6 h. For short-range (0-6 h) forecasts, Sun4Cast leverages several observation-based nowcasting technologies. These technologies are blended via the Nowcasting Expert System Integrator (NESI). The NESI and DICast systems are subsequently blended to produce short to mid-term irradiance forecasts for solar array locations. The irradiance forecasts are translated into power with uncertainties quantified using an analog ensemble approach, and are provided to the industry partners for real-time decision-making. The Sun4Cast system ran operationally throughout 2015 and results were assessed. As a result, this paper analyzes the collaborative design process, discusses the project results, and provides recommendations for best-practice solar forecasting.« less

Design for low-cost gas metal arc weld-based aluminum 3-D printing

NASA Astrophysics Data System (ADS)

Haselhuhn, Amberlee S.

Additive manufacturing, commonly known as 3-D printing, has the potential to change the state of manufacturing across the globe. Parts are made, or printed, layer by layer using only the materials required to form the part, resulting in much less waste than traditional manufacturing methods. Additive manufacturing has been implemented in a wide variety of industries including aerospace, medical, consumer products, and fashion, using metals, ceramics, polymers, composites, and even organic tissues. However, traditional 3-D printing technologies, particularly those used to print metals, can be prohibitively expensive for small enterprises and the average consumer. A low-cost open-source metal 3-D printer has been developed based upon gas metal arc weld (GMAW) technology. Using this technology, substrate release mechanisms have been developed, allowing the user to remove a printed metal part from a metal substrate by hand. The mechanical and microstructural properties of commercially available weld alloys were characterized and used to guide alloy development in 4000 series aluminum-silicon alloys. Wedge casting experiments were performed to screen magnesium, strontium, and titanium boride alloying additions in hypoeutectic aluminum-silicon alloys for their properties and the ease with which they could be printed. Finally, the top performing alloys, which were approximately 11.6% Si modified with strontium and titanium boride were cast, extruded, and drawn into wire. These wires were printed and the mechanical and microstructural properties were compared with those of commercially available alloys. This work resulted in an easier-to-print aluminum-silicon-strontium alloy that exhibited lower porosity, equivalent yield and tensile strengths, yet nearly twice the ductility compared to commercial alloys.

Carbon nanotube embedded PVDF membranes: Effect of solvent composition on the structural morphology for membrane distillation

NASA Astrophysics Data System (ADS)

Mapunda, Edgar C.; Mamba, Bhekie B.; Msagati, Titus A. M.

2017-08-01

Rapid population increase, growth in industrial and agricultural sectors and global climate change have added significant pressure on conventional freshwater resources. Tapping freshwater from non-conventional water sources such as desalination and wastewater recycling is considered as sustainable alternative to the fundamental challenges of water scarcity. However, affordable and sustainable technologies need to be applied for the communities to benefit from the treatment of non-conventional water source. Membrane distillation is a potential desalination technology which can be used sustainably for this purpose. In this work multi-walled carbon nanotube embedded polyvinylidene fluoride membranes for application in membrane distillation desalination were prepared via non-solvent induced phase separation method. The casting solution was prepared using mixed solvents (N, N-dimethylacetamide and triethyl phosphate) at varying ratios to study the effect of solvent composition on membrane morphological structures. Membrane morphological features were studied using a number of techniques including scanning electron microscope, atomic force microscope, SAXSpace tensile strength analysis, membrane thickness, porosity and contact angle measurements. It was revealed that membrane hydrophobicity, thickness, tensile strength and surface roughness were increasing as the composition of N, N-dimethylacetamide in the solvent was increasing with maximum values obtained between 40 and 60% N, N-dimethylacetamide. Internal morphological structures were changing from cellular structures to short finger-like and sponge-like pores and finally to large macro void type of pores when the amount of N, N-dimethylacetamide in the solvent was changed from low to high respectively. Multi-walled carbon nanotube embedded polyvinylidene fluoride membranes of desired morphological structures and physical properties can be synthesized by regulating the composition of solvents used to prepare the casting solution.

A new large-volume metal reference standard for radioactive waste management.

PubMed

Tzika, F; Hult, M; Stroh, H; Marissens, G; Arnold, D; Burda, O; Kovář, P; Suran, J; Listkowska, A; Tyminski, Z

2016-03-01

A new large-volume metal reference standard has been developed. The intended use is for calibration of free-release radioactivity measurement systems and is made up of cast iron tubes placed inside a box of the size of a Euro-pallet (80 × 120 cm). The tubes contain certified activity concentrations of (60)Co (0.290 ± 0.006 Bq g(-1)) and (110m)Ag (3.05 ± 0.09 Bq g(-1)) (reference date: 30 September 2013). They were produced using centrifugal casting from a smelt into which (60)Co was first added and then one piece of neutron irradiated silver wire was progressively diluted. The iron castings were machined to the desirable dimensions. The final material consists of 12 iron tubes of 20 cm outer diameter, 17.6 cm inner diameter, 40 cm length/height and 245.9 kg total mass. This paper describes the reference standard and the process of determining the reference activity values. © The Author 2015. Published by Oxford University Press.

A Comparison of the Behaviour of AlTiB and AlTiC Grain Refiners

NASA Astrophysics Data System (ADS)

Schneider, W.; Kearns, M. A.; McGarry, M. J.; Whitehead, A. J.

AlTiC master alloys present a new alternative to AlTiB grain refiners which have enjoyed pre-eminence in cast houses for several decades. Recent investigations have shown that, under defined casting conditions, AlTiC is a more efficient grain refiner than AlTiB, is less prone to agglomeration and is more resistant to poisoning by Zr, Cr. Moreover it is observed that there are differences in the mechanism of grain refinement for the different alloys. This paper describes the influence of melt temperature and addition rate on the performance of both types of grain refiner in DC casting tests on different wrought alloys. Furthermore the effects of combined additions of the grain refiners and the recycling behaviour of the treated alloys are presented. Results are compared with laboratory test data. Finally, mechanisms of grain refinement are discussed which are consistent with the observed differences in behaviour with AlTiC and AlTiB.

The interrelation between mechanical properties, corrosion resistance and microstructure of Pb-Sn casting alloys for lead-acid battery components

NASA Astrophysics Data System (ADS)

Peixoto, Leandro C.; Osório, Wislei R.; Garcia, Amauri

It is well known that there is a strong influence of thermal processing variables on the solidification structure and as a direct consequence on the casting final properties. The morphological microstructural parameters such as grain size and cellular or dendritic spacings will depend on the heat transfer conditions imposed by the metal/mould system. There is a need to improve the understanding of the interrelation between the microstructure, mechanical properties and corrosion resistance of dilute Pb-Sn casting alloys which are widely used in the manufacture of battery components. The present study has established correlations between cellular microstructure, ultimate tensile strength and corrosion resistance of Pb-1 wt% Sn and Pb-2.5 wt% Sn alloys by providing a combined plot of these properties as a function of cell spacing. It was found that a compromise between good corrosion resistance and good mechanical properties can be attained by choosing an appropriate cell spacing range.

Effect of a new tension system, used in acrylic resin flasking, on the dimensional stability of denture bases.

PubMed

Consani, Rafael Leonardo Xediek; Domitti, Saide Sarckis; Consani, Simonides

2002-09-01

The pressure of final closure may be released when the flask is removed from the mechanical or pneumatic press and placed in the spring clamp. This release in pressure may result in dimensional changes that distort the denture base. The purpose of this study was to investigate differences between the dimensional stability of standardized simulated denture bases processed by traditional moist heat-polymerization and those processed by use of a new tension system. A metal master die was fabricated to simulate an edentulous maxillary arch without irregularities in the alveolar ridge walls. A silicone mold of this metallic die was prepared, and 40 stone casts were formed from the mold with type III dental stone. The casts were randomly assigned to 4 test groups (A-D) of 10 specimens each. A uniform denture base pattern was made on each stone cast with a 1.5-mm thickness of base-plate wax, measured with a caliper. The patterns were invested for traditional hot water processing. A polymethyl methacrylate dough was prepared and packed for processing. The flasks in groups A and B were closed with the traditional pressure technique and placed in spring clamps after final closure. The flasks in groups C and D were pressed between the metallic plates of the new tension system after the final closure. The group A and C flasks were immediately immersed in the water processing unit at room temperature (25 degrees +/- 2 degrees C). The unit was programmed to raise the temperature to 74 degrees C over 1 hour, and then maintained the temperature at 74 degrees C for 8 hours. The group B and D flasks were bench stored at room temperature (25 degrees +/- 2 degrees C) for 6 hours and were then subjected to the same moist heat polymerization conditions as groups A and C. All processed dentures were bench cooled for 3 hours. After recovery from the flasks, the base-cast sets were transversally sectioned into 3 parts (corresponding to 3 zones): (1) distal of the canines, (2) mesial of the first molars, and (3) mesial of the posterior palate). These areas had been previously established and standardized by use of a pattern denture in the sawing device to determine the sections in each base-cast set. Base-cast gaps were measured at 5 predetermined points on each section with an optical micrometer that had a tolerance of 0.001 mm. Collected data were analyzed with analysis of variance and Tukey's test. Denture bases processed with the new tension system exhibited significantly better base adaptation than those processed with traditional acrylic resin packing. Immediately after polymerization (Groups A and C), mean dimensional change values were 0.213 +/- 0.055 mm for the traditional packing technique and 0.173 +/- 0.050 mm for new tension system. After delayed polymerization (Groups B and D), the values were 0.216 +/- 0.074 mm for the traditional packing technique and 0.164 +/- 0.032 mm for new tension system. With both techniques, dimensional changes in the posterior palatal zone were greater (conventional = 0.286 +/- 0.038 mm; new system = 0.214 +/- 0.024 mm) than those elsewhere on the base-cast set. Within the limitations of this study, the new tension packing system was associated with decreased dimensional changes in the simulated maxillary denture bases processed with heat-polymerization.

Potential Technology Transfer to the DoD Unmanned Ground Vehicle Program.

DTIC Science & Technology

1996-10-01

Germany. This process combines x-ray lithography, galvanic casting, and micromolding technology and can be used to produce a variety of sensors and...whether circulation is being obstructed by atherosclerosis . Finally, work is being done at the University of Minnesota on a microrobotic device

Spherical Primary Optical Telescope (SPOT) Segment Fabrication

DTIC Science & Technology

2010-06-07

of Pyrex. One mirror (segment) was figured at GSFC and final figured at QED using Magnetorheological Finishing . Two other segments are in process...point) have been cast • Segment 1 was figured at GSFC completed at QED using magnetorheological finishing (MRF) • New GSFC figuring facility brought on

Stacked dielectric elastomer actuator (SDEA): casting process, modeling and active vibration isolation

NASA Astrophysics Data System (ADS)

Li, Zhuoyuan; Sheng, Meiping; Wang, Minqing; Dong, Pengfei; Li, Bo; Chen, Hualing

2018-07-01

In this paper, a novel fabrication process of stacked dielectric elastomer actuator (SDEA) is developed based on casting process and elastomeric electrode. The so-fabricated SDEA benefits the advantages of homogenous and reproducible properties as well as little performance degradation after one-year use. A coupling model of SDEA is established by taking into consideration of the elastomeric electrode and the calculated results agree with the experiments. Based on the model, we attain the method to optimize the SDEA’s parameters. Finally, the SDEA is used as an isolator in active vibration isolation system to verify the feasibility in dynamic application. And the experiment results show a great prospect for SDEA in such application.

Metal plasticity and ductile fracture modeling for cast aluminum alloy parts

DOE PAGES

Lee, Jinwoo; Kim, Se-Jong; Park, Hyeonil; ...

2018-01-06

Here in this study, plasticity and ductile fracture properties were characterized by performing various tension, shear, and compression tests. A series of 10 experiments were performed using notched round bars, flat-grooved plates, in-plane shear plates, and cylindrical bars. Two cast aluminum alloys used in automotive suspension systems were selected. Plasticity modelling was performed and the results were compared with experimental and corresponding simulation results; further, the relationships among the stress triaxiality, Lode angle parameter, and equivalent plastic strain at the onset of failure were determined to calibrate a ductile fracture model. Finally, the proposed ductile fracture model shows good agreementmore » with experimental results.« less

Metal plasticity and ductile fracture modeling for cast aluminum alloy parts

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lee, Jinwoo; Kim, Se-Jong; Park, Hyeonil

Here in this study, plasticity and ductile fracture properties were characterized by performing various tension, shear, and compression tests. A series of 10 experiments were performed using notched round bars, flat-grooved plates, in-plane shear plates, and cylindrical bars. Two cast aluminum alloys used in automotive suspension systems were selected. Plasticity modelling was performed and the results were compared with experimental and corresponding simulation results; further, the relationships among the stress triaxiality, Lode angle parameter, and equivalent plastic strain at the onset of failure were determined to calibrate a ductile fracture model. Finally, the proposed ductile fracture model shows good agreementmore » with experimental results.« less

A Removable Long-arm Soft Cast to Treat Nondisplaced Pediatric Elbow Fractures: A Randomized, Controlled Trial.

PubMed

Silva, Mauricio; Sadlik, Gal; Avoian, Tigran; Ebramzadeh, Edward

2018-04-01

The ideal type of immobilization for nondisplaced pediatric elbow fractures has not been established. We hypothesized that the use of a long-arm cylinder made of soft cast material will result in similar outcomes to those obtained with a traditional long-arm hard cast. We randomly assigned 100 consecutive children who presented with a closed, nondisplaced, type I supracondylar humeral fracture or an occult, closed, acute elbow injury, to 1 of 2 groups: group A (n=50) received a long-arm, traditional fiberglass (hard) cast. Group B (n=50) received a long-arm, soft fiberglass cast. After 4 weeks, the cast was removed in group A by a member of our staff using a cast saw, and in group B by one of the patient's parents by rolling back the soft fiberglass material. We compared the amount of fracture displacement and/or angulation, recovery of range of motion, elbow pain, and patient satisfaction. There were no instances of unplanned removal of the cast by the patient or parent. No evidence of fracture displacement or angulation was seen in either group. The final carrying angle of the affected elbow was nearly identical of that of the normal, contralateral elbow in both groups (P=0.64). At the latest follow-up appointment, elbows in groups A and B had a similar mean arc of motion (156 vs. 154 degrees; P=0.45), and had achieved identical relative arc of motion of 99.6% and 99.5% of that of the normal, contralateral side, respectively (P=0.94). Main pain scores were low and comparable over the study period. All patients in both groups reported the highest rate of satisfaction at the eighth week of follow-up. The results indicate that children with nondisplaced supracondylar humeral fractures can be successfully managed with the use of a removable long-arm soft cast, maintaining fracture alignment and resulting in comparable rates of range of motion, pain, and patient satisfaction. The use of a removable immobilization that can reliably maintain fracture alignment and result in similar outcomes, while minimizing the risk of noncompliance, could be advantageous. Although we elected to remove the soft cast during a scheduled follow-up, it appears that such immobilization could be removed easily and safely at home, potentially resulting in a lower number of patient visits, decreased health care costs, and higher patient/parent satisfaction. Level I.

[Measurement of chemical agents in metallurgy field: electric steel plant].

PubMed

Cottica, D; Grignani, E; Ghitti, R; Festa, D; Apostoli, P

2012-01-01

The steel industry maintains its important position in the context of the Italian production involving thousands of workers. The iron and steel processes are divided into primary steel industry, production of intermediate minerals, and secondary steel, scrap from the production of semi-finished industrial and consumer sector (metal inserted into components and metal used for dissipative uses, primarily coatings) and industrial waste. The paper presents the results of environmental monitoring carried out in some electric steel plant for the measurement of airborne chemicals that characterize the occupational exposure of workers employed in particular area like electric oven, to treatment outside the furnace, continuous casting area. For the sampling of the pollutants were used both personal and in fixed positions samplers. The pollutants measured are those typical of steel processes inhalable dust, metals, respirable dust, crystalline silica, but also Polycyclic Aromatic Hydrocarbons (PAH), polychlorinated dioxins (PCDDs) and polychlorinated dibenzofurans (PCDFs).

Control-release of antimicrobial sophorolipid employing different biopolymer matrices

USDA-ARS?s Scientific Manuscript database

Sophorolipid (SL) purified from fermentation broth of Candida bombicola grown on oleic acid and glucose substrates was embedded at 0, 9, 17, and 29% (%-total weight of final product) in solvent-cast films of poly(L-lactic acid) (PLLA), poly(epsilon-caprolactone)(PCL), and poly(hydroxybutyrate)(PHB)....

Shear repair methods for conventionally reinforced concrete girders and bent caps : final report, December 2009.

DOT National Transportation Integrated Search

2009-12-01

Thirteen large-scale girders and two bent caps that replicated as close as possible bridge components from the 1950s were cast and loaded to cause initial cracking similar to that observed in the field. The girders were repaired with epoxy crack inje...

Lawmakers target PURPA for repeal

DOE Office of Scientific and Technical Information (OSTI.GOV)

Burkhart, L.A.

This article is a review of current legislative initiatives to repeal certain sections of the Public Utilities Regulatory Policy Act (PURPA). Targeted for repeal is Section 210 of PURPA, which mandates purchases from qualifying facilities at avoided-cost rates. Pros and cons of this proposed repeal are reviewed, with Administration officials lining up against the repeal and industry casting their vote for repeal of this and other sections of PURPA.

Methods of Enhancing the Operating Characteristics of Gas-Turbine Blades

NASA Astrophysics Data System (ADS)

Ospennikova, O. G.; Visik, E. M.; Gerasimov, V. V.; Kolyadov, E. V.

2017-12-01

This paper considers the main tendencies of development and ways of introduction of new technological solutions and alloys in the production of industrial gas-turbine unit (GTU) blades and presents a review of modern corrosion-resistant alloys, casting units for high-gradient directional solidification, and the techniques providing the preparation of a single-crystal structure in the blades of stationary turbine plants.

Influence of Low-Frequency Vibration and Modification on Solidification and Mechanical Properties of Al-Si Casting Alloy.

PubMed

Selivorstov, Vadim; Dotsenko, Yuri; Borodianskiy, Konstantin

2017-05-20

One of the major aims of the modern materials foundry industry is the achievement of advanced mechanical properties of metals, especially of light non-ferrous alloys such as aluminum. Usually an alloying process is applied to obtain the required properties of aluminum alloys. However, the presented work describes an alternative approach through the application of vibration treatment, modification by ultrafine powder and a combination of these two methods. Microstructural studies followed by image analysis revealed the refinement of α-Al grains with an increase in the Si network area around them. As evidence, the improvement of the mechanical properties of Al casting alloy was detected. It was found that the alloys subjected to the vibration treatment displayed an increase in tensile and yield strengths by 20% and 10%, respectively.

Recycle of radioactive scrap metal from the Oak Ridge Gaseous Diffusion Plant (K-25 Site)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Meehan, R.W.

1997-02-01

The scale of the metal available for reuse at the plant includes 22 million pounds of Ni, 17 million pounds of Al, 47 million pounds of copper, and 835 million pounds of steels. In addition there is a wide range of industrial equipment and other items of value. The author describes small bench scale and pilot plant scale efforts made at treating metal for decontamination and fabrication into cast stock or specialized containers for reuse within the DOE complex or release. These projects show that much of the material can be cleaned or chemically decontaminated to a level where itmore » can be free released to various markets. Of the remaining metals, much of it can be cast into products which can be absorbed within the DOE complex.« less

Influence of Low-Frequency Vibration and Modification on Solidification and Mechanical Properties of Al-Si Casting Alloy

PubMed Central

Selivorstov, Vadim; Dotsenko, Yuri; Borodianskiy, Konstantin

2017-01-01

One of the major aims of the modern materials foundry industry is the achievement of advanced mechanical properties of metals, especially of light non-ferrous alloys such as aluminum. Usually an alloying process is applied to obtain the required properties of aluminum alloys. However, the presented work describes an alternative approach through the application of vibration treatment, modification by ultrafine powder and a combination of these two methods. Microstructural studies followed by image analysis revealed the refinement of α-Al grains with an increase in the Si network area around them. As evidence, the improvement of the mechanical properties of Al casting alloy was detected. It was found that the alloys subjected to the vibration treatment displayed an increase in tensile and yield strengths by 20% and 10%, respectively. PMID:28772922

Effects of N/C Ratio on Solidification Behaviors of Novel Nb-Bearing Austenitic Heat-Resistant Cast Steels for Exhaust Components of Gasoline Engines

NASA Astrophysics Data System (ADS)

Zhang, Yinhui; Li, Mei; Godlewski, Larry A.; Zindel, Jacob W.; Feng, Qiang

2017-03-01

In order to comply with more stringent environmental and fuel consumption regulations, novel Nb-bearing austenitic heat-resistant cast steels that withstand exhaust temperatures as high as 1,323 K (1,050 °C) is urgently demanded from automotive industries. In the current research, the solidification behavior of these alloys with variations of N/C ratio is investigated. Directional solidification methods were carried out to examine the microstructural development in mushy zones. Computational thermodynamic calculations under partial equilibrium conditions were performed to predict the solidification sequence of different phases. Microstructural characterization of the mushy zones indicates that N/C ratio significantly influenced the stability of γ-austenite and the precipitation temperature of NbC/Nb(C,N), thereby altering the solidification path, as well as the morphology and distribution of NbC/Nb(C,N) and γ-ferrite. The solidification sequence of different phases predicted by thermodynamic software agreed well with the experimental results, except the specific precipitation temperatures. The generated data and fundamental understanding will be helpful for the application of computational thermodynamic methods to predict the as-cast microstructure of Nb-bearing austenitic heat-resistant steels.

Fabrication of Activated Rice Husk Charcoal by Slip Casting as a Hybrid Material for Water Filter Aid

NASA Astrophysics Data System (ADS)

Tuaprakone, T.; Wongphaet, N.; Wasanapiarnpong, T.

2011-04-01

Activated charcoal has been widely used as an odor absorbent in household and water purification industry. Filtration equipment for drinking water generally consists of four parts, which are microporous membrane (porous alumina ceramic or diatomite, or porous polymer), odor absorbent (activated carbon), hard water treatment (ion exchange resin), and UV irradiation. Ceramic filter aid is usually prepared by slip casting of alumina or diatomite. The membrane offers high flux, high porosity and maximum pore size does not exceed 0.3 μm. This study investigated the fabrication of hybrid activated charcoal tube for water filtration and odor absorption by slip casting. The suitable rice husk charcoal and water ratio was 48 to 52 wt% by weight with 1.5wt% (by dry basis) of CMC binder. The green rice husk charcoal bodies were dried and fired between 700-900 °C in reduction atmosphere. The resulting prepared slip in high speed porcelain pot for 60 min and sintered at 700 °C for 1 h showed the highest specific surface area as 174.95 m2/g. The characterizations of microstructure and pore size distribution as a function of particle size were investigated.

Theoretical Model for Volume Fraction of UC, 235U Enrichment, and Effective Density of Final U 10Mo Alloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Devaraj, Arun; Prabhakaran, Ramprashad; Joshi, Vineet V.

2016-04-12

The purpose of this document is to provide a theoretical framework for (1) estimating uranium carbide (UC) volume fraction in a final alloy of uranium with 10 weight percent molybdenum (U-10Mo) as a function of final alloy carbon concentration, and (2) estimating effective 235U enrichment in the U-10Mo matrix after accounting for loss of 235U in forming UC. This report will also serve as a theoretical baseline for effective density of as-cast low-enriched U-10Mo alloy. Therefore, this report will serve as the baseline for quality control of final alloy carbon content

Spherical primary optical telescope (SPOT) segments

NASA Astrophysics Data System (ADS)

Hall, Christopher; Hagopian, John; DeMarco, Michael

2012-09-01

The spherical primary optical telescope (SPOT) project is an internal research and development program at NASA Goddard Space Flight Center. The goals of the program are to develop a robust and cost effective way to manufacture spherical mirror segments and demonstrate a new wavefront sensing approach for continuous phasing across the segmented primary. This paper focuses on the fabrication of the mirror segments. Significant cost savings were achieved through the design, since it allowed the mirror segments to be cast rather than machined from a glass blank. Casting was followed by conventional figuring at Goddard Space Flight Center. After polishing, the mirror segments were mounted to their composite assemblies. QED Technologies used magnetorheological finishing (MRF®) for the final figuring. The MRF process polished the mirrors while they were mounted to their composite assemblies. Each assembly included several magnetic invar plugs that extended to within an inch of the face of the mirror. As part of this project, the interaction between the MRF magnetic field and invar plugs was evaluated. By properly selecting the polishing conditions, MRF was able to significantly improve the figure of the mounted segments. The final MRF figuring demonstrates that mirrors, in the mounted configuration, can be polished and tested to specification. There are significant process capability advantes due to polishing and testing the optics in their final, end-use assembled state.

Microstructure and texture development of 7075 alloy during homogenisation

NASA Astrophysics Data System (ADS)

Ghosh, Abhishek; Ghosh, Manojit

2018-06-01

The microstructure evolution of Al-Zn-Mg-Cu alloy during homogenisation was studied by optical microscope, field emission scanning electron microscope, energy dispersive X-ray Spectroscopy, differential scanning calorimetry and X-ray diffraction in detailed. It has been found that primary cast structure consisted of primary α (Al), lamellar eutectic structure η Mg(Zn, Cu, Al)2 and a small amount of θ (Al2Cu) phase. A transformation of primary eutectic phase from η Mg(Zn, Cu, Al)2 to S (Al2CuMg) was observed after 6 h of homogenisation treatment. The volume fraction of dendrite network structure and intermetallic phase was decreased with increase in holding time and finally disappeared after 96 h of homogenisation, which is consistent with the results of homogenisation kinetic analysis. Crystallographic texture of this alloy after casting and 96 h of homogenisation was also studied. It was found that casting process led the development of strong Goss, Brass, P and CuT components, while after homogenisation Cube, S and Copper components became predominant. Mechanical tests revealed higher hardness, yield strength and tensile strength for cast materials compared to homogenised alloys due to the presence of coarse micro-segregation of MgZn2 phase. The significant improvement of ductility was observed after 96-h homogenisation, which was attributed to dissolution of second phase particles and grain coarsening. Fracture surfaces of the cast samples indicated the presence of shrinkage porosity and consequently failure occurred in the interdendritic regions or grain boundaries with brittle mode, while homogenised alloys failed under ductile mode as evident by the presence of fine dimple surfaces.

Comparison of implant cast accuracy of multiple implant impression technique with different splinting materials: An in vitro study

PubMed Central

Selvaraj, Sunantha; Dorairaj, Jayachandran; Mohan, Jayashree; Simon, Paul

2016-01-01

Introduction: An accurate and passive fit of implant framework prosthesis, as well as the successful surgical operation is suggested as one of the critical requirements for long-term implant success. Objective: The purpose of this in vitro study was to evaluate the accuracy of the master cast using open tray impression technique with conventional and novel splinting materials. Methodology: A mandibular reference model with four ADIN implants was done. Ten custom trays were fabricated using the light curable resin sheets. Medium body polyether impression material was used. These trays were randomly divided between the two groups, with five trays in each group. Impression techniques were divided into two groups namely: Group A: Direct impression technique with open tray impression copings splinted with autopolymerizing acrylic resin (GC pattern resin). Group B: Direct impression technique with open tray impression copings splinted with Pro-temp TM 4 (bis-GMA) syringable temporization material. Thus, final impressions were made. Total of 10 master casts were fabricated. Evaluation of casts using Dynascope-Vision Engineering, TESA microhite two- dimension and coordinate measuring machine were used. Results: Statistical comparisons were made using ANOVA test and post-hoc test. Same amount of deviation values obtained with resin splinted and bis-GMA splinted impression copings. Conclusion: The master cast obtained by both the splinting material exhibits no difference from the reference model. So bis-GMA can be used, which is easy to handle, less time consuming, less technique sensitive, rigid, and readily available material in clinics. PMID:27141167

Evaluation of Mechanical Properties of MWCNT / Nanoclay Reinforced Aluminium alloy Metal Matrix Composite

NASA Astrophysics Data System (ADS)

Ratna Kumar, P. S. Samuel; Robinson Smart, D. S.; Alexis, S. John

2018-04-01

Aluminium alloy 5083 (AA5083) is a widely used material in aerospace, marine, defence and structural applications were mechanical and corrosion resistance property plays a vital role. For the present work, MWCNT / Nanoclay (montmorillonite (MMT) K10) mixed with AA5083 for different composition in weight percentage to enhance the mechanical property. Semi-solid state casting method (Compo-casting) was used to fabricate the composite materials. By using Field-emission scanning electron microscope (FESEM) the uniform dispersion of the reinforcement and microstructure were studied. Finally, the addition of Nanoclay shows decrease in tensile strength compared to the AA5083 / MWCNT composites and hardness value of the composites (AA5083 / MWCNT and AA5083 / Nanoclay) was found to increase significantly.

Post-cast EDM method for reducing the thickness of a turbine nozzle wall

DOEpatents

Jones, Raymond Joseph; Bojappa, Parvangada Ganapathy; Kirkpatrick, Francis Lawrence; Schotsch, Margaret Jones; Rajan, Rajiv; Wei, Bin

2002-01-01

A post-cast EDM process is used to remove material from the interior surface of a nozzle vane cavity of a turbine. A thin electrode is passed through the cavity between opposite ends of the nozzle vane and displaced along the interior nozzle wall to remove the material along a predetermined path, thus reducing the thickness of the wall between the cavity and the external surface of the nozzle. In another form, an EDM process employing a profile as an electrode is disposed in the cavity and advanced against the wall to remove material from the wall until the final wall thickness is achieved, with the interior wall surface being complementary to the profile surface.

DYNAMIC PROPERTIES OF SHOCK LOADED THIN URANIUM FOILS

DOE Office of Scientific and Technical Information (OSTI.GOV)

Robbins, D. L.; Kelly, A. M.; Alexander, D. J.

A series of spall experiments has been completed with thin depleted uranium targets, nominally 0.1 mm thick. The first set of uranium spall targets was cut and ground to final thickness from electro-refined, high-purity, cast uranium. The second set was rolled to final thickness from low purity uranium. The impactors for these experiments were laser-launched 0.05-mm thick copper flyers, 3 mm in diameter. Laser energies were varied to yield a range of flyer impact velocities. This resulted in varying degrees of damage to the uranium spall targets, from deformation to complete spall or separation at the higher velocities. Dynamic measurementsmore » of the uranium target free surface velocities were obtained with dual velocity interferometers. Uranium targets were recovered and sectioned after testing. Free surface velocity profiles were similar for the two types of uranium, but spall strengths (estimated from the magnitude of the pull-back signal) are higher for the high-purity cast uranium. Velocity profiles and microstructural evidence of spall from the sectioned uranium targets are presented.« less

JPRS Report. Soviet Union: World Economy & International Relations, No. 2, February 1989

DTIC Science & Technology

1989-05-13

a small group of the biggest companies of a number of highly concentrated base sectors of industry—steel casting, automotive, chemical , industrial...forth. As of the present the TNC practically share among themselves the capitalist markets for automobiles and steel and a number of chemical ...automobile, textile, chemical and agricultural commodity, electronics and transport services markets. Competition is now heating up not only in the sphere of

The Impacts of Industrial Robots

DTIC Science & Technology

1981-11-01

plastics, ’and strain gauges are used to measure very small forces at a number of points on the robot’s "end effector. Except for the simplest on-off...devices, tactile sensors are not yet found on commercially available robots. Forces are sensed by using strain gauges or piezoelectric sensors to...tools: deburring, drilling , grinding,milling,routing machines ii. plastic materialsformirg and injection machines iii. metal die casting machines iv

Effects of Exposures on Superalloys for Space Applications

NASA Technical Reports Server (NTRS)

Gabb, Tim; Garg, Anita; Gayda, John

2007-01-01

The industry is demanding longer term service at high temperatures for nickel-base superalloys in gas turbine engine as well as potential space applications. However, longer term service can severely tax alloy phase stability, to the potential detriment of mechanical properties. Cast Mar-M247LC and wrought Haynes 230 superalloys were exposed and creep tested for extended times at elevated temperature. Microstructure and phase evaluations were then undertaken for comparisons.

Characterization and Mechanical Properties of 2014 Aluminum Alloy Reinforced with Al2O3p Composite Produced by Two-Stage Stir Casting Route

NASA Astrophysics Data System (ADS)

Bharath, V.; Ajawan, Santhrusht S.; Nagaral, Madev; Auradi, Virupaxi; Kori, Shivaputrappa Amarappa

2018-02-01

Metal matrix composites (MMC's) form appropriate choice of materials where there is a demand for stiffness, strength combined with low weight for different applications. The applications of Aluminum based MMC's as engineering materials has been exceedingly increased in almost all industrial sectors. Aluminum strengthened with Al2O3p gives excellent physical and mechanical properties like high hardness, low density, high electrical conductivity etc., which are generally used in the field of aerospace, automobile and industrial applications. In present work, an attempt is being made to integrate 2014 Al alloy with Al2O3p by two stage stir casting with addition level of reinforcement maintained at 9 and 12 wt%. Microstructural characterization carried out using scanning electron microscopy showed fairly uniform distribution of Al2O3p with grain refinement of the matrix. These prepared composites are mechanically characterized as per the ASTM standards using computerized universal testing machine. Improvements in tensile strength, density and hardness of the prepared composites were observed with increase in the reinforcement wt%. Percentage improvements of 5.09% (9 wt%), 17.65% (12 wt%) in terms of tensile strength and 29.18% (9 wt%), 43.69% (12 wt%) in terms of hardness were obtained respectively.

Three-dimensional printing of transparent fused silica glass

NASA Astrophysics Data System (ADS)

Kotz, Frederik; Arnold, Karl; Bauer, Werner; Schild, Dieter; Keller, Nico; Sachsenheimer, Kai; Nargang, Tobias M.; Richter, Christiane; Helmer, Dorothea; Rapp, Bastian E.

2017-04-01

Glass is one of the most important high-performance materials used for scientific research, in industry and in society, mainly owing to its unmatched optical transparency, outstanding mechanical, chemical and thermal resistance as well as its thermal and electrical insulating properties. However, glasses and especially high-purity glasses such as fused silica glass are notoriously difficult to shape, requiring high-temperature melting and casting processes for macroscopic objects or hazardous chemicals for microscopic features. These drawbacks have made glasses inaccessible to modern manufacturing technologies such as three-dimensional printing (3D printing). Using a casting nanocomposite, here we create transparent fused silica glass components using stereolithography 3D printers at resolutions of a few tens of micrometres. The process uses a photocurable silica nanocomposite that is 3D printed and converted to high-quality fused silica glass via heat treatment. The printed fused silica glass is non-porous, with the optical transparency of commercial fused silica glass, and has a smooth surface with a roughness of a few nanometres. By doping with metal salts, coloured glasses can be created. This work widens the choice of materials for 3D printing, enabling the creation of arbitrary macro- and microstructures in fused silica glass for many applications in both industry and academia.

Comparison of Structural Relaxation Behavior in As-Cast and Pre-Annealed Zr-Based Bulk Metallic Glasses Just below Glass Transition

DOE PAGES

Haruyama, Osami; Yoshikawa, Kazuyoshi; Yamazaki, Yoshikatsu; ...

2015-04-25

In this paper, the α-relaxation of pre-annealed Zr 55Cu 30Ni 5Al 10 bulk metallic glasses (BMGs) was compared with that of as-cast Zr-based BMGs including Zr 55Cu 30Ni 5Al 10. The α-relaxation was investigated by volume relaxation. The relaxation behavior was well described by a stretched exponential relaxation function, Φ (t) ≈ exp [ - (t/τ α ) β α ], with the isothermal relaxation time, τ α, and the Kohlrausch exponent, β α. The β α exhibited the strong temperature dependence for the pre-annealed BMG, while the weak temperature dependence was visualized for the as-cast BMG similar to themore » dynamic relaxation. The τ α’s were modified by Moynihan and Narayanaswamy-Tool-Moynihan methods that reduce the difference in the thermal history of sample. Finally, as a result, the relaxation kinetics in the glass resembled that of a liquid deduced from the behavior of viscosity in the supercooled liquid.« less

Effect of processing parameters on the earing and mechanical properties of strip cast type 3004 Al alloy

NASA Astrophysics Data System (ADS)

Es-Said, O. S.; Zeihen, A.; Ruprich, M.; Quattrocchi, J.; Thomas, M.; H. Shin, K.; O'Brien, M.; Johansen, D.; Tijoe, W. H.; Ruhl, D.

1995-06-01

Electrical resistivity, superficial hardness, tensile testing, and quantitative metallography techniques were used in this study. The strip cast type 3004 aluminum alloy received sixteen different thermomechanical treatments before cups were drawn. The top edges of the drawn cups were not flat. Rather there were high points or ears with valleys between them. The homogenization temperature varied form 510 to 621 °C at 24 h. Some samples received an additional 426 °C/24 h homogenization anneal. Most specimens were rolled along the longitudinal direction of the as-cast material, and some were rolled in the transverse direction. Most samples were recrystallized at 454 °C for 24 h in addition to the homogenization treatment. Some were recrystallized for 168 h. All samples were subsequently rolled to 0.33 mm for cup drawing and percent earing determination. The percent earing results of some samples were less than 1.5%, but the mechanical strength was also lowered. The high-temperature recrystallization anneal of 454 °C was the controlling factor in determining the earing and mechanical strength of the final rolled sheet.

Effect of processing parameters on the earing and mechanical properties of strip cast type 3004 Al alloy

NASA Astrophysics Data System (ADS)

Es-Said, O. S.; Zeihen, A.; Ruprich, M.; Quattrocchi, J.; Thomas, M.; Shin, K. H.; O'Brien, M.; Johansen, D.; Tijoe, W. H.; Ruhl, D.

1994-02-01

Electrical resistivity, superficial hardness, tensile testing, and quantitative metallography techniques were used in this study. The strip cast type 3004 aluminum alloy received sixteen different thermomechanical treatments before cups were drawn. The top edges of the drawn cups were not flat. Rather, there were high points or ears with valleys between them. The homogenization temperature varied from 510 to 621 °C at 24 h. Some samples received an additional 426 °C/24 h homogenization anneal. Most specimens were rolled along the longitudinal direction of the as-cast material, and some were rolled in the transverse direction. Most samples were recrystallized at 454 °C for 24 h in addition to the homogenization treatment. Some were recrystallized for 168 h. All samples were subsequently rolled to 0.33 mm for cup drawing and percent earing determination. The percent earing results of some samples were less than 1.5%, but the mechanical strength was also lowered. The high-temperature recrystallization anneal of 454 °C was the controlling factor in determining the earing and mechanical strength of the final rolled sheet.

Industrial Technology Modernization Program. Project 28. Automation of Receiving, Receiving Inspection and Stores

DTIC Science & Technology

1987-06-15

001 GENERAL DYNAMICS 00 FORT WORTH DIVISION INDUSTRIAL TECHNOLOGY MODERNIZATION PROGRAM Phase 2 Final Project Repc t JUNG 0 ?7 PROJECT 28 AUTOMATION...DYNAMICS FORT WORTH DIVISION INDUSTRIAL TECHNOLOGY MODERNIZATION PROGRAM Phase 2 Final Project Report PROJECT 28 AUTOMATION OF RECEIVING, RECEIVING...13 6 PROJECT ASSUMPTIONS 20 7 PRELIMINARY/FINAL DESIGN AND FINDINGS 21 8 SYSTEM/EQUIPMENT/MACHINING SPECIFICATIONS 37 9 VENDOR/ INDUSTRY ANALYSIS

Juvenile Hormone Biosynthesis Gene Expression in the corpora allata of Honey Bee (Apis mellifera L.) Female Castes

PubMed Central

Rosa, Gustavo Conrado Couto; Moda, Livia Maria; Martins, Juliana Ramos; Bitondi, Márcia Maria Gentile; Hartfelder, Klaus; Simões, Zilá Luz Paulino

2014-01-01

Juvenile hormone (JH) controls key events in the honey bee life cycle, viz. caste development and age polyethism. We quantified transcript abundance of 24 genes involved in the JH biosynthetic pathway in the corpora allata-corpora cardiaca (CA-CC) complex. The expression of six of these genes showing relatively high transcript abundance was contrasted with CA size, hemolymph JH titer, as well as JH degradation rates and JH esterase (jhe) transcript levels. Gene expression did not match the contrasting JH titers in queen and worker fourth instar larvae, but jhe transcript abundance and JH degradation rates were significantly lower in queen larvae. Consequently, transcriptional control of JHE is of importance in regulating larval JH titers and caste development. In contrast, the same analyses applied to adult worker bees allowed us inferring that the high JH levels in foragers are due to increased JH synthesis. Upon RNAi-mediated silencing of the methyl farnesoate epoxidase gene (mfe) encoding the enzyme that catalyzes methyl farnesoate-to-JH conversion, the JH titer was decreased, thus corroborating that JH titer regulation in adult honey bees depends on this final JH biosynthesis step. The molecular pathway differences underlying JH titer regulation in larval caste development versus adult age polyethism lead us to propose that mfe and jhe genes be assayed when addressing questions on the role(s) of JH in social evolution. PMID:24489805

Generation of strip-format fibrin-based engineered heart tissue (EHT).

PubMed

Schaaf, Sebastian; Eder, Alexandra; Vollert, Ingra; Stöhr, Andrea; Hansen, Arne; Eschenhagen, Thomas

2014-01-01

This protocol describes a method for casting fibrin-based engineered heart tissue (EHT) in standard 24-well culture dishes. In principle, a hydrogel tissue engineering method requires cardiomyocytes, a liquid matrix that forms a gel, a casting mold, and a device that keeps the developing tissue in place. This protocol refers to neonatal rat heart cells as the cell source; the matrix of choice is fibrin, and the tissues are generated in rectangular agarose-casting molds (12 × 3 × 3 mm) prepared in standard 24-well cell culture dishes, in which a pair of flexible silicone posts is suspended from above. A master mix of freshly isolated cells, medium, fibrinogen, and thrombin is pipetted into the casting mold and, over a period of 2 h, polymerizes and forms a fibrin cell block around two silicone posts. Silicone racks holding four pairs of silicone posts each are used to transfer the fresh fibrin cell blocks into new 24-well dishes with culture medium. Without further handling, the cells start to remodel the fibrin gel, form contacts with each other, elongate, and condense the gel to approximately ¼ of the initial volume. Spontaneous and rhythmic contractions start after 1 week. EHTs are viable and relatively stable for several weeks in this format and can be subjected to repeated measurements of contractile function and final morphological and molecular analyses.

Letter Report: LAW Simulant Development for Cast Stone Screening Test

DOE Office of Scientific and Technical Information (OSTI.GOV)

Russell, Renee L.; Westsik, Joseph H.; Swanberg, David J.

2013-03-27

More than 56 million gallons of radioactive and hazardous waste are stored in 177 underground storage tanks at the U.S. Department of Energy’s (DOE’s) Hanford Site in southeastern Washington State. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) is being constructed to treat the wastes and immobilize them in a glass waste form. The WTP includes a pretreatment facility to separate the wastes into a small volume of high-level waste (HLW) containing most of the radioactivity and a larger volume of low-activity waste (LAW) containing most of the nonradioactive chemicals. The HLW will be converted to glass in themore » HLW vitrification facility for ultimate disposal at an offsite federal repository. At least a portion (~35%) of the LAW will be converted to glass in the LAW vitrification facility and will be disposed of onsite at the Integrated Disposal Facility (IDF). The pretreatment and HLW vitrification facilities will have the capacity to treat and immobilize the wastes destined for each facility. However, a second facility will be needed for the expected volume of additional LAW requiring immobilization. A cementitious waste form known as Cast Stone is being considered to provide the required additional LAW immobilization capacity. The Cast Stone waste form must be acceptable for disposal in the IDF. The Cast Stone waste form and immobilization process must be tested to demonstrate that the final Cast Stone waste form can comply with waste acceptance criteria for the IDF disposal facility and that the immobilization processes can be controlled to consistently provide an acceptable waste form product. Further, the waste form must be tested to provide the technical basis for understanding the long term performance of the waste form in the IDF disposal environment. These waste form performance data are needed to support risk assessment and performance assessment (PA) analyses of the long-term environmental impact of the waste disposal in the IDF. A testing program was developed in fiscal year (FY) 2012 describing in some detail the work needed to develop and qualify Cast Stone as a waste form for the solidification of Hanford LAW (Westsik et al. 2012). Included within Westsik et al. (2012) is a section on the near-term needs to address Tri-Party Agreement Milestone M-062-40ZZ. The objectives of the testing program to be conducted in FY 2013 and FY 2014 are to: • Determine an acceptable formulation for the LAW Cast Stone waste form. • Evaluate sources of dry materials for preparing the LAW Cast Stone. • Demonstrate the robustness of the Cast Stone waste form for a range of LAW compositions. • Demonstrate the robustness of the formulation for variability in the Cast Stone process. • Provide Cast Stone contaminant release data for PA and risk assessment evaluations. The first step in determining an acceptable formulation for the LAW Cast Stone waste form is to conduct screening tests to examine expected ranges in pretreated LAW composition, waste stream concentrations, dry-materials sources, and mix ratios of waste feed to dry blend. A statistically designed test matrix will be used to evaluate the effects of these key parameters on the properties of the Cast Stone as it is initially prepared and after curing. The second phase of testing will focus on selection of a baseline Cast Stone formulation for LAW and demonstrating that Cast Stone can meet expected waste form requirements for disposal in the IDF. It is expected that this testing will use the results of the screening tests to define a smaller suite of tests to refine the composition of the baseline Cast Stone formulation (e.g. waste concentration, water to dry mix ratio, waste loading).« less

Improving the fit of implant prosthetics: an in vitro study.

PubMed

Yannikakis, Stavros; Prombonas, Anthony

2013-01-01

Accurate and passive fit between a prosthesis and its supporting implants has been considered a prerequisite for successful long-term osseointegration. The objective of this in vitro study was to evaluate the strain development during tightening of a five-unit screw-retained superstructure constructed using five different methods. Five-unit screw-retained fixed partial prostheses (n = 25) were fabricated on three implants embedded in an epoxy resin block using five different methods: (1) cobalt-chromium (Co-Cr), plastic cylinders, one-piece cast; (2) Co-Cr, plastic cylinders, framework sectioned, preceramic laser-welding soldering; (3) gold-platinum (Au-Pt), gold cylinders, one-piece cast; (4) Au-Pt, gold cylinders, framework sectioned, preceramic laser-welding soldering; (5) Co-Cr, one-piece cast, and cementation to "passive abutments" (Southern Implants) after final finishing and polishing. Strain gauges (SG) were attached to the fixed partial prosthesis (FPP) and to the resin block to measure the stress created during screw tightening. The combination of Co-Cr alloy and plastic cylinders in a one-piece cast showed such an inadequate fit among the fabricated methods that this group was excluded from the remainder of the experiment. Specimens of Au-Pt cast on gold cylinders in one piece showed higher strain development than the other groups used in this study, with strains ranging from 223.1 to 2,198.1 Μm/m. Sectioning and soldering significantly improved the overall fit. FPPs of Co-Cr in a one-piece cast cemented to "passive abutments" produced the best level of fit, with the least strain development in the prosthesis and the resin block (59 to 204.6 Μm/m). Absolute fit of superstructures on implants is not possible using conventional laboratory procedures. Cementing FPPs onto prefabricated cylinders directly onto the implants significantly reduces strain development compared to the other fabrication methods.

Mechanical characterization of SiC particulate & E-glass fiber reinforced Al 3003 hybrid metal matrix composites

NASA Astrophysics Data System (ADS)

Narayana, K. S. Lakshmi; Shivanand, H. K.

2018-04-01

Metal matrix composites constitute a class of low cost high quality materials which offer high performance for various industrial applications. The orientation of this research is towards the study of mechanical properties of as cast silicon carbide (SiC) particulates and Short E-Glass fibers reinforced Aluminum matrix composites (AMCs). The Hybrid metal matrix composite is developed by reinforcing SiC particulates of 100 microns and short E-Glass fibers of 2-3 mm length with Al 3003 in different compositions. The vortex method of stir casting was employed, in which the reinforcements were introduced into the vortex created by the molten metal by means of mechanical stirrer. The mechanical properties of the prepared metal matrix composites were analyzed. From the studies it was noticed that an improvement in mechanical properties of the reinforced alloys compared to unreinforced alloys.

Investigation of Coatings Which Prevent Molten Aluminum/Water Explosions

NASA Astrophysics Data System (ADS)

León, D. D.; Richter, R. T.; Levendusky, T. L.

The Aluminum Association contracted Alcoa in 1995 to identify and test new protective coatings for casting pits as a replacement for Porter International's 7001 (Tarset Standard). Three new coatings have been identified through a series of selection criteria including: 1) A standardized splash test used to evaluate personal protective clothing, 2) An industry-standard molten metal explosion test, 3) A multiple-exposure test to measure durability, and 4) An external shock impact test. The results of this program will be reviewed. This study only tested protective coatings at the "in-service cure time", as defined by the manufacturer. These curing times can be excessive for a production casting facility. The Aluminum Association has contracted Alcoa in a second program to investigate the effect of reduced cure times on adhesion and their effectiveness in preventing molten metal/water explosions. A status update of this new two year program is provided.

Metallurgical reactions in two industrially strip-cast aluminum-manganese alloys

NASA Astrophysics Data System (ADS)

Hansen, V.; Andersson, B.; Tibballs, J. E.; Gjønnes, J.

1995-08-01

Precipitation, phase transformation, subgrain growth, and recrystallization that occur during heat treatment of two strip-cast, cold-rolled, high manganese aluminum alloys have been studied mainly by transmission electron microscopy (TEM). The alloys differ in silicon content. The isothermal heat treatments have been performed in a salt bath at temperatures between 330 °C and 530 °C for times up to 1000 hours. Size distributions for each type of secondary particle have been determined. After short annealing times, small quasicrystals precipitated and subsequently transformed to α phase. The densities of these precipitates controlled dislocation movement and regulated subgrain sizes. Prolonged heating resulted in peritectoid reactions to Al6Mn or Al12Mn. Recrystallization, which is associated with the formation of Al12Mn, is advanced by increasing the silicon content; the nucleation and growth of Al12Mn occurs only at the expense of other phases that stabilize the subgrain network.

Hot tearing studies in AA5182

NASA Astrophysics Data System (ADS)

van Haaften, W. M.; Kool, W. H.; Katgerman, L.

2002-10-01

One of the major problems during direct chill (DC) casting is hot tearing. These tears initiate during solidification of the alloy and may run through the entire ingot. To study the hot tearing mechanism, tensile tests were carried out in semisolid state and at low strain rates, and crack propagation was studied in situ by scanning electron microscopy (SEM). These experimentally induced cracks were compared with hot tears developed in an AA5182 ingot during a casting trial in an industrial research facility. Similarities in the microstructure of the tensile test specimens and the hot tears indicate that hot tearing can be simulated by performing tensile tests at semisolid temperatures. The experimental data were compared with existing hot tearing models and it was concluded that the latter are restricted to relatively high liquid fractions because they do not take into account the existence of solid bridges in the crack.

Comprehensive chemical characterization of industrial PM2.5 from steel industry activities

NASA Astrophysics Data System (ADS)

Sylvestre, Alexandre; Mizzi, Aurélie; Mathiot, Sébastien; Masson, Fanny; Jaffrezo, Jean L.; Dron, Julien; Mesbah, Boualem; Wortham, Henri; Marchand, Nicolas

2017-03-01

Industrial sources are among the least documented PM (Particulate Matter) source in terms of chemical composition, which limits our understanding of their effective impact on ambient PM concentrations. We report 4 chemical emission profiles of PM2.5 for multiple activities located in a vast metallurgical complex. Emissions profiles were calculated as the difference of species concentrations between an upwind and a downwind site normalized by the absolute PM2.5 enrichment between both sites. We characterized the PM2.5 emissions profiles of the industrial activities related to the cast iron (complex 1) and the iron ore conversion processes (complex 2), as well as 2 storage areas: a blast furnace slag area (complex 3) and an ore terminal (complex 4). PM2.5 major fractions (Organic Carbon (OC) and Elemental Carbon (EC), major ions), organic markers as well as metals/trace elements are reported for the 4 industrial complexes. Among the trace elements, iron is the most emitted for the complex 1 (146.0 mg g-1 of PM2.5), the complex 2 (70.07 mg g-1) and the complex 3 (124.4 mg g-1) followed by Al, Mn and Zn. A strong emission of Polycyclic Aromatic Hydrocarbons (PAH), representing 1.3% of the Organic Matter (OM), is observed for the iron ore transformation complex (complex 2) which merges the activities of coke and iron sinter production and the blast furnace processes. In addition to unsubstituted PAHs, sulfur containing PAHs (SPAHs) are also significantly emitted (between 0.011 and 0.068 mg g-1) by the complex 2 and could become very useful organic markers of steel industry activities. For the complexes 1 and 2 (cast iron and iron ore converters), a strong fraction of sulfate ranging from 0.284 to 0.336 g g-1) and only partially neutralized by ammonium, is observed indicating that sulfates, if not directly emitted by the industrial activity, are formed very quickly in the plume. Emission from complex 4 (Ore terminal) are characterized by high contribution of Al (125.7 mg g-1 of PM2.5) but also, in a lesser extent, of Fe, Mn, Ti and Zn. We also highlighted high contribution of calcium ranging from 0.123 to 0.558 g g-1 for all of the industrial complexes under study. Since calcium is also widely used as a proxy of the dust contributions in source apportionment studies, our results suggest that this assumption should be reexamined in environments impacted by industrial emissions.

Multi-surface topography targeted plateau honing for the processing of cylinder liner surfaces of automotive engines

NASA Astrophysics Data System (ADS)

Lawrence, K. Deepak; Ramamoorthy, B.

2016-03-01

Cylinder bores of automotive engines are 'engineered' surfaces that are processed using multi-stage honing process to generate multiple layers of micro geometry for meeting the different functional requirements of the piston assembly system. The final processed surfaces should comply with several surface topographic specifications that are relevant for the good tribological performance of the engine. Selection of the process parameters in three stages of honing to obtain multiple surface topographic characteristics simultaneously within the specification tolerance is an important module of the process planning and is often posed as a challenging task for the process engineers. This paper presents a strategy by combining the robust process design and gray-relational analysis to evolve the operating levels of honing process parameters in rough, finish and plateau honing stages targeting to meet multiple surface topographic specifications on the final running surface of the cylinder bores. Honing experiments were conducted in three stages namely rough, finish and plateau honing on cast iron cylinder liners by varying four honing process parameters such as rotational speed, oscillatory speed, pressure and honing time. Abbott-Firestone curve based functional parameters (Rk, Rpk, Rvk, Mr1 and Mr2) coupled with mean roughness depth (Rz, DIN/ISO) and honing angle were measured and identified as the surface quality performance targets to be achieved. The experimental results have shown that the proposed approach is effective to generate cylinder liner surface that would simultaneously meet the explicit surface topographic specifications currently practiced by the industry.

Radioactive waste management in the Federal Republic of Germany: Industrial practices and results

DOE Office of Scientific and Technical Information (OSTI.GOV)

Grabener, K.H.

In the Federal Republic of Germany (FRG), the production and use of nuclear-generated electricity expanded steadily despite the fact that opposition from the environmentalists led to the impression of an upcoming moratorium for nuclear energy. With this increase in capacity--by the year 1990, nearly 25 000 MW will be on the line--there will be an increase in the volume of low-level (non-heat-generating) radwaste originating from nuclear power plants. Radwaste management has been influenced to a considerable extent by the requirements of the final repository. Following a period of trial storage in the Asse repository, preparations are now being made formore » storage in the Konrad ore mine. It is intended to begin storage in 1991. Requirements for the packages specify containers with a volume from 3.9 to 10.9 m/sup 3/ or cast iron safety drums. These drums are suitable for radioactive materials in powder form (resins, dried concentrates) without the need for embedding materials. Storage in standard 55-gal drums is no longer permitted. The costs for final storage will be very high so that volume reduction is of prime importance. Kraftwerk Union (KWU) as a supplier of nuclear power plants (NPPs) examined the radwaste market and decided to combine delivery of radwaste treatment systems to NPPs with service jobs including radwaste handling and conditioning in its own service and maintenance plant at Karlstein.« less

Materials Selection and Their Characteristics as Used in Rapid Prototyping

NASA Technical Reports Server (NTRS)

Cooper, K.; Salvail, P.; Vesely, E.; Wells, D.

1999-01-01

NASA's Marshall Space Flight Center (MSFC) conducted a program to evaluate six technologies used in Rapid Prototyping (RP) to produce investment casting patterns. In this paper, RP refers to the collective additive fabrication technologies known as Solid Free-Form Fabrication. Such technologies are being used with increasing frequency in manufacturing applications, due in part to their rapidly expanding capabilities to fabricate models from many types of materials. This study used ABS plastic, polycarbonate, TrueForm PM6, epoxy resin, paper, starch, and wax. The baseline model was a semi-complex prototype fuel pump housing, intended for use in the X-33 reusable launch vehicle. All models were shelled in a production- grade colloidal silica ceramic. Primary coats were zircon-base flour with zircon backup, while secondary coats were silica grains with a tabular alumina backup. Each model was shelled in an identical manner, using the same atmospheric conditions and drying times, as well as the same number of layers. Bake-outs and firing cycles were consistent with the leach ability of each material. Preheat and bath temperatures were also kept consistent. All molds were cast in vacuum using a hydrogen-resistant superalloy (NASA- 23) that was developed in-house. The final technical evaluation included detailed measurements of the model and the final casting, in order to determine any dimensional changes caused by different pattern materials, as well as documentation of all defects and any obvious refractory/model reactions. Prototype production costs were estimated for each method and taken into consideration during trade-off analysis.

Improvements in Fabrication of Sand/Binder Cores for Casting

NASA Technical Reports Server (NTRS)

Bakhitiyarov, Sayavur I.; Overfelt, Ruel A.; Adanur, Sabit

2005-01-01

Three improvements have been devised for the cold-box process, which is a special molding process used to make sand/binder cores for casting hollow metal parts. These improvements are: The use of fiber-reinforced composite binder materials (in contradistinction to the non-fiber-reinforced binders used heretofore), The substitution of a directed-vortex core-blowing subprocess for a prior core-blowing process that involved a movable gassing plate, and The use of filters made from filtration-grade fabrics to prevent clogging of vents. For reasons that exceed the scope of this article, most foundries have adopted the cold-box process for making cores for casting metals. However, this process is not widely known outside the metal-casting industry; therefore, a description of pertinent aspects of the cold-box process is prerequisite to a meaningful description of the aforementioned improvements. In the cold-box process as practiced heretofore, sand is first mixed with a phenolic resin (considered to be part 1 of a three-part binder) and an isocyanate resin (part 2 of the binder). Then by use of compressed air, the mixture is blown into a core box, which is a mold for forming the core. Next, an amine gas (part 3 of the binder) that acts as a catalyst for polymerization of parts 1 and 2 is blown through the core box. Alternatively, a liquid amine that vaporizes during polymerization can be incorporated into the sand/resin mixture. Once polymerization is complete, the amine gas is purged from the core box by use of compressed air. The finished core is then removed from the core box.

Modelling the strength of an aluminium-steel nailed joint

NASA Astrophysics Data System (ADS)

Goldspiegel, Fabien; Mocellin, Katia; Michel, Philippe

2018-05-01

For multi-material applications in automotive industry, a cast aluminium (upper layer) and dual-phase steel (lower layer) superposition joined with High-Speed Nailing process is investigated through an experimental vs numerical framework. Using FORGE® finite-element software, results from joining simulations have been inserted into models in charge of nailed-joint mechanical testings. Numerical Shear and Cross-tensile tests are compared to experimental ones to discuss discrepancy and possible improvements.

Effect of Structure Factor on High-Temperature Ductility of Pipe Steels

NASA Astrophysics Data System (ADS)

Kolbasnikov, N. G.; Matveev, M. A.; Mishnev, P. A.

2016-05-01

Effects of various factors such as the grain size, the morphology of nonmetallic inclusions, and joint microalloying with boron and titanium on the high-temperature ductility of pipe steels are studied. Physical modeling of the conditions of cooling of the skin of a continuous-cast preform in the zone of secondary cooling in a Gleeble facility is performed. Technical recommendations are given for raising the hot ductility of steels under industrial conditions.

Energy and Process Optimization and Benchmarking of Army Industrial Processes

DTIC Science & Technology

2006-09-01

casting is a metal part formed by pouring molten iron, steel, aluminum, zinc , titanium, magnesium, copper, brass, bronze or cobalt, in nearly all...blanketing techniques. The loss of high-priced alloys is also mini- mized, while slag or dross rates are cut in half to help decrease disposal costs...fabricated of iron and steel; hot dip coating such items with aluminum, lead, or zinc ; retin- ning cans and utensils; (3) engraving, chasing and

Mineral resource of the month: bismuth

USGS Publications Warehouse

Carlin, James F.

2006-01-01

Bismuth compounds are most known for their soothing effects on the stomach, wounds and sores. These properties make the compounds an essential part of many medicinal and cosmetic preparations, which until 1930 accounted for about 90 percent of the bismuth used. The subsequent development of low-melting alloys and chemical catalysts containing bismuth, as well as its use as an additive to casting alloys, has resulted in a wider variety of industrial applications for bismuth.

Molecular characterization of the gene feminizer in the stingless bee Melipona interrupta (Hymenoptera: Apidae) reveals association to sex and caste development.

PubMed

Brito, Diana V; Silva, Carlos Gustavo N; Hasselmann, Martin; Viana, Luciana S; Astolfi-Filho, Spartaco; Carvalho-Zilse, Gislene A

2015-11-01

In highly eusocial insects, development of reproductive traits are regulated not only by sex determination pathway, but it also depends on caste fate. The molecular basis of both mechanisms in stingless bees and possible interaction with each other is still obscure. Here, we investigate sex determination in Melipona interrupta, focusing on characterization and expression analysis of the feminizer gene (Mi-fem), and its association to a major component of caste determination, the juvenile hormone (JH). We present evidence that Mi-fem mRNA is sex-specifically spliced in which only the female splice variant encodes the full length protein, following the same principle known for other bee species. We quantified Mi-fem expression among developmental stages, sexes and castes. Mi-fem expression varies considerably throughout development, with higher expression levels in embryos. Also, fem levels in pupae and newly emerged adults were significantly higher in queens than workers and males. Finally, we ectopically applied JH in cocoon spinning larvae, which correspond to the time window where queen/worker phenotypes diverge. We observed a significantly increase in Mi-fem expression compared to control groups. Since up to 100% of females turn into queens when treated with JH (while control groups are composed mainly of workers), we propose that fem might act to regulate queens' development. Our findings provide support for the conserved regulatory function of fem in Melipona bees and demonstrate a significant correlation between key elements of sex and caste determination pathways, opening the avenue to further investigate the molecular basis of these complex traits. Copyright © 2015 Elsevier Ltd. All rights reserved.

Bond strength of poly(methyl methacrylate) denture base material to cast titanium and cobalt-chromium alloy.

PubMed

Matsuda, Yasuhiro; Yanagida, Hiroaki; Ide, Takako; Matsumura, Hideo; Tanoue, Naomi

2010-06-01

The shear bond strength of an auto-polymerizing poly(methyl methacrylate) denture base resin material to cast titanium and cobalt-chromium alloy treated with six conditioning methods was investigated. Disk specimens (10 mm in diameter and 2.5 mm in thickness) were cast from pure titanium and cobalt-chromium alloy. The specimens were wet ground to a final surface finish of 600 grit, air dried, and treated with the following bonding systems: 1) air abraded with 50-70-microm-grain alumina (SAN); 2) air abraded with 50-70-microm-grain alumina + conditioned with Alloy Primer (ALP); 3) air abraded with 50-70-microm-grain alumina + conditioned with AZ Primer (AZP); 4) air abraded with 50-70-microm-grain alumina + conditioned with Estenia Opaque Primer (EOP); 5) air abraded with 50-70-microm-grain alumina + conditioned with Metal Link Primer (MLP), and 6) treated with ROCATEC system (ROC). A denture base material (Palapress Vario) was then applied to each metal specimen. Shear bond strengths were determined before and after 10,000 thermocycles. The strengths decreased after thermocycling in all combinations. Among the treatment methods assessed, groups 2 and 4 showed significantly (p < 0.05) enhanced shear bond strengths for both metals. In group 4, the strength in MPa (n = 7) after thermocycling for cobalt-chromium alloy was 38.3, which was statistically (p < 0.05) higher than that for cast titanium (34.7). Air abrasion followed by the application of two primers containing a hydrophobic phosphate monomer (MDP) effectively improved the strength of the bond of denture base material to cast titanium and cobalt-chromium alloy.

3 CFR 13639 - Executive Order 13639 of March 28, 2013. Establishment of the Presidential Commission on Election...

Code of Federal Regulations, 2014 CFR

2014-01-01

... laws of the United States of America, and in order to promote the efficient administration of Federal... experience of voters facing other obstacles in casting their ballots, such as members of the military... to the Commission's work. (b) The Commission shall be advisory in nature and shall submit a final...

Progress of food irradiation in the United States

NASA Astrophysics Data System (ADS)

Derr, D. D.; Engeljohn, D. L.; Griffin, R. L.

1995-02-01

Irradiated foods have not yet made a significant impact in the United States marketplace. What progress has occurred to facilitate their commercialization? Irradiated produce has been sold in small quantities since 1992 and irradiated poultry was introduced in the marketplace in 1993. Federal inspection of irradiated commodities has settled into a regular routine. What must occur to further expand irradiated foods in the marketplace? Petitions to permit irradiation of red meats and seafood are being considered by the Food and Drug Administration (FDA) and a petition to permit the irradiation of shell eggs is being prepared for submission to FDA. In addition, the U.S. Department of Agriculture (USDA) has accelerated efforts to develop the policies and regulatory structure needed to facilitate the approval of new irradiation treatments for imported plant products regulated by quarantine. When will greater commercialization occur? More positive coverage to food irradiation in recent months by both the trade and popular press indicates a change in attitude towards irradiated foods by both consumers and the food industry. Finally, actual consumer response to available irradiated foods casts a favorable light on the potential for increased marketing of value-added irradiated foods.

Microstructure and properties of thermally sprayed Al-Sn-based alloys for plain bearing applications

NASA Astrophysics Data System (ADS)

Marrocco, T.; Driver, L. C.; Harris, S. J.; McCartney, D. G.

2006-12-01

Al-Sn plain bearings for automotive applications traditionally comprise a multilayer structure. Conventionally, bearing manufacturing involves casting the Al-Sn alloy and roll-bonding to a steel backing strip. Recently, high-velocity oxyfuel (HVOF) thermal spraying has been used as a novel alternative manufacturing route. The present project extends previous work on ternary Al-Sn-Cu alloys to quaternary systems, which contain specific additions for potentially enhanced properties. Two alloys were studied in detail, namely, Al-20wt.%Sn-1wt.%Cu-2wt.%Ni and Al-20wt.%Sn-1wt.%Cu-7wt.%Si. This article will describe the microstructural evolution of these alloys following HVOF spraying onto steel substrates and subsequent heat treatment. The microstructures of powders and coatings were investigated by scanning electron microscopy, and the phases were identified by x-ray diffraction. Coating microhardnesses were determined under both as-sprayed and heat-treated conditions, and by the differences related to the microstructures that developed. Finally, the wear behavior of the sprayed and heat-treated coatings in hot engine oil was measured using an industry standard test and was compared with that of previous work on a ternary alloy.

Reliable and cost effective design of intermetallic Ni2Si nanowires and direct characterization of its mechanical properties

NASA Astrophysics Data System (ADS)

Han, Seung Zeon; Kang, Joonhee; Kim, Sung-Dae; Choi, Si-Young; Kim, Hyung Giun; Lee, Jehyun; Kim, Kwangho; Lim, Sung Hwan; Han, Byungchan

2015-10-01

We report that a single crystal Ni2Si nanowire (NW) of intermetallic compound can be reliably designed using simple three-step processes: casting a ternary Cu-Ni-Si alloy, nucleate and growth of Ni2Si NWs as embedded in the alloy matrix via designing discontinuous precipitation (DP) of Ni2Si nanoparticles and thermal aging, and finally chemical etching to decouple the Ni2Si NWs from the alloy matrix. By direct application of uniaxial tensile tests to the Ni2Si NW we characterize its mechanical properties, which were rarely reported in previous literatures. Using integrated studies of first principles density functional theory (DFT) calculations, high-resolution transmission electron microscopy (HRTEM), and energy-dispersive X-ray spectroscopy (EDX) we accurately validate the experimental measurements. Our results indicate that our simple three-step method enables to design brittle Ni2Si NW with high tensile strength of 3.0 GPa and elastic modulus of 60.6 GPa. We propose that the systematic methodology pursued in this paper significantly contributes to opening innovative processes to design various kinds of low dimensional nanomaterials leading to advancement of frontiers in nanotechnology and related industry sectors.

Reliable and cost effective design of intermetallic Ni2Si nanowires and direct characterization of its mechanical properties.

PubMed

Han, Seung Zeon; Kang, Joonhee; Kim, Sung-Dae; Choi, Si-Young; Kim, Hyung Giun; Lee, Jehyun; Kim, Kwangho; Lim, Sung Hwan; Han, Byungchan

2015-10-12

We report that a single crystal Ni2Si nanowire (NW) of intermetallic compound can be reliably designed using simple three-step processes: casting a ternary Cu-Ni-Si alloy, nucleate and growth of Ni2Si NWs as embedded in the alloy matrix via designing discontinuous precipitation (DP) of Ni2Si nanoparticles and thermal aging, and finally chemical etching to decouple the Ni2Si NWs from the alloy matrix. By direct application of uniaxial tensile tests to the Ni2Si NW we characterize its mechanical properties, which were rarely reported in previous literatures. Using integrated studies of first principles density functional theory (DFT) calculations, high-resolution transmission electron microscopy (HRTEM), and energy-dispersive X-ray spectroscopy (EDX) we accurately validate the experimental measurements. Our results indicate that our simple three-step method enables to design brittle Ni2Si NW with high tensile strength of 3.0 GPa and elastic modulus of 60.6 GPa. We propose that the systematic methodology pursued in this paper significantly contributes to opening innovative processes to design various kinds of low dimensional nanomaterials leading to advancement of frontiers in nanotechnology and related industry sectors.

Cost Models for MMC Manufacturing Processes

NASA Technical Reports Server (NTRS)

Elzey, Dana M.; Wadley, Haydn N. G.

1996-01-01

Processes for the manufacture of advanced metal matrix composites are rapidly approaching maturity in the research laboratory and there is growing interest in their transition to industrial production. However, research conducted to date has almost exclusively focused on overcoming the technical barriers to producing high-quality material and little attention has been given to the economical feasibility of these laboratory approaches and process cost issues. A quantitative cost modeling (QCM) approach was developed to address these issues. QCM are cost analysis tools based on predictive process models relating process conditions to the attributes of the final product. An important attribute, of the QCM approach is the ability to predict the sensitivity of material production costs to product quality and to quantitatively explore trade-offs between cost and quality. Applications of the cost models allow more efficient direction of future MMC process technology development and a more accurate assessment of MMC market potential. Cost models were developed for two state-of-the art metal matrix composite (MMC) manufacturing processes: tape casting and plasma spray deposition. Quality and Cost models are presented for both processes and the resulting predicted quality-cost curves are presented and discussed.

R-HPDC Process with Forced Convection Mixing Device for Automotive Part of A380 Aluminum Alloy

PubMed Central

Zhou, Bing; Kang, Yonglin; Qi, Mingfan; Zhang, Huanhuan; Zhu, Guoming

2014-01-01

The continuing quest for cost-effective and complex shaped aluminum castings with fewer defects for applications in the automotive industries has aroused the interest in rheological high pressure die casting (R-HPDC). A new machine, forced convection mixing (FCM) device, based on the mechanical stirring and convection mixing theory for the preparation of semisolid slurry in convenience and functionality was proposed to produce the automotive shock absorber part by R-HPDC process. The effect of barrel temperature and rotational speed of the device on the grain size and morphology of semi-solid slurry were extensively studied. In addition, flow behavior and temperature field of the melt in the FCM process was investigated combining computational fluid dynamics simulation. The results indicate that the microstructure and pore defects at different locations of R-HPDC casting have been greatly improved. The vigorous fluid convection in FCM process has changed the temperature field and composition distribution of conventional solidification. Appropriately increasing the rotational speed can lead to a uniform temperature filed sooner. The lower barrel temperature leads to a larger uniform degree of supercooling of the melt that benefits the promotion of nucleation rate. Both of them contribute to the decrease of the grain size and the roundness of grain morphology. PMID:28788608

Research on High-efficient Remanufacturing Technologies and Application of Electric Motor

NASA Astrophysics Data System (ADS)

Liu, Ren; Zhao, Yuejin; Yang, Xu; Wang, Gen

2017-09-01

The energy conservation of electric motor system is the key of industrial energy conservation. With the implementation and acceleration of electric motor energy efficiency improvement plan, more and more electric motors are knocked out. High-efficient remanufacturing of electric motor refers to improving the efficiency of electric motor and recycling the resources by replacing the winding, iron core and other components of electric motor on the basis of the low-efficient/outdated electric motors, which conforms to China’s policy of circular economy and resource recovery. The remanufacturing of electric motor not only maximizes the use of resources, but also reduces the energy consumption generated by reprocessing of cast iron, silicon steel sheet and other materials in dismantling of electric motor. However, structures and iron core materials used in design and manufacture of electric motors are different, and the degrees of wear of electric motors are also different under different operating conditions, which further result in diversified design schemes, increased remanufacturing cost and reduced remanufacturing efficiency. This paper analyzes the key process technologies for remanufacturing of electric motors are researched by analyzing the remanufacturing technologies of electric motors, and presents the feasibility to replace the cast-aluminum rotor with cast-copper rotor in high-efficient remanufacturing process of electric motor.

High-Temperature Properties of Mold Flux Observed and Measured In Situ by Single/Double Hot-Thermocouple Technique

NASA Astrophysics Data System (ADS)

Wang, Wanlin; Lyu, Peisheng; Zhou, Lejun; Li, Huan; Zhang, Tongsheng

2018-05-01

Mold flux plays very important roles in the continuous casting process, and its high-temperature properties affect the quality of the final as-cast product greatly. Investigations on the melting, isothermal and nonisothermal crystallization, and phase evolution behaviors under a simulated temperature field for the mold flux system using the single/double hot-thermocouple technique (S/DHTT) were reviewed. Meanwhile, further in situ observations on the wetting behavior and heat transfer ability of the mold flux system were also carried out using the S/DHTT. The results summarized here provide a clear understanding of both the high-temperature properties of mold flux and the detailed application of advanced real-time visual high-temperature S/DHTT to this molten slag system.

Posttest analysis of a laboratory-cast monolith of salt-saturated concrete. Final report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wakeley, L.D.; Poole, T.S.

A salt-saturated concrete was formulated for laboratory testing of cementitious mixtures with potential for use in disposal of radioactive wastes in a geologic repository in halite rock. Cores were taken from a laboratory-cast concrete monolith on completion of tests of permeability, strain, and stress. The cores were analyzed for physical and chemical evidence of brine migration through the concrete, and other features with potential impact on installation of crete plugs at the Waste Isolation Pilot Plant (WIPP) in New Mexico. The posttest analyses of the cores provided evidence of brine movement along the interface between concrete and pipe, and littlemore » indication of permeability through the monolith itself. There may also have been diffusion of chloride into the monolith without actual brine flow.« less

FInal Report - Investment Casting Shell Cracking

DOE Office of Scientific and Technical Information (OSTI.GOV)

Von Richards

2003-12-01

This project made a significant contribution to the understanding of the investment casting shell cracking problem. The effects of wax properties on the occurrence of shell cracking were demonstrated and can be measured. The properties measured include coefficient of thermal expansion, heating rate and crystallinity of the structure. The important features of production molds and materials properties have been indicated by case study analysis and fractography of low strength test bars. It was found that stress risers in shell cavity design were important and that typical critical flaws were either oversize particles or large pores just behind the prime coat.more » It was also found that the true effect of fugitive polymer fibers was not permeability increase, but rather a toughening mechanism due to crack deflection.« less

Environmentally benign processing of YAG transparent wafers

NASA Astrophysics Data System (ADS)

Yang, Yan; Wu, Yiquan

2015-12-01

Transparent yttrium aluminum garnet (YAG) wafers were successfully produced via aqueous tape casting and vacuum sintering techniques using a new environmentally friendly binder, a copolymer of isobutylene and maleic anhydride with the commercial name ISOBAM (noted as ISOBAM). Aqueous YAG slurries were mixed by ball-milling, which was followed by de-gassing and tape casting of wafers. The final YAG green tapes were homogenous and flexible, and could be bent freely without cracking. After the drying and sintering processes, transparent YAG wafers were achieved. The microstructures of both the green tape and vacuum-sintered YAG ceramic were observed by scanning electronic microscopy (SEM). Phase compositions were examined by X-ray diffraction (XRD). Optical transmittance was measured in UV-VIS regions with the result that the transmittance is 82.6% at a wavelength of 800 nm.

Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting

PubMed Central

Mun, Jiwon; Ju, Jaehyung; Thurman, James

2016-01-01

One of the typical methods to manufacture 3D lattice metals is the direct-metal additive manufacturing (AM) process such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM). In spite of its potential processing capability, the direct AM method has several disadvantages such as high cost, poor surface finish of final products, limitation in material selection, high thermal stress, and anisotropic properties of parts. We propose a cost-effective method to manufacture 3D lattice metals. The objective of this study is to provide a detailed protocol on fabrication of 3D lattice metals having a complex shape and a thin wall thickness; e.g., octet truss made of Al and Cu alloys having a unit cell length of 5 mm and a cell wall thickness of 0.5 mm. An overall experimental procedure is divided into eight sections: (a) 3D printing of sacrificial patterns (b) melt-out of support materials (c) removal of residue of support materials (d) pattern assembly (e) investment (f) burn-out of sacrificial patterns (g) centrifugal casting (h) post-processing for final products. The suggested indirect AM technique provides the potential to manufacture ultra-lightweight lattice metals; e.g., lattice structures with Al alloys. It appears that the process parameters should be properly controlled depending on materials and lattice geometry, observing the final products of octet truss metals by the indirect AM technique. PMID:27214495

Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting.

PubMed

Mun, Jiwon; Ju, Jaehyung; Thurman, James

2016-05-14

One of the typical methods to manufacture 3D lattice metals is the direct-metal additive manufacturing (AM) process such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM). In spite of its potential processing capability, the direct AM method has several disadvantages such as high cost, poor surface finish of final products, limitation in material selection, high thermal stress, and anisotropic properties of parts. We propose a cost-effective method to manufacture 3D lattice metals. The objective of this study is to provide a detailed protocol on fabrication of 3D lattice metals having a complex shape and a thin wall thickness; e.g., octet truss made of Al and Cu alloys having a unit cell length of 5 mm and a cell wall thickness of 0.5 mm. An overall experimental procedure is divided into eight sections: (a) 3D printing of sacrificial patterns (b) melt-out of support materials (c) removal of residue of support materials (d) pattern assembly (e) investment (f) burn-out of sacrificial patterns (g) centrifugal casting (h) post-processing for final products. The suggested indirect AM technique provides the potential to manufacture ultra-lightweight lattice metals; e.g., lattice structures with Al alloys. It appears that the process parameters should be properly controlled depending on materials and lattice geometry, observing the final products of octet truss metals by the indirect AM technique.

Linking climate change mitigation and coastal eutrophication management through biogas technology: Evidence from a new Danish bioenergy concept.

PubMed

Kaspersen, Bjarke Stoltze; Christensen, Thomas Budde; Fredenslund, Anders Michael; Møller, Henrik Bjarne; Butts, Michael Brian; Jensen, Niels H; Kjaer, Tyge

2016-01-15

The interest in sustainable bioenergy solutions has gained great importance in Europe due to the need to reduce GHG emissions and to meet environmental policy targets, not least for the protection of groundwater and surface water quality. In the Municipality of Solrød in Denmark, a novel bioenergy concept for anaerobic co-digestion of food industry residues, manure and beach-cast seaweed has been developed and tested in order to quantify the potential for synergies between climate change mitigation and coastal eutrophication management in the Køge Bay catchment. The biogas plant, currently under construction, was designed to handle an annual input of up to 200,000 t of biomass based on four main fractions: pectin wastes, carrageenan wastes, manure and beach-cast seaweed. This paper describes how this bioenergy concept can contribute to strengthening the linkages between climate change mitigation strategies and Water Framework Directive (WFD) action planning. Our assessments of the projected biogas plant indicate an annual reduction of GHG emissions of approx. 40,000 t CO2 equivalents, corresponding to approx. 1/3 of current total GHG emissions in the Municipality of Solrød. In addition, nitrogen and phosphorous loads to Køge Bay are estimated to be reduced by approx. 63 t yr.(-1) and 9 tyr.(-1), respectively, contributing to the achievement of more than 70% of the nutrient reduction target set for Køge Bay in the first WFD river basin management plan. This study shows that anaerobic co-digestion of the specific food industry residues, pig manure and beach-cast seaweed is feasible and that there is a very significant, cost-effective GHG and nutrient loading mitigation potential for this bioenergy concept. Our research demonstrates how an integrated planning process where considerations about the total environment are integrated into the design and decision processes can support the development of this kind of holistic bioenergy solutions. Copyright © 2015 Elsevier B.V. All rights reserved.

Novel multiphase systems based on thermoplastic chitosan: Analysis of the structure-properties relationships

NASA Astrophysics Data System (ADS)

Avérous, Luc; Pollet, Eric

2016-03-01

In the last years, biopolymers have attracted great attention. It is for instance the case of chitosan, a linear polysaccharide. It is a deacetylated derivative of chitin, which is the second most abundant polysaccharide found in nature after cellulose. Chitosan has been found to be nontoxic, biodegradable, biofunctional, and biocompatible in addition to having antimicrobial and antifungal properties, and thus has a great potential for environmental (packaging,) or biomedical applications.For preparing chitosan-based materials, only solution casting or similar methods have been used in all the past studies. Solution casting have the disadvantage in low efficiency and difficulty in scaling-up towards industrial applications. Besides, a great amount of environmentally unfriendly chemical solvents are used and released to the environment in this method. The reason for not using a melt processing method like extrusion or kneading in the past studies is that chitosan, like many other polysaccharides such as starch, has very low thermal stability and degrade prior to melting. Therefore, even if the melt processing method is more convenient and highly preferred for industrial production, its adaptation for polysaccharide-based materials remains very difficult. However, our recently published studies has demonstrated the successful use of an innovative melt processing method (internal mixer, extrusion,) as an alternative route to solution casting, for preparing materials based on thermoplastic chitosan. These promising thermoplastic materials, obtained by melt processing, have been the main topic of recent international projects, with partners from different countries Multiphase systems based on various renewable plasticizers have been elaborated and studied. Besides, different blends, and nano-biocomposites based on nanoclays, have been elaborated and fully analyzed. The initial consortium of this vast project was based on an international consortium (Canada, Australia, France). This project is currently ongoing and open, with new international academic partners (Mexico, Brazil and Spain).

[Noise hazard and hearing loss in workers in automotive component manufacturing industry in Guangzhou, China].

PubMed

Wang, Zhi; Liang, Jiabin; Rong, Xing; Zhou, Hao; Duan, Chuanwei; Du, Weijia; Liu, Yimin

2015-12-01

To investigate noise hazard and its influence on hearing loss in workers in the automotive component manufacturing industry. Noise level in the workplace of automotive component manufacturing enterprises was measured and hearing examination was performed for workers to analyze the features and exposure levels of noise in each process, as well as the influence on hearing loss in workers. In the manufacturing processes for different products in this industry, the manufacturing processes of automobile hub and suspension and steering systems had the highest degrees of noise hazard, with over-standard rates of 79.8% and 57.1%, respectively. In the different technical processes for automotive component manufacturing, punching and casting had the highest degrees of noise hazard, with over-standard rates of 65.0% and 50%, respectively. The workers engaged in the automotive air conditioning system had the highest rate of abnormal hearing ability (up to 3.1%). In the automotive component manufacturing industry, noise hazard exceeds the standard seriously. Although the rate of abnormal hearing is lower than the average value of the automobile manufacturing industry in China, this rate tends to increase gradually. Enough emphasis should be placed on the noise hazard in this industry.

Stress and structure development in polymeric coatings

NASA Astrophysics Data System (ADS)

Vaessen, Diane Melissa

2002-09-01

The main goal of this research is to measure the stress evolution in various polymer coating systems to establish the mechanisms responsible for stress development, stress relaxation, and defect formation. Investigated systems include ultraviolet (UV)-curable coatings, dense and porous coatings from polymer solutions, and latex coatings. Coating stress was measured using a controlled environment stress apparatus based on a cantilever deflection principle. For acrylate coatings, it was found that by cycling a UV-lamp on and off, keeping the total dose constant, coating stress was lowered by 60% by decreasing the cycle period. A stress minimum was also found to exist for a given dose of radiation. The lower stress is attributed to stress relaxation and/or slower reaction during dark periods. A viscoelastic stress model of this process was formulated and predicted stress values close to those observed experimentally. During drying of cellulose acetate (CA) coatings cast in acetone, final stress increased from 10 to 45 MPa as coating thickness decreased from 60 to 10 mum. This thickness dependent coating stress for a solvent-cast polymer coating is a new finding and is attributed to (1) less shrinkage in thicker coatings due to more trapped solvent (from skinning) and (2) greater amounts of polymer stress relaxation in thicker coatings. For porous CA coatings prepared by dry-cast phase separation, final in-plane stresses ranged from 20 MPa for coatings containing small pores (˜1 mum) to 5 MPa for coatings containing small pores and macrovoids (˜200 mum). For these coatings, a small amount of stress relaxation occurs due to capillary pressure relief. A stress plateau for the macrovoid-containing coating is likely caused by stress-induced rupture of the polymer-rich phase. Measured stress in pigment-free latex coatings was much lower (˜0.3 MPa) than UV-curable and solvent-cast polymer coatings and was found to increase with increasing latex glass transition temperature. Observations from infrared spectroscopy, scanning electron microscopy, camera imaging, and indentation were also studied to correlate coating properties to measured stresses. The results obtained in this thesis will lead to strategies for material selection, process optimization, and defect elimination in polymeric coatings.

A Process for Manufacturing Metal-Ceramic Cellular Materials with Designed Mesostructure

NASA Astrophysics Data System (ADS)

Snelling, Dean Andrew, Jr.

The goal of this work is to develop and characterize a manufacturing process that is able to create metal matrix composites with complex cellular geometries. The novel manufacturing method uses two distinct additive manufacturing processes: i) fabrication of patternless molds for cellular metal castings and ii) printing an advanced cellular ceramic for embedding in a metal matrix. However, while the use of AM greatly improves the freedom in the design of MMCs, it is important to identify the constraints imposed by the process and its process relationships. First, the author investigates potential differences in material properties (microstructure, porosity, mechanical strength) of A356 - T6 castings resulting from two different commercially available Binder Jetting media and traditional "no-bake" silica sand. It was determined that they yielded statistically equivalent results in four of the seven tests performed: dendrite arm spacing, porosity, surface roughness, and tensile strength. They differed in sand tensile strength, hardness, and density. Additionally, two critical sources of process constraints on part geometry are examined: (i) depowdering unbound material from intricate casting channels and (ii) metal flow and solidification distances through complex mold geometries. A Taguchi Design of Experiments is used to determine the relationships of important independent variables of each constraint. For depowdering, a minimum cleaning diameter of 3 mm was determined along with an equation relating cleaning distance as a function of channel diameter. Furthermore, for metal flow, choke diameter was found to be significantly significant variable. Finally, the author presents methods to process complex ceramic structure from precursor powders via Binder Jetting AM technology to incorporate into a bonded sand mold and the subsequently casted metal matrix. Through sintering experiments, a sintering temperature of 1375°C was established for the ceramic insert (78% cordierite). Upon printing and sintering the iii ceramic, three point bend tests showed the MMCs had less strength than the matrix material likely due to the relatively high porosity developed in the body. Additionally, it was found that the ceramic metal interface had minimal mechanical interlocking and chemical bonding limiting the strength of the final MMCs.

Formation of β-NiAl Phase During Casting of a Ni-Based Superalloy

NASA Astrophysics Data System (ADS)

Detrois, Martin; Jablonski, Paul D.

2018-04-01

A high-refractory Ni-based superalloy prototype was melted on a research scale while simulating industry practices. Ingots were vacuum induction melted and subjected to a computationally optimized homogenization heat treatment prior to fabrication which consisted of forging and hot rolling. Failure of one of the ingots at the early stage of the forging process was attributed to the precipitation of the β-NiAl phase during melting which stabilized the eutectic constituent.

Clear Castable Polyurethane Elastomer for Fabrication of Microfluidic Devices

PubMed Central

Domansky, Karel; Leslie, Daniel C.; McKinney, James; Fraser, Jacob P.; Sliz, Josiah D.; Hamkins-Indik, Tiama; Hamilton, Geraldine A.; Bahinski, Anthony; Ingber, Donald E.

2013-01-01

Polydimethylsiloxane (PDMS) has numerous desirable properties for fabricating microfluidic devices, including optical transparency, flexibility, biocompatibility, and fabrication by casting; however, partitioning of small hydrophobic molecules into the bulk of PDMS hinders industrial acceptance of PDMS microfluidic devices for chemical processing and drug development applications. Here we describe an attractive alternative material that is similar to PDMS in terms of optical transparency, flexibility and castability, but that is also resistant to absorption of small hydrophobic molecules. PMID:23954953

What are the Dominant Factors of Students’ Productive Skills in Construction Services?

NASA Astrophysics Data System (ADS)

Oroh, R. R.; S, Haris A.; Sugandi, R. M.; Isnandar

2018-02-01

The purpose of this study to determine the dominant factors of students’ productive skills in doing the work of concrete structures that fit the needs of construction services. Sample of the respondents is vocational high school students from several districts and cities in North Sulawesi, Indonesia. Data are obtained through the performance test instruments of student. Whereas, data analysis is performed using factor analysis. The result of this research show the dominant factors of the students’ productive skills in doing the work of concrete structures that is according to the need of construction services, namely: (a) factor the working of concrete casting consists of making scaffolding from good materials and conducting concrete casting according to working method; and (b) factor the working of concrete reinforcing consists of read the working drawings for concrete reinforcement and make the concrete formwork from good material. Some of the respondent’s students in doing some concrete structure work have done well, but not yet according to working drawings, working methods and technical specifications of the work. The learning is done in accordance with the competency-oriented school curriculum but the teaching materials given have not been maximized in accordance with the needs of productive skills required construction services industry. The results have an impact on the low absorption of graduates in the implementation of the construction services industry.

Implementation of 3D Optical Scanning Technology for Automotive Applications

PubMed Central

Kuş, Abdil

2009-01-01

Reverse engineering (RE) is a powerful tool for generating a CAD model from the 3D scan data of a physical part that lacks documentation or has changed from the original CAD design of the part. The process of digitizing a part and creating a CAD model from 3D scan data is less time consuming and provides greater accuracy than manually measuring the part and designing the part from scratch in CAD. 3D optical scanning technology is one of the measurement methods which have evolved over the last few years and it is used in a wide range of areas from industrial applications to art and cultural heritage. It is also used extensively in the automotive industry for applications such as part inspections, scanning of tools without CAD definition, scanning the casting for definition of the stock (i.e. the amount of material to be removed from the surface of the castings) model for CAM programs and reverse engineering. In this study two scanning experiments of automotive applications are illustrated. The first one examines the processes from scanning to re-manufacturing the damaged sheet metal cutting die, using a 3D scanning technique and the second study compares the scanned point clouds data to 3D CAD data for inspection purposes. Furthermore, the deviations of the part holes are determined by using different lenses and scanning parameters. PMID:22573995

Fundamental phenomena on fuel decomposition and boundary layer combustion processes with applications to hybrid rocket motors

NASA Technical Reports Server (NTRS)

Kuo, Kenneth K.; Lu, Y. C.; Chiaverini, Martin J.; Harting, George C.

1994-01-01

An experimental study on the fundamental processes involved in fuel decomposition and boundary layer combustion in hybrid rocket motors is being conducted at the High Pressure Combustion Laboratory of the Pennsylvania State University. This research should provide a useful engineering technology base in the development of hybrid rocket motors as well as a fundamental understanding of the complex processes involved in hybrid propulsion. A high pressure slab motor has been designed and manufactured for conducting experimental investigations. Oxidizer (LOX or GOX) supply and control systems have been designed and partly constructed for the head-end injection into the test chamber. Experiments using HTPB fuel, as well as fuels supplied by NASA designated industrial companies will be conducted. Design and construction of fuel casting molds and sample holders have been completed. The portion of these items for industrial company fuel casting will be sent to the McDonnell Douglas Aerospace Corporation in the near future. The study focuses on the following areas: observation of solid fuel burning processes with LOX or GOX, measurement and correlation of solid fuel regression rate with operating conditions, measurement of flame temperature and radical species concentrations, determination of the solid fuel subsurface temperature profile, and utilization of experimental data for validation of a companion theoretical study (Part 2) also being conducted at PSU.

Mixed Matrix PVDF Membranes With in Situ Synthesized PAMAM Dendrimer-Like Particles: A New Class of Sorbents for Cu(II) Recovery from Aqueous Solutions by Ultrafiltration.

PubMed

Kotte, Madhusudhana Rao; Kuvarega, Alex T; Cho, Manki; Mamba, Bhekie B; Diallo, Mamadou S

2015-08-18

Advances in industrial ecology, desalination, and resource recovery have established that industrial wastewater, seawater, and brines are important and largely untapped sources of critical metals and elements. A Grand Challenge in metal recovery from industrial wastewater is to design and synthesize high capacity, recyclable and robust chelating ligands with tunable metal ion selectivity that can be efficiently processed into low-energy separation materials and modules. In our efforts to develop high capacity chelating membranes for metal recovery from impaired water, we report a one-pot method for the preparation of a new family of mixed matrix polyvinylidene fluoride (PVDF) membranes with in situ synthesized poly(amidoamine) [PAMAM] particles. The key feature of our new membrane preparation method is the in situ synthesis of PAMAM dendrimer-like particles in the dope solutions prior to membrane casting using low-generation dendrimers (G0 and G1-NH2) with terminal primary amine groups as precursors and epichlorohydrin (ECH) as cross-linker. By using a combined thermally induced phase separation (TIPS) and nonsolvent induced phase separation (NIPS) casting process, we successfully prepared a new family of asymmetric PVDF ultrafiltration membranes with (i) neutral and hydrophilic surface layers of average pore diameters of 22-45 nm, (ii) high loadings (∼48 wt %) of dendrimer-like PAMAM particles with average diameters of ∼1.3-2.4 μm, and (iii) matrices with sponge-like microstructures characteristics of membranes with strong mechanical integrity. Preliminary experiments show that these new mixed matrix PVDF membranes can serve as high capacity sorbents for Cu(II) recovery from aqueous solutions by ultrafiltration.

Precise Analysis of Microstructural Effects on Mechanical Properties of Cast ADC12 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Okayasu, Mitsuhiro; Takeuchi, Shuhei; Yamamoto, Masaki; Ohfuji, Hiroaki; Ochi, Toshihiro

2015-04-01

The effects of microstructural characteristics (secondary dendrite arm spacing, SDAS) and Si- and Fe-based eutectic structures on the mechanical properties and failure behavior of an Al-Si-Cu alloy are investigated. Cast Al alloy samples are produced using a special continuous-casting technique with which it is easy to control both the sizes of microstructures and the direction of crystal orientation. Dendrite cells appear to grow in the casting direction. There are linear correlations between SDAS and tensile properties (ultimate tensile strength σ UTS, 0.2 pct proof strength σ 0.2, and fracture strain ɛ f). These linear correlations, however, break down, especially for σ UTS vs SDAS and ɛ f vs SDAS, as the eutectic structures become more than 3 μm in diameter, when the strength and ductility ( σ UTS and ɛ f) decrease significantly. For eutectic structures larger than 3 μm, failure is dominated by the brittle eutectic phases, for which SDAS is no longer strongly correlated with σ UTS and ɛ f. In contrast, a linear correlation is obtained between σ 0.2 and SDAS, even for eutectic structures larger than 3 μm, and the eutectic structure does not have a strong effect on yield behavior. This is because failure in the eutectic phases occurs just before final fracture. In situ failure observation during tensile testing is performed using microstructural and lattice characteristics. From the experimental results obtained, models of failure during tensile loading are proposed.

75 FR 20335 - Certain Oil Country Tubular Goods from the People's Republic of China: Final Determination of...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-04-19

... tubing, of iron (other than cast iron) or steel (both carbon and alloy), whether seamless or welded... Seamless Tube Mill of Inner Mongolia Baotou Steel 29.94 and Trading Co., Ltd Union Co., Ltd.\\27\\ Benxi... Century Machinery Co. Ltd.;Tianjin Seamless Steel Pipe Plant; Baoshan Iron & Steel Co. Ltd Shengli...

77 FR 31577 - Non-Malleable Cast Iron Pipe Fittings From the People's Republic of China: Final Results of...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-05-29

... as ``flared joint.'' The flared joint, once made fast, permits brake fluid to flow through channels...), or push on ends (PO), or flanged ends and produced to the American Water Works Association (AWWA... flared joint, once made fast, permits brake fluid to flow through channels that never exceed 3.8...

9. VIEW OF MILLING AND LATHE MACHINES, MILLING AND LATHE ...

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

9. VIEW OF MILLING AND LATHE MACHINES, MILLING AND LATHE MACHINES WERE USED TO FORM COMPONENTS INTO THEIR FINAL SHAPE. IN THE FOUNDRY, ENRICHED URANIUM WAS CAST INTO SPHERICAL SHAPES OR INGOT FROM WHICH WEAPONS COMPONENTS WERE FABRICATED. (4/4/66) - Rocky Flats Plant, General Manufacturing, Support, Records-Central Computing, Southern portion of Plant, Golden, Jefferson County, CO

Study Casts Doubt on Strength of Charter Managers: Author Says Final Text Eased Negative Findings on CMOs

ERIC Educational Resources Information Center

Viadero, Debra

2009-01-01

A report from Education Sector raises questions about the ability of charter schools and charter-management organizations (CMOs) to scale up as dramatically as their supporters might hope. "The extraordinary demands of educating disadvantaged students to higher standards, the challenges of attracting the talent required to do that work, the burden…

75 FR 3203 - Certain Oil Country Tubular Goods From the People's Republic of China: Amended Final Affirmative...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-01-20

... cross-section, including oil well casing and tubing, of iron (other than cast iron) or steel (both carbon and alloy), whether seamless or welded, regardless of end finish (e.g., whether or not plain end... December 14, 2009, petitioners United States Steel Corporation (``U.S. Steel'') and TMK IPSCO et al.\\1...

Function-based design process for an intelligent ground vehicle vision system

NASA Astrophysics Data System (ADS)

Nagel, Robert L.; Perry, Kenneth L.; Stone, Robert B.; McAdams, Daniel A.

2010-10-01

An engineering design framework for an autonomous ground vehicle vision system is discussed. We present both the conceptual and physical design by following the design process, development and testing of an intelligent ground vehicle vision system constructed for the 2008 Intelligent Ground Vehicle Competition. During conceptual design, the requirements for the vision system are explored via functional and process analysis considering the flows into the vehicle and the transformations of those flows. The conceptual design phase concludes with a vision system design that is modular in both hardware and software and is based on a laser range finder and camera for visual perception. During physical design, prototypes are developed and tested independently, following the modular interfaces identified during conceptual design. Prototype models, once functional, are implemented into the final design. The final vision system design uses a ray-casting algorithm to process camera and laser range finder data and identify potential paths. The ray-casting algorithm is a single thread of the robot's multithreaded application. Other threads control motion, provide feedback, and process sensory data. Once integrated, both hardware and software testing are performed on the robot. We discuss the robot's performance and the lessons learned.

Oromucosal film preparations: points to consider for patient centricity and manufacturing processes.

PubMed

Krampe, Raphael; Visser, J Carolina; Frijlink, Henderik W; Breitkreutz, Jörg; Woerdenbag, Herman J; Preis, Maren

2016-01-01

According to the European Pharmacopoeia, oromucosal films comprise mucoadhesive buccal films and orodispersible films. Both oral dosage forms receive considerable interest in the recent years as commercially available pharmaceutical products and as small scale personalized extemporaneous preparations. In this review, technological issues such as viscosity of the casting liquid, mechanical properties of the film, upscaling and the stability of the casting solution and produced films will be discussed. Furthermore, patient-related problems like appearance, mucosal irritation, taste, drug load, safety and biopharmaceutics are described. Current knowledge and directions for solutions are summarized. The viscosity of the casting solution is a key factor for producing suitable films. This parameter is amongst others dependent on the polymer and active pharmaceutical ingredient, and the further excipients that are used. For optimal patient compliance, an acceptable taste and palatability are desirable. Safe and inert excipients should be used and appropriate packaging should be provided to produced films. Absorption through the oral mucosa will vary for each active compound, formulation and patient, which gives rise to pharmacokinetic questions. Finally, the European Pharmacopoeia needs to specify methods, requirement and definitions for oromucosal film preparations based on bio-relevant data.

Effective Process Design for the Production of HIC-Resistant Linepipe Steels

NASA Astrophysics Data System (ADS)

Nieto, J.; Elías, T.; López, G.; Campos, G.; López, F.; Garcia, R.; De, Amar K.

2013-09-01

Production of slabs for sour service applications requires stringent control in slab internal quality and secondary processing so as to guarantee resistance against hydrogen-induced cracking (HIC). ArcelorMittal Steelmaking facility at Lazaro Cardenas, Mexico had recently implemented key steelmaking and casting processing technologies for production of sound, centerline free slabs for catering to the growing API Linepipe and off-shore market for sour service applications. State-of-the-art steelmaking with use of residual-free Direct-reduced Iron and continuous casting facilities with dynamic soft reduction were introduced for the production of slabs with ultra clean centerline. Introduction of controlled cooling of slabs for atomic hydrogen control well below 2 ppm has enabled production of slabs suitable for excellent HIC-resistant plate processing. Substantial tonnages of slabs were produced for production of API X52-X65 grade plates and pipes for sour service. Stringent quality control at each stage of steelmaking, casting, and slab inspection ensured slabs with excellent internal quality suitable for HIC resistance to be guaranteed in final product (Plates & Pipes). Details of production steps which resulted in successful HIC-resistant slab production have been described in this article.

Mechanical Performance of Cold-Sprayed A357 Aluminum Alloy Coatings for Repair and Additive Manufacturing

NASA Astrophysics Data System (ADS)

Petráčková, K.; Kondás, J.; Guagliano, M.

2017-12-01

Cold-sprayed coatings made of A357 aluminum alloy, a casting alloy widely used in aerospace, underwent set of standard tests as well as newly developed fatigue test to gain an information about potential of cold spray for repair and additive manufacturing of loaded parts. With optimal spray parameters, coating deposition on substrate with smooth surface resulted in relatively good bonding, which can be further improved by application of grit blasting on substrate's surface. However, no enhancement of adhesion was obtained for shot-peened surface. Process temperature, which was set either to 450 or 550 °C, was shown to have an effect on adhesion and cohesion strength, but it does not influence residual stress in the coating. To assess cold spray perspectives for additive manufacturing, flat tensile specimens were machined from coating and tested in as-sprayed and heat-treated (solution treatment and aging) condition. Tensile properties of the coating after the treatment correspond to properties of the cast A357-T61 aluminum alloy. Finally, fatigue specimen was proposed to test overall performance of the coating and coating's fatigue limit is compared to the results obtained on cast A357-T61 aluminum alloy.

Cost effective aluminum beryllium mirrors for critical optics applications

NASA Astrophysics Data System (ADS)

Say, Carissa; Duich, Jack; Huskamp, Chris; White, Ray

2013-09-01

The unique performance of aluminum-beryllium frequently makes it an ideal material for manufacturing precision optical-grade metal mirrors. Traditional methods of manufacture utilize hot-pressed powder block in billet form which is subsequently machined to final dimensions. Complex component geometries such as lightweighted, non-plano mirrors require extensive tool path programming, fixturing, and CNC machining time and result in a high buy-to-fly ratio (the ratio of the mass of raw material purchased to the mass of the finished part). This increases the cost of the mirror structure as a significant percentage of the procurement cost is consumed in the form of machining, tooling, and scrap material that do not add value to the final part. Inrad Optics, Inc. and IBC Advanced Alloys Corp. undertook a joint study to evaluate the suitability of investment-cast Beralcast® 191 and 363 aluminum-beryllium as a precision mirror substrate material. Net shape investment castings of the desired geometry minimizes machining to just cleanup stock, thereby reducing the recurring procurement cost while still maintaining performance. The thermal stability of two mirrors, (one each of Beralcast® 191 and Beralcast® 363), was characterized from -40°F to +150°F. A representative pocketed mirror was developed, including the creation of a relevant geometry and production of a cast component to validate the approach. Information from the demonstration unit was used as a basis for a comparative cost study of the representative mirror produced in Beralcast® and one machined from a billet of AlBeMet® 162 (AlBeMet® is a registered trademark of Materion Corporation). The technical and financial results of these studies will be discussed in detail.

Accuracy of implant impressions without impression copings: a three-dimensional analysis.

PubMed

Kwon, Joo-Hyun; Son, Yong-Ha; Han, Chong-Hyun; Kim, Sunjai

2011-06-01

Implant impressions without impression copings can be used for cement-retained implant restorations. A comparison of the accuracy of implant impressions with and without impression copings is needed. The purpose of this study was to evaluate and compare the dimensional accuracy of implant definitive casts that are fabricated by implant impressions with and without impression copings. An acrylic resin maxillary model was fabricated, and 3 implant replicas were secured in the right second premolar, first, and second molars. Two impression techniques were used to fabricate definitive casts (n=10). For the coping group (Group C), open tray impression copings were used for the final impressions. For the no-coping group (Group NC), cementable abutments were connected to the implant replicas, and final impressions were made assuming the abutments were prepared teeth. Computerized calculation of the centroids and long axes of the implant or stone abutment replicas was performed. The Mann-Whitney U test analyzed the amount of linear and rotational distortion between groups (α =.05). At the first molar site, Group NC showed significantly greater linear distortion along the Y-axis, with a small difference between the groups (Group C, 7.8 ± 7.4 μm; Group NC, 19.5 ± 12.2). At the second molar site, increased distortion was noted in Group NC for every linear and rotational variable, except for linear distortion along the Z-axis. Implant impression with open tray impression copings produced more accurate definitive casts than those fabricated without impression copings, especially those with greater inter-abutment distance. Copyright © 2011 The Editorial Council of the Journal of Prosthetic Dentistry. Published by Mosby, Inc. All rights reserved.

Uncovering the local inelastic interactions during manufacture of ductile cast iron: How the substructure of the graphite particles can induce residual stress concentrations in the matrix

NASA Astrophysics Data System (ADS)

Andriollo, Tito; Hellström, Kristina; Sonne, Mads Rostgaard; Thorborg, Jesper; Tiedje, Niels; Hattel, Jesper

2018-02-01

Recent X-ray diffraction (XRD) measurements have revealed that plastic deformation and a residual elastic strain field can be present around the graphite particles in ductile cast iron after manufacturing, probably due to some local mismatch in thermal contraction. However, as only one component of the elastic strain tensor could be obtained from the XRD data, the shape and magnitude of the associated residual stress field have remained unknown. To compensate for this and to provide theoretical insight into this unexplored topic, a combined experimental-numerical approach is presented in this paper. First, a material equivalent to the ductile cast iron matrix is manufactured and subjected to dilatometric and high-temperature tensile tests. Subsequently, a two-scale hierarchical top-down model is devised, calibrated on the basis of the collected data and used to simulate the interaction between the graphite particles and the matrix during manufacturing of the industrial part considered in the XRD study. The model indicates that, besides the viscoplastic deformation of the matrix, the effect of the inelastic deformation of the graphite has to be considered to explain the magnitude of the XRD strain. Moreover, the model shows that the large elastic strain perturbations recorded with XRD close to the graphite-matrix interface are not artifacts due to e.g. sharp gradients in chemical composition, but correspond to residual stress concentrations induced by the conical sectors forming the internal structure of the graphite particles. In contrast to common belief, these results thus suggest that ductile cast iron parts cannot be considered, in general, as stress-free at the microstructural scale.

Formation of Hot Tear Under Controlled Solidification Conditions

NASA Astrophysics Data System (ADS)

Subroto, Tungky; Miroux, Alexis; Bouffier, Lionel; Josserond, Charles; Salvo, Luc; Suéry, Michel; Eskin, Dmitry G.; Katgerman, Laurens

2014-06-01

Aluminum alloy 7050 is known for its superior mechanical properties, and thus finds its application in aerospace industry. Vertical direct-chill (DC) casting process is typically employed for producing such an alloy. Despite its advantages, AA7050 is considered as a "hard-to-cast" alloy because of its propensity to cold cracking. This type of cracks occurs catastrophically and is difficult to predict. Previous research suggested that such a crack could be initiated by undeveloped hot tears (microscopic hot tear) formed during the DC casting process if they reach a certain critical size. However, validation of such a hypothesis has not been done yet. Therefore, a method to produce a hot tear with a controlled size is needed as part of the verification studies. In the current study, we demonstrate a method that has a potential to control the size of the created hot tear in a small-scale solidification process. We found that by changing two variables, cooling rate and displacement compensation rate, the size of the hot tear during solidification can be modified in a controlled way. An X-ray microtomography characterization technique is utilized to quantify the created hot tear. We suggest that feeding and strain rate during DC casting are more important compared with the exerted force on the sample for the formation of a hot tear. In addition, we show that there are four different domains of hot-tear development in the explored experimental window—compression, microscopic hot tear, macroscopic hot tear, and failure. The samples produced in the current study will be used for subsequent experiments that simulate cold-cracking conditions to confirm the earlier proposed model.

Transient and residual stresses in large castings, taking time effects into account

NASA Astrophysics Data System (ADS)

Thorborg, J.; Klinkhammer, J.; Heitzer, M.

2012-07-01

Casting of large scale steel and iron parts leads to long solidification and cooling times. Solid mechanical calculations for these castings have to take the time scale of the process into account, in order to predict the transient and residual stress levels with a reasonable accuracy. This paper presents a study on the modelling of the thermo-mechanical conditions in the cast material using a unified approach to describe the constitutive behaviour. This means a classical splitting of the mechanical strain into an elastic and an inelastic contribution, where the inelastic strain is only formulated in the deviatoric space in terms of the J2 invariant. At high temperatures, creep is pronounced. Since the cooling time is long, the model includes a type of Norton's power law to integrate the significant contribution of creep to the inelastic strains. At these temperature levels, annealing effects are also dominant and hence no hardening is modelled. However, at intermediate and lower temperature levels, hardening is more pronounced and isotropic hardening is considered. Different hardening models have been studied and selected based on their ability to describe the behaviour at the different temperature levels. At the lower temperature levels, time effects decrease and the formulation reduces to a time independent formulation, like classical J2-flow theory. Several tensile and creep experiments have been made at different temperature levels to provide input data for selecting the appropriate contributions to the material model. The measurements have furthermore been used as input for extracting material data for the model. The numerical model is applied on different industrial examples to verify the agreement between measured and calculated deformations.

Random lattice structures. Modelling, manufacture and FEA of their mechanical response

NASA Astrophysics Data System (ADS)

Maliaris, G.; Sarafis, I. T.; Lazaridis, T.; Varoutoglou, A.; Tsakataras, G.

2016-11-01

The implementation of lightweight structures in various applications, especially in Aerospace/ Automotive industries and Orthopaedics, has become a necessity due to their exceptional mechanical properties with respect to reduced weight. In this work we present a Voronoi tessellation based algorithm, which has been developed for modelling stochastic lattice structures. With the proposed algorithm, is possible to generate CAD geometry with controllable structural parameters, such as porosity, cell number and strut thickness. The digital structures were transformed into physical objects through the combination of 3D printing technics and investment casting. This process was applied to check the mechanical behaviour of generated digital models. Until now, the only way to materialize such structures into physical objects, was feasible through 3D printing methods such as Selective Laser Sintering/ Melting (SLS/ SLM). Investment casting possesses numerous advantages against SLS or SLA, with the major one being the material variety. On the other hand, several trials are required in order to calibrate the process parameters to have successful castings, which is the major drawback of investment casting. The manufactured specimens were subjected to compression tests, where their mechanical response was registered in the form of compressive load - displacement curves. Also, a finite element model was developed, using the specimens’ CAD data and compression test parameters. The FE assisted calculation of specimen plastic deformation is identical with the one of the physical object, which validates the conclusions drawn from the simulation results. As it was observed, strut contact is initiated when specimen deformation is approximately 5mm. Although FE calculated compressive force follows the same trend for the first 3mm of compression, then diverges because of the elasto-plastic FE model type definition and the occurred remeshing steps.

Effect of Casting Material on the Cast Pressure After Sequential Cast Splitting.

PubMed

Roberts, Aaron; Shaw, K Aaron; Boomsma, Shawn E; Cameron, Craig D

2017-01-01

Circumferential casting is a vital component of nonoperative fracture management. These casts are commonly valved to release pressure and decrease the risk of complications from swelling. However, little information exists regarding the effect of different casting supplies on the pressure within the cast. Seventy-five long-arm casts were performed on human volunteers, divided between 5 experimental groups with 15 casts in each groups. Testing groups consisted of 2 groups with a plaster short-arm cast overwrapped with fiberglass to a long arm with either cotton or synthetic cast padding. The 3 remaining groups included fiberglass long-arm casts with cotton, synthetic, or waterproof cast padding. A pediatric blood pressure cuff bladder was placed within the cast and inflated to 100 mm Hg. After inflation, the cast was sequentially released with pressure reading preformed after each stage. Order of release consisted of cast bivalve, cast padding release, and cotton stockinet release. After release, the cast was overwrapped with a loose elastic bandage. Difference in pressure readings were compared based upon the cast material. Pressures within the cast were found to decrease with sequential release of cast. The cast type had no effect of change in pressure. Post hoc testing demonstrated that the type of cast padding significantly affected the cast pressures with waterproof padding demonstrating the highest pressure readings at all time-points in the study, followed by synthetic padding. Cotton padding had the lowest pressure readings at all time-points. Type of cast padding significantly influences the amount of pressure within a long-arm cast, even after bivalving the cast and cutting the cast padding. Cotton cast padding allows for the greatest change in pressure. Cotton padding demonstrates the greatest change in pressure within a long-arm cast after undergoing bivalve. Synthetic and waterproof cast padding should not be used in the setting of an acute fracture to accommodate swelling.

Comparison of marginal accuracy of castings fabricated by conventional casting technique and accelerated casting technique: an in vitro study.

PubMed

Reddy, S Srikanth; Revathi, Kakkirala; Reddy, S Kranthikumar

2013-01-01

Conventional casting technique is time consuming when compared to accelerated casting technique. In this study, marginal accuracy of castings fabricated using accelerated and conventional casting technique was compared. 20 wax patterns were fabricated and the marginal discrepancy between the die and patterns were measured using Optical stereomicroscope. Ten wax patterns were used for Conventional casting and the rest for Accelerated casting. A Nickel-Chromium alloy was used for the casting. The castings were measured for marginal discrepancies and compared. Castings fabricated using Conventional casting technique showed less vertical marginal discrepancy than the castings fabricated by Accelerated casting technique. The values were statistically highly significant. Conventional casting technique produced better marginal accuracy when compared to Accelerated casting. The vertical marginal discrepancy produced by the Accelerated casting technique was well within the maximum clinical tolerance limits. Accelerated casting technique can be used to save lab time to fabricate clinical crowns with acceptable vertical marginal discrepancy.

High-temperature ceramic heat exchanger element for a solar thermal receiver

NASA Technical Reports Server (NTRS)

Strumpf, H. J.; Kotchick, D. M.; Coombs, M. G.

1982-01-01

A study has been completed on the development of a high-temperature ceramic heat exchanger element to be integrated into a solar reciver producing heated air. A number of conceptual designs were developed for heat exchanger elements of differing configuration. These were evaluated with respect to thermal performance, pressure drop, structural integrity, and fabricability. The final design selection identified a finned ceramic shell as the most favorable concept. The ceramic shell is surrounded by a larger metallic shell. The flanges of the two shells are sealed to provide a leak-tight pressure vessel. The ceramic shell is fabricated by an innovative combination of slip casting the receiver walls and precision casting the heat transfer finned plates. The fins are bonded to the shell during firing. Fabrication of a one-half scale demonstrator ceramic receiver has been completed.

Role of copper in precipitation hardening of high-alloy Cr-Ni cast steels

NASA Astrophysics Data System (ADS)

Gajewski, Mirosław

2006-02-01

The mechanism of strengthening with second-phase particles that results from heat treatment, i.e., precipitate hardening, plays an important role in modern alloys. The strengthening effect of such particles can result from their coherence with the matrix, inhibition of dislocation slip, inhibition of grain boundary slip, as well as hampering recovery processes due to dislocation network pinning. The results of investigations into high-alloy Cr-Ni-Cu cast steels precipitate hardened with highly dispersed ɛ phase particles are presented within. The influence of heat treatment on changes in microstructure, mechanical properties, and morphology of fracture surfaces obtained under loading have been analyzed. It has been demonstrated that, with the appropriate selection of heat treatment parameters, it is possible to control the precipitation of the hardening ɛ phase and, thus, to change the final mechanical and functional properties.

A process chain for integrating piezoelectric transducers into aluminum die castings to generate smart lightweight structures

NASA Astrophysics Data System (ADS)

Stein, Stefan; Wedler, Jonathan; Rhein, Sebastian; Schmidt, Michael; Körner, Carolin; Michaelis, Alexander; Gebhardt, Sylvia

The application of piezoelectric transducers to structural body parts of machines or vehicles enables the combination of passive mechanical components with sensor and actuator functions in one single structure. According to Herold et al. [1] and Staeves [2] this approach indicates significant potential regarding smart lightweight construction. To obtain the highest yield, the piezoelectric transducers need to be integrated into the flux of forces (load path) of load bearing structures. Application in a downstream process reduces yield and process efficiency during manufacturing and operation, due to the necessity of a subsequent process step of sensor/actuator application. The die casting process offers the possibility for integration of piezoelectric transducers into metal structures. Aluminum castings are particularly favorable due to their high quality and feasibility for high unit production at low cost (Brunhuber [3], Nogowizin [4]). Such molded aluminum parts with integrated piezoelectric transducers enable functions like active vibration damping, structural health monitoring or energy harvesting resulting in significant possibilities of weight reduction, which is an increasingly important driving force of automotive and aerospace industry (Klein [5], Siebenpfeiffer [6]) due to increasingly stringent environmental protection laws. In the scope of those developments, this paper focuses on the entire process chain enabling the generation of lightweight metal structures with sensor and actuator function, starting from the manufacturing of piezoelectric modules over electrical and mechanical bonding to the integration of such modules into aluminum (Al) matrices by die casting. To achieve this challenging goal, piezoceramic sensors/actuator modules, so-called LTCC/PZT modules (LPM) were developed, since ceramic based piezoelectric modules are more likely to withstand the thermal stress of about 700 °C introduced by the casting process (Flössel et al., [7]). The modules are made of low temperature cofired ceramic (LTCC) tapes with an embedded lead zirconate titanate (PZT) plate and are manufactured in multilayer technique. For joining conducting copper (Cu) wires with the electrode structure of the LPM, a novel laser drop on demand wire bonding method (LDB) is applied, which is based on the melting of a spherical CuSn12 braze preform with a liquidus temperature Tliquid of 989.9 °C (Deutsches Kupfer-Institut Düsseldorf, [8]) providing sufficient thermal stability for a subsequent casting process.

Alloy Design and Development of Cast Cr-W-V Ferritic Steels for Improved High-Temperature Strength for Power Generation Applications

DOE Office of Scientific and Technical Information (OSTI.GOV)

Klueh, R L; Maziasz, P J; Vitek, J M

2006-09-23

Economic and environmental concerns demand that the power-generation industry seek increased efficiency for gas turbines. Higher efficiency requires higher operating temperatures, with the objective temperature for the hottest sections of new systems {approx} 593 C, and increasing to {approx} 650 C. Because of their good thermal properties, Cr-Mo-V cast ferritic steels are currently used for components such as rotors, casings, pipes, etc., but new steels are required for the new operating conditions. The Oak Ridge National Laboratory (ORNL) has developed new wrought Cr-W-V steels with 3-9% Cr, 2-3% W, 0.25% V (compositions are in wt.%), and minor amounts of additionalmore » elements. These steels have the strength and toughness required for turbine applications. Since cast alloys are expected to behave differently from wrought material, work was pursued to develop new cast steels based on the ORNL wrought compositions. Nine casting test blocks with 3, 9, and 11% Cr were obtained. Eight were Cr-W-V-Ta-type steels based on the ORNL wrought steels; the ninth was COST CB2, a 9Cr-Mo-Co-V-Nb cast steel, which was the most promising cast steel developed in a European alloy-development program. The COST CB2 was used as a control to which the new compositions were compared, and this also provided a comparison between Cr-W-V-Ta and Cr-Mo-V-Nb compositions. Heat treatment studies were carried out on the nine castings to determine normalizing-and-tempering treatments. Microstructures were characterized by both optical and transmission electron microscopy (TEM). Tensile, impact, and creep tests were conducted. Test results on the first nine cast steel compositions indicated that properties of the 9Cr-Mo-Co-V-Nb composition of COST CB2 were better than those of the 3Cr-, 9Cr-, and 11Cr-W-V-Ta steels. Analysis of the results of this first iteration using computational thermodynamics raised the question of the effectiveness in cast steels of the Cr-W-V-Ta combination versus the Cr-Mo-V-Nb combination in COST CB2. To explore this question, nine more casting test blocks, four 3Cr steels and five 11Cr steels were purchased, and microstructure and mechanical properties studies similar to those described above for the first iteration of test blocks were conducted. Experimental results from the second iteration indicated that 11 Cr steels with excellent properties are possible. The 11Cr-1.5Mo-V-Nb steels were superior to 11Cr-2W-V-Ta steels, and it appears the former class of steels can be developed to have tensile and creep properties exceeding those of COST CB2. The W-Nb combination in an 11Cr-2W-V-Nb steel had tensile and short-time creep properties at 650 C better than the 11Cr-1.5Mo-V-Nb steels, although long-time low-stress properties may not be as good because of Laves phase formation. Based on the results, the next step in the development of improved casting steels involves acquisition of 11Cr-1.5Mo-V-Nb-N-B-C and 11Cr-2W-V-Nb-N-B-C steels on which long-term creep-rupture tests (>10,000 h) be conducted. For better oxidation and corrosion resistance, development of 11Cr steels, as opposed to a 9Cr steels, such as COST CB2, are important for future turbine designs that envision operating temperatures of 650 C.« less

Ultrasound Burst Phase Thermography (UBP) for Applications in the Automotive Industry

NASA Astrophysics Data System (ADS)

Zweschper, T.; Riegert, G.; Dillenz, A.; Busse, G.

2003-03-01

The use of elastic waves in combination with thermal waves allows to separate structural information about investigated components from defect specific thermal signatures. Ultrasound Burst Phase thermography (UBP) is an defect-selective and fast imaging tool for damage detection. This contribution presents results obtained on various kinds of problems related to modern automobile production (crack detection in grey cast iron and aluminum, characterization of adhesive-bonded joints etc.). Advances resulting from frequency modulated ultrasound excitation will be presented.

Scalable Production Method for Graphene Oxide Water Vapor Separation Membranes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Fifield, Leonard S.; Shin, Yongsoon; Liu, Wei

ABSTRACT Membranes for selective water vapor separation were assembled from graphene oxide suspension using techniques compatible with high volume industrial production. The large-diameter graphene oxide flake suspensions were synthesized from graphite materials via relatively efficient chemical oxidation steps with attention paid to maintaining flake size and achieving high graphene oxide concentrations. Graphene oxide membranes produced using scalable casting methods exhibited water vapor flux and water/nitrogen selectivity performance meeting or exceeding that of membranes produced using vacuum-assisted laboratory techniques. (PNNL-SA-117497)

Automation of Space Processing Applications Shuttle payloads

NASA Technical Reports Server (NTRS)

Crosmer, W. E.; Neau, O. T.; Poe, J.

1975-01-01

The Space Processing Applications Program is examining the effect of weightlessness on key industrial materials processes, such as crystal growth, fine-grain casting of metals, and production of unique and ultra-pure glasses. Because of safety and in order to obtain optimum performance, some of these processes lend themselves to automation. Automation can increase the number of potential Space Shuttle flight opportunities and increase the overall productivity of the program. Five automated facility design concepts and overall payload combinations incorporating these facilities are presented.

Roseburg repeat : Roseburg Forest Products' sawmill at Dillard, Ore was the biggest producer in a year that ended with a whimper

Treesearch

Henry Spelter

2009-01-01

A vintage year for sawmilling 2008 was not. In an industry strongly driven to produce, we were apprehensive that firms would be more shy than usual about divulging their 2008 activities. So this year we cast a wider net but, in the end, 149 out of the 200 mills appearing on the Top 200 list, and 48 out of the top 50, volunteered their numbers. For the remainder,...

Production and properties of high strength Ni free Zr-based BMGs

NASA Astrophysics Data System (ADS)

Iqbal, M.; Wang, W. H.

2014-06-01

Bulk metallic glasses (BMGs) are well known for very attractive physical, mechanical and thermal properties. Zr-based BMGs are used as structural materials in sports goods, electronics, jewelry, medical and aerospace applications. Ni free Zr48Cu36Al8M8 (M = Nb, Ti and Ta) BMGs are successfully synthesized by Cu mold casting technique. Differential scanning calorimetery (DSC) results show that the Zr48Cu36Al8Nb8 BMG have good thermal stability, wide supercooled liquid region of 80 K and contain the double stage crystallization. The alloy has fracture strength of 1.953 GPa. Shear angle was measured to be in the range of 43.5±5° for the alloy studied. Vicker's hardness of the BMGs was found to be over 500 Hv for the as cast alloy which enhanced about 11 % more by annealing up to 600 °C/20 min. Intersected shear bands were observed. The observed promising mechanical and thermal properties showed that BMG studied can be used for industrial applications.

Simulation of Channel Segregation During Directional Solidification of In—75 wt pct Ga. Qualitative Comparison with In Situ Observations

NASA Astrophysics Data System (ADS)

Saad, Ali; Gandin, Charles-André; Bellet, Michel; Shevchenko, Natalia; Eckert, Sven

2015-11-01

Freckles are common defects in industrial casting. They result from thermosolutal convection due to buoyancy forces generated from density variations in the liquid. The present paper proposes a numerical analysis for the formation of channel segregation using the three-dimensional (3D) cellular automaton (CA)—finite element (FE) model. The model integrates kinetics laws for the nucleation and growth of a microstructure with the solution of the conservation equations for the casting, while introducing an intermediate modeling scale for a direct representation of the envelope of the dendritic grains. Directional solidification of a cuboid cell is studied. Its geometry, the alloy chosen as well as the process parameters are inspired from experimental observations recently reported in the literature. Snapshots of the convective pattern, the solute distribution, and the morphology of the growth front are qualitatively compared. Similitudes are found when considering the coupled 3D CAFE simulations. Limitations of the model to reach direct simulation of the experiments are discussed.

A new lead alloy for automotive batteries operating under high-temperature conditions

NASA Astrophysics Data System (ADS)

Albert, L.; Goguelin, A.; Jullian, E.

The operating conditions of automotive and some industrial batteries are involving increasingly higher temperatures and heavier duty cycles. These place stress on the positive-grid materials which are presently not sufficiently resistant to corrosion and to creep. Conventional lead-calcium-tin-aluminium alloys can usually be optimized by a proper choice of calcium and tin contents for each specific manufacturing technology. With the new requirements of customers and the typical behaviour of these conventional alloys, however, there is no more room for improvement without searching for additional alloying elements. The work reported here shows how the doping of conventional lead-calcium-tin-aluminium alloys with barium improves mechanical properties (tensile strength and creep resistance) and increases corrosion resistance at temperatures between 50 and 75°C. Grid materials prepared by two manufacturing technologies (gravity cast; continuous cast followed by expansion) are investigated. Both the mechanical properties and the corrosion behaviour of the resulting grids are evaluated.

Analysis and calculation of macrosegregation in a casting ingot. MPS solidification model. Volume 3: Operating manual

NASA Technical Reports Server (NTRS)

Maples, A. L.

1980-01-01

The operation of solidification model 1 is described. Model 1 calculates the macrosegregation in a rectangular ingot of a binary alloy as a result of horizontal axisymmetric bidirectional solidification. The calculation is restricted to steady-state solidification; there is no variation in final local average composition in the direction of isotherm movement. The physics of the model are given.

Isocyanate exposure assessment combining industrial hygiene methods with biomonitoring for end users of orthopedic casting products.

PubMed

Pearson, Ronald L; Logan, Perry W; Kore, Anita M; Strom, Constance M; Brosseau, Lisa M; Kingston, Richard L

2013-07-01

Previous studies have suggested a potential risk to healthcare workers applying isocyanate-containing casts, but the authors reached their conclusions based on immunological or clinical pulmonology test results alone. We designed a study to assess potential exposure to methylene diphenyl diisocyanate (MDI) among medical personnel applying orthopedic casts using two different application methods. Air, dermal, surface, and glove permeation sampling methods were combined with urinary biomonitoring to assess the overall risk of occupational asthma to workers handling these materials. No MDI was detected in any of the personal and area air samples obtained. No glove permeation of MDI was detected. A small proportion of surface (3/45) and dermal wipe (1/60) samples were positive for MDI, but were all from inexperienced technicians. Urinary metabolites of MDI [methylenedianiline (MDA)] were detected in three of six study participants prior to both a 'dry' and 'wet' application method, five of six after the dry method, and three of six after the wet method. All MDA results were below levels noted in worker or general populations. Our conclusion is that the risk of MDI exposure is small, but unquantifiable. Because there is some potential risk of dermal exposure, medical personnel are instructed to wear a minimum of 5-mil-thick (5 mil = 0.005 inches) nitrile gloves and avoid contact to unprotected skin. This could include gauntlets, long sleeves, and/or a laboratory coat.

Thermal Stress Analysis for Ceramics Stalk in the Low Pressure Die Casting Machine

NASA Astrophysics Data System (ADS)

Noda, Nao-Aki; Hendra, Nao-Aki; Takase, Yasushi; Li, Wenbin

Low pressure die casting (LPDC) is defined as a net shape casting technology in which the molten metal is injected at high speeds and pressure into a metallic die. The LPDC process is playing an increasingly important role in the foundry industry as a low-cost and high-efficiency precision forming technique. The LPDC process is that the permanent die and filling systems are placed over the furnace containing the molten alloy. The filling of the cavity is obtained by forcing the molten metal by means of a pressurized gas in order to rise into a ceramic tube, which connects the die to the furnace. The ceramics tube called stalk has high temperature resistance and high corrosion resistance. However, attention should be paid to the thermal stress when the stalk is dipped into the molten aluminum. It is important to develop the design of the stalk to reduce the risk of fracture because of low fracture toughness of ceramics. In this paper, therefore, the finite element method is applied to calculate the thermal stresses when the stalk is dipped into the crucible by varying the dipping speeds and dipping directions. It is found that the thermal stress can be reduced by dipping slowly if the stalk is dipped into the crucible vertically, while the thermal stress can be reduced by dipping fast if it is dipped horizontally.

Fatigue in a heat treatable high silicon containing aluminium alloy

NASA Astrophysics Data System (ADS)

González, J. A.; Talamantes-Silva, J.; Valtierra, S.; Colás, Rafael

2017-05-01

The use of cast aluminium alloys in automobiles contributes to reductions in weight and fuel consumption without impairing the safety for the occupants or the performance of the car. Most of the alloys used are heat treatable hypoeutectic Al-Si alloys, which have the drawback of exhibiting low wear resistance. So industry relies in wear resistant alloys, such as grey iron, for the liners of the combustion chambers in engine blocks, which increase the weight of the engine. Therefore, it is of interest to cast high silicon containing alloys into engine components that are able to resist wear while maintaining the mechanical properties required by the components. This work presents the result of the work carried out in a high silicon containing heat treatable aluminium alloy as it is subjected to high cycle fatigue. The alloy was prepared and cast in ingots designed to promote one dimensional solidification gradient to obtain samples to study the high cycle fatigue. The material was machined into hour-glass specimens that were tested at room temperature in a servohydraulic machine under load control following the stair case method. The results show that the resistance to fatigue depends on the microstructure of the sample, as the fatigue cracks originate in pores close to the surface of the sample and propagate through the eutectic aggregate. The results from this work are compared with those from previously obtained with hypoeutectic alloys.

Soft cast versus rigid cast for treatment of distal radius buckle fractures in children.

PubMed

Witney-Lagen, Caroline; Smith, Christine; Walsh, Graham

2013-04-01

Buckle fractures are extremely common and their optimum management is still under debate. This study aimed to ascertain whether buckle fractures of the distal radius can be safely and effectively treated in soft cast with only a single orthopaedic outpatient clinic appointment. A total of 232 children with buckle fractures of the distal radius were included in the study. 111 children with 112 distal radius fractures were treated in full rigid cast and 121 children with 123 fractures were treated with soft cast. The rigid cast children attended outpatient clinic for removal of cast at 3 weeks. Soft casts were removed by parents unwinding the cast at home after 3 weeks. Follow-up was conducted prospectively by telephone questionnaire at an average of 6 weeks post-injury. Outcome data were available for 117 children treated in soft cast and for 102 children treated in rigid cast. The most common mechanism of injury was a fall sustained from standing or running, followed by falls from bikes and then trampoline accidents. Overall, both groups recovered well. Overall satisfaction with the outcome of treatment was 97.4% in soft cast and 95.2% in rigid cast. Casts were reported as comfortable by 95.7% in soft cast and 93.3% in rigid cast. Cast changes were required for 6.8% of soft casts and 11.5% of rigid casts. The most frequent cause for changing rigid casts was getting the cast wet. None of the improved scores seen in the soft cast group were statistically significant. No re-fractures were seen in either group. Nearly all (94.9%) children in soft cast did bathe, shower or swim in their cast. Parents of both groups preferred treatment with soft cast (p < 0.001). Reasons given for preferring the soft cast included the ability to get the cast wet, avoidance of the plaster saw and not having to take time off work to attend a follow-up visit for cast removal. Buckle fractures of the distal radius can be safely and effectively treated in soft cast with only a single orthopaedic outpatient clinic appointment. Copyright © 2012 Elsevier Ltd. All rights reserved.

Sugar Industry and Coronary Heart Disease Research: A Historical Analysis of Internal Industry Documents.

PubMed

Kearns, Cristin E; Schmidt, Laura A; Glantz, Stanton A

2016-11-01

Early warning signals of the coronary heart disease (CHD) risk of sugar (sucrose) emerged in the 1950s. We examined Sugar Research Foundation (SRF) internal documents, historical reports, and statements relevant to early debates about the dietary causes of CHD and assembled findings chronologically into a narrative case study. The SRF sponsored its first CHD research project in 1965, a literature review published in the New England Journal of Medicine, which singled out fat and cholesterol as the dietary causes of CHD and downplayed evidence that sucrose consumption was also a risk factor. The SRF set the review's objective, contributed articles for inclusion, and received drafts. The SRF's funding and role was not disclosed. Together with other recent analyses of sugar industry documents, our findings suggest the industry sponsored a research program in the 1960s and 1970s that successfully cast doubt about the hazards of sucrose while promoting fat as the dietary culprit in CHD. Policymaking committees should consider giving less weight to food industry-funded studies and include mechanistic and animal studies as well as studies appraising the effect of added sugars on multiple CHD biomarkers and disease development.

26 CFR 1.142(a)(6)-1 - Exempt facility bonds: solid waste disposal facilities.

Code of Federal Regulations, 2012 CFR

2012-04-01

... biological, engineering, industrial, or technological method. (1) Final disposal process. The term final... solid material derived from any agricultural, commercial, consumer, governmental, or industrial... industrial operation or activity, or a component of any such product or activity, and that has been used...

26 CFR 1.142(a)(6)-1 - Exempt facility bonds: solid waste disposal facilities.

Code of Federal Regulations, 2013 CFR

2013-04-01

... biological, engineering, industrial, or technological method. (1) Final disposal process. The term final... solid material derived from any agricultural, commercial, consumer, governmental, or industrial... industrial operation or activity, or a component of any such product or activity, and that has been used...

Advanced Industrial Materials (AIM) program. Annual progress report. FY 1996

DOE Office of Scientific and Technical Information (OSTI.GOV)

NONE

1997-04-01

The Advanced Industrial Materials (AIM) Program underwent a major transformation in Fiscal Year 1995 and these changes have continued to the present. When the Program was established in 1990 as the Advanced Industrial Concepts (AIC) Materials Program, the mission was to conduct applied research and development to bring materials and processing technologies from the knowledge derived from basic research to the maturity required for the end use sectors for commercialization. In 1995, the Office of Industrial Technologies (OIT) made radical changes in structure and procedures. All technology development was directed toward the seven `Vision Industries` that use about 80% ofmore » industrial energy and generated about 90% of industrial wastes. These are: aluminium; chemical; forest products; glass; metal casting; refineries; and steel. OIT is working with these industries, through appropriate organizations, to develop Visions of the desired condition of each industry some 20 or 25 years in the future and then to prepare Road Maps and Implementation Plans to enable them to reach their goals. The mission of AIM has, therefore, changed to `Support development and commercialization of new or improved materials to improve productivity, product quality, and energy efficiency in the major process industries.` Though AIM remains essentially a National Laboratory Program, it is necessary that each project have industrial partners, including suppliers to, and customers of, the seven industries. Now, well into FY 1996, the transition is nearly complete and the AIM Program remains healthy and productive, thanks to the superb investigators and Laboratory Program Managers. Separate abstracts have been indexed into the energy database for articles from this report.« less

Poly β-hydroxybutyrate production by Bacillus subtilis NG220 using sugar industry waste water.

PubMed

Singh, Gulab; Kumari, Anish; Mittal, Arpana; Yadav, Anita; Aggarwal, Neeraj K

2013-01-01

The production of poly β-hydroxybutyrate (PHB) by Bacillus subtilis NG220 was observed utilizing the sugar industry waste water supplemented with various carbon and nitrogen sources. At a growth rate of 0.14 g h(-1) L(-1), using sugar industry waste water was supplemented with maltose (1% w/v) and ammonium sulphate (1% w/v); the isolate produced 5.297 g/L of poly β-hydroxybutyrate accumulating 51.8% (w/w) of biomass. The chemical nature of the polymer was confirmed with nuclear magnetic resonance, Fourier transform infrared, and GC-MS spectroscopy whereas thermal properties were monitored with differential scanning calorimetry. In biodegradability study, when PHB film of the polymer (made by traditional solvent casting technique) was subjected to degradation in various natural habitats like soil, compost, and industrial sludge, it was completely degraded after 30 days in the compost having 25% (w/w) moisture. So, the present study gives insight into dual benefits of conversion of a waste material into value added product, PHB, and waste management.

Poly β-Hydroxybutyrate Production by Bacillus subtilis NG220 Using Sugar Industry Waste Water

PubMed Central

Singh, Gulab; Kumari, Anish; Mittal, Arpana; Yadav, Anita; Aggarwal, Neeraj K.

2013-01-01

The production of poly β-hydroxybutyrate (PHB) by Bacillus subtilis NG220 was observed utilizing the sugar industry waste water supplemented with various carbon and nitrogen sources. At a growth rate of 0.14 g h−1 L−1, using sugar industry waste water was supplemented with maltose (1% w/v) and ammonium sulphate (1% w/v); the isolate produced 5.297 g/L of poly β-hydroxybutyrate accumulating 51.8% (w/w) of biomass. The chemical nature of the polymer was confirmed with nuclear magnetic resonance, Fourier transform infrared, and GC-MS spectroscopy whereas thermal properties were monitored with differential scanning calorimetry. In biodegradability study, when PHB film of the polymer (made by traditional solvent casting technique) was subjected to degradation in various natural habitats like soil, compost, and industrial sludge, it was completely degraded after 30 days in the compost having 25% (w/w) moisture. So, the present study gives insight into dual benefits of conversion of a waste material into value added product, PHB, and waste management. PMID:24027767

Incidence and etiology of unplanned cast changes for fractures in the pediatric population.

PubMed

DiPaola, Matthew J; Abzug, Joshua M; Pizzutillo, Peter D; Herman, Martin J

2014-09-01

The majority of pediatric fractures are treated in casts due to the child's ability to heal rapidly and remodel. Unplanned cast changes are a time and economic burden with potentially adverse effects on fracture management. The purpose of this study is to document the incidence, etiology, and complications related to unplanned cast changes. A prospective study was conducted over a 6-month period to determine the incidence of unplanned cast changes. All casts applied were nonwaterproof. Data collected include the reason for cast placement, type of cast placed, duration of wear before the unplanned change, reason for the unplanned change, experience level of the original cast applicator, and cast-related complications. A total of 1135 casts were placed with 58% placed by a resident, 38% by a cast technician, 2% by a physician's assistant, and 2% by an attending physician. Sixty casts (5.3%) required an unplanned change including 19 short-arm casts, 18 short-leg casts, 17 long-arm casts, 4 thumb spica casts, and 2 long-leg casts. The average duration from cast application until the unplanned change was 13 days. Twenty-eight (47%) were changed for wetness, 20 (33%) for wear/breakage, 2 (3%) for skin irritation, and 10 (17%) for other reasons including objects in the cast and patient self-removal. Two patients had superficial skin infections requiring oral antibiotics. No fracture reductions were lost secondary to an unplanned cast change. The need for an unplanned cast change did not correlate with the level of experience of the applicator. Most unplanned cast changes were the result of patient nonadherence to instructions and not related to cast application technique. Improved patient and family education regarding cast care may reduce the frequency of unplanned cast changes, thus reducing an economic and time burden on the health care system. Level II--prognostic study.

The effect of tantalum on the structure/properties of two polycrystalline nickel-base superalloys: B-1900 + Hf MAR-M247. M.S. Thesis, Final Report

NASA Technical Reports Server (NTRS)

Janowski, G. M.

1985-01-01

The microstructure, phase compositions, and phase fractions were studied in conventionally cast B-1900 + Hf and both conventionally cast and directionally solidified MAR-M247 as a function of tantalum concentration. The hot tensile and creep rupture properties of the solutionized and aged MAR-M247-type alloys were also determined as a function of tantalum level. The effects of tantalum on the microstructure and phase compositions of B-1900 + Hf and MAR-M247 (conventionally cast and directionally solidified) were found to be very similar. The addition of tantalum to the as cast and heat treated alloys was shown to cause the partial replacement of the Hf in the MC carbides by Ta, although the degree of replacement was decreased by the solutionizing and aging heat treatment. The gamma prime and minor phase fractions (primarily MC type carbides) both increased approximately linearly with tantalum concentration. The gamma prime phase compositions were relatively insensitive to tantalum variations with the exception of the tantalum and/or hafnium levels. Bulk tantalum additions increased the tantalum, chromium, and cobalt levels of the gamma phase in both alloy series. The increase in the concentrations of the latter two elements in the gamma phase was a result of the decrease in the gamma phase fraction with increasing bulk tantalum concentration and constant gamma/gamma prime partitioning ratio. Tantalum additions increased the yield stress and ultimate tensile strength of the directionally solidified MAR-M247 type alloys and had no significant effect on ductility.

A versatile approach to vacuum injection casting for materials research and development.

PubMed

Xu, Donghua; Xu, Yifan

2017-03-01

Vacuum injection casting (VIC) is important for research and development (R&D) of materials that are prone to oxidation at high temperatures, particularly metals and metallic alloys (e.g., metallic glasses and high entropy alloys). VIC in R&D laboratories often involves initial melting/alloying in a prior step, transporting the sample to a dedicated vacuum chamber, re-melting the sample in a quartz tube, and finally injecting the melt with an inert gas to a dedicated mold. Here we present a new approach to laboratory VIC that requires no sample transfer (for a variety of materials), no dedicated vacuum chamber/space nor dedicated mold, and hence provides more versatility and higher efficiency and yet lowers the capital equipment cost. Our approach takes advantage of the exceptional portability, thermal and chemical stability, and thermoplastic processability of quartz glass and uses quartz tubes for all the melting, re-melting, injection casting, and molding. In addition, our approach includes oxygen gettering to remove residual oxygen for all the steps and allows for slow or fast cooling (e.g., water quenching) upon injection. This paper focuses on the design, the procedures, and the versatile features of this new approach while also demonstrating the practical implementation of this approach and computational modeling of the heat transfer and the cooling rates for two exemplary cases. The new approach is expected to bring notable expedition to sample fabrication and materials discovery, as well as wider adoption of vacuum injection casting in materials science and condensed matter physics research laboratories.

A versatile approach to vacuum injection casting for materials research and development

NASA Astrophysics Data System (ADS)

Xu, Donghua; Xu, Yifan

2017-03-01

Vacuum injection casting (VIC) is important for research and development (R&D) of materials that are prone to oxidation at high temperatures, particularly metals and metallic alloys (e.g., metallic glasses and high entropy alloys). VIC in R&D laboratories often involves initial melting/alloying in a prior step, transporting the sample to a dedicated vacuum chamber, re-melting the sample in a quartz tube, and finally injecting the melt with an inert gas to a dedicated mold. Here we present a new approach to laboratory VIC that requires no sample transfer (for a variety of materials), no dedicated vacuum chamber/space nor dedicated mold, and hence provides more versatility and higher efficiency and yet lowers the capital equipment cost. Our approach takes advantage of the exceptional portability, thermal and chemical stability, and thermoplastic processability of quartz glass and uses quartz tubes for all the melting, re-melting, injection casting, and molding. In addition, our approach includes oxygen gettering to remove residual oxygen for all the steps and allows for slow or fast cooling (e.g., water quenching) upon injection. This paper focuses on the design, the procedures, and the versatile features of this new approach while also demonstrating the practical implementation of this approach and computational modeling of the heat transfer and the cooling rates for two exemplary cases. The new approach is expected to bring notable expedition to sample fabrication and materials discovery, as well as wider adoption of vacuum injection casting in materials science and condensed matter physics research laboratories.

Simulation of dental collisions and occlusal dynamics in the virtual environment.

PubMed

Stavness, I K; Hannam, A G; Tobias, D L; Zhang, X

2016-04-01

Semi-adjustable articulators have often been used to simulate occlusal dynamics, but advances in intra-oral scanning and computer software now enable dynamics to be modelled mathematically. Computer simulation of occlusal dynamics requires accurate virtual casts, records to register them and methods to handle mesh collisions during movement. Here, physical casts in a semi-adjustable articulator were scanned with a conventional clinical intra-oral scanner. A coordinate measuring machine was used to index their positions in intercuspation, protrusion, right and left laterotrusion, and to model features of the articulator. Penetrations between the indexed meshes were identified and resolved using restitution forces, and the final registrations were verified by distance measurements between dental landmarks at multiple sites. These sites were confirmed as closely approximating via measurements made from homologous transilluminated vinylpolysiloxane interocclusal impressions in the mounted casts. Movements between the indexed positions were simulated with two models in a custom biomechanical software platform. In model DENTAL, 6 degree-of-freedom movements were made to minimise deviation from a straight line path and also shaped by dynamic mesh collisions detected and resolved mathematically. In model ARTIC, the paths were further constrained by surfaces matching the control settings of the articulator. Despite these differences, the lower mid-incisor point paths were very similar in both models. The study suggests that mathematical simulation utilising interocclusal 'bite' registrations can closely replicate the primary movements of casts mounted in a semi-adjustable articulator. Additional indexing positions and appropriate software could, in some situations, replace the need for mechanical semi-adjustable articulation and/or its virtual representation. © 2015 John Wiley & Sons Ltd.