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Sample records for die casting applications

  1. Vacuum Die Casting of Silicon Sheet for Photovoltaic Applications

    NASA Technical Reports Server (NTRS)

    1979-01-01

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

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

    SciTech Connect

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

    2003-05-01

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

  3. Sputtered protective coatings for die casting dies

    NASA Technical Reports Server (NTRS)

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

    1981-01-01

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

  4. Casting Characteristics of Aluminum Die Casting Alloys

    SciTech Connect

    Makhlouf M. Makhlouf; Diran Apelian

    2002-02-05

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

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

    NASA Astrophysics Data System (ADS)

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

    2015-05-01

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

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

    SciTech Connect

    Sabau, Adrian S

    2007-01-01

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

  7. Energy Consumption of Die Casting Operations

    SciTech Connect

    Jerald Brevick; clark Mount-Campbell; Carroll Mobley

    2004-03-15

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

  8. Prediction of Part Distortion in Die Casting

    SciTech Connect

    R. Allen Miller

    2005-03-30

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

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

    NASA Astrophysics Data System (ADS)

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

    2014-05-01

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

  10. Use of RSP Tooling to Manufacture Die Casting Dies

    SciTech Connect

    Kevin McHugh

    2004-07-01

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

  11. Modeling the Mechanical Performance of Die Casting Dies

    SciTech Connect

    R. Allen Miller

    2004-02-27

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

  12. Enhancements in Magnesium Die Casting Impact Properties

    SciTech Connect

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

    2000-06-30

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

  13. Sputtered protective coatings for die casting dies

    NASA Technical Reports Server (NTRS)

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

    1981-01-01

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

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

    SciTech Connect

    Mc Hugh, Kevin Matthew

    2000-06-01

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

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

    SciTech Connect

    K. M. McHugh; B. R. Wickham

    2000-06-26

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

  16. Fatigue of die cast zinc alloys

    SciTech Connect

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

    2006-04-01

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

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

    SciTech Connect

    Jensen, D.

    1994-06-01

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

  18. Characterization of Spray Lubricants for the Die Casting Process

    SciTech Connect

    Sabau, Adrian S

    2008-01-01

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

  19. Improved die castings through plasma surface modification, improved sensors and die soldering prevention. Quarterly progress report 1, July 1--September 30, 1994

    SciTech Connect

    Mobley, C.; Brevick, J.

    1994-10-17

    This quarterly report covers activities of the Die Casting Research project during the period July 1, 1994 through September 30, 1994, at The Ohio State University. The objective of the Die Casting Research project is to enhance the competitiveness of the US die casting industry. To accomplish this objective, the Center for Die Casting at The Ohio State University shall perform tasks that focus on three general areas: the application of plasma surface modifications to aluminum and zinc casting dies; the development and evaluation of systems to monitor temperature, pressure, and gas content of die casting cavities; and the determination of causes of die soldering in zinc die castings. This quarterly report covers work on Task 2 -- Commercial Sensor Evaluation.

  20. Deburring die-castings by wet vibratory plant

    NASA Technical Reports Server (NTRS)

    Loeschbart, H. M.

    1980-01-01

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

  1. Deburring die-castings by wet vibratory plant

    NASA Astrophysics Data System (ADS)

    Loeschbart, H. M.

    1980-02-01

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

  2. Development of Thin Section Zinc Die Casting Technology

    SciTech Connect

    Goodwin, Frank

    2013-10-31

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

  3. High pressure die casting of Fe-based metallic glass

    NASA Astrophysics Data System (ADS)

    Ramasamy, Parthiban; Szabo, Attila; Borzel, Stefan; Eckert, Jürgen; Stoica, Mihai; Bárdos, András

    2016-10-01

    Soft ferromagnetic Fe-based bulk metallic glass key-shaped specimens with a maximum and minimum width of 25.4 and 5 mm, respectively, were successfully produced using a high pressure die casting (HPDC) method, The influence of die material, alloy temperature and flow rate on the microstructure, thermal stability and soft ferromagnetic properties has been studied. The results suggest that a steel die in which the molten metal flows at low rate and high temperature can be used to produce completely glassy samples. This can be attributed to the laminar filling of the mold and to a lower heat transfer coefficient, which avoids the skin effect in the steel mold. In addition, magnetic measurements reveal that the amorphous structure of the material is maintained throughout the key-shaped samples. Although it is difficult to control the flow and cooling rate of the molten metal in the corners of the key due to different cross sections, this can be overcome by proper tool geometry. The present results confirm that HPDC is a suitable method for the casting of Fe-based bulk glassy alloys even with complex geometries for a broad range of applications.

  4. High pressure die casting of Fe-based metallic glass

    PubMed Central

    Ramasamy, Parthiban; Szabo, Attila; Borzel, Stefan; Eckert, Jürgen; Stoica, Mihai; Bárdos, András

    2016-01-01

    Soft ferromagnetic Fe-based bulk metallic glass key-shaped specimens with a maximum and minimum width of 25.4 and 5 mm, respectively, were successfully produced using a high pressure die casting (HPDC) method, The influence of die material, alloy temperature and flow rate on the microstructure, thermal stability and soft ferromagnetic properties has been studied. The results suggest that a steel die in which the molten metal flows at low rate and high temperature can be used to produce completely glassy samples. This can be attributed to the laminar filling of the mold and to a lower heat transfer coefficient, which avoids the skin effect in the steel mold. In addition, magnetic measurements reveal that the amorphous structure of the material is maintained throughout the key-shaped samples. Although it is difficult to control the flow and cooling rate of the molten metal in the corners of the key due to different cross sections, this can be overcome by proper tool geometry. The present results confirm that HPDC is a suitable method for the casting of Fe-based bulk glassy alloys even with complex geometries for a broad range of applications. PMID:27725780

  5. Microstructures and properties of aluminum die casting alloys

    SciTech Connect

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

    1998-10-01

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

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

    NASA Technical Reports Server (NTRS)

    1982-01-01

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

  7. An indicator for fitting castings to a die.

    PubMed

    Troendle, G R; Troendle, K B

    1992-10-01

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

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

    SciTech Connect

    Shivpuri, R.

    1997-09-18

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

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

    SciTech Connect

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

    1998-05-01

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

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

    SciTech Connect

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

    1998-09-01

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

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

    SciTech Connect

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

    2007-09-01

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

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

    NASA Astrophysics Data System (ADS)

    Cao, Yongyou; Guo, Zhipeng; Xiong, Shoumei

    2012-07-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-02-01

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

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

    SciTech Connect

    Carroll Mobley; Yogeshwar Sahai; Jerry Brevick

    2003-10-10

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

  15. Microstructural analysis of aluminum high pressure die castings

    NASA Astrophysics Data System (ADS)

    David, Maria Diana

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

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

    SciTech Connect

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

    1998-05-01

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

  17. Surface morphology of a die-cast Mg alloy

    NASA Astrophysics Data System (ADS)

    Unigovski, Ya. B.; Gutman, E. M.

    1999-12-01

    We have studied the microstructure, phase composition and morphology of the intermetallic β-phase in the surface layer of the most widespread magnesium alloy AZ91D (Mg-9 wt.% Al-1 wt.% Zn) used in pressure die casting. Auger electron spectroscopy (AES), energy dispersive spectroscopy (EDS), scanning electron microscopy (SEM) and optical microscopy have been applied. The surface of the AZ91D Mg alloy consists of an oxide-metallic film with a thickness of about 0.15 micron containing Mg and Al oxides. Prolonged aging in air at 200°C promotes an increase in the MgO/Al 2O 3 ratio from 9±2 to 14±2. The aluminum concentration gradient in the surface layer is rather significant. The external layer of as-cast specimens contains up to 32 at.% Al, whereas α-Mg grains in the bulk contain, on the average, about 5 at.% Al. Aging leads to a substantial increase in the surface concentration of aluminum at the expense of the acceleration of its diffusion and the intensification of supersaturated solid solution decomposition. During creep tests at elevated temperatures the morphology of the β-phase is significantly affected by strain and, to a lesser extent, by the casting temperature.

  18. Investment cast AISI H13 tooling for automotive applications

    SciTech Connect

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

    1995-07-01

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

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

    SciTech Connect

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

    2010-10-26

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

  20. Die Materials for Critical Applications and Increased Production Rates

    SciTech Connect

    David Schwam; John Wallace; Sebastian Birceanu

    2002-11-30

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

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

    SciTech Connect

    Jerald Brevick; R. Allen Miller

    2004-03-15

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

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

    NASA Astrophysics Data System (ADS)

    Bračun, Drago; Gruden, Valter; Možina, Janez

    2008-04-01

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

  3. 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.

  4. Casting dimensional control and fatigue life prediction for permanent mold casting dies. Technical report, September 29, 1993--May 31, 1997

    SciTech Connect

    1997-06-01

    Efforts as part of a three year program to address metal casting dimensional control and fatigue life prediction for permanent mold casting dies are described. Procedures have been developed and implemented to collect dimensional variability data from production steel casting. The influence of process variation and casting geometry variables on dimensional tolerances have been investigated. Also efforts leading to the developments and validation of a CAD/CAE model to predict the thermal fatigue life of permanent molds for aluminum castings are described. An appropriate thermomechanical property database for metal, mold and coating materials has been constructed. A finite element model has been developed to simulate the mold temperature distribution during repeated casting cycles. Validation trials using a permanent mold casting machine have indicated the success of the temperature distribution model developed. A combination of experimental and modeling techniques have been employed to extend their knowledge of permanent mold casting. The influence of coatings on casting solidification and mold temperatures has been determined. The computer model has been extended to predict thermally induced stresses and strains in the mold and to predict the number of cycles required to crack the mold. Experimental results have been used to validate the extended model.

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

    SciTech Connect

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

    2012-07-31

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

  6. Evaluation of Cooling Rate Effects on the Mechanical Properties of Die Cast Magnesium Alloy AM60

    NASA Astrophysics Data System (ADS)

    Sharifi, P.; Fan, Y.; Anaraki, H. B.; Banerjee, A.; Sadayappan, K.; Wood, J. T.

    2016-10-01

    With the increased application of magnesium high-pressure die castings (HPDC), it is necessary to better understand process-structure-mechanical properties. In the case of HPDC, ductility and yield strength strongly depend on porosity, grain size, and the skin thickness. In this contribution, a new method is developed which employs knowledge of local cooling rates to predict the grain size and the skin thickness of HPDC magnesium components. The centreline cooling curve, together with the die temperature, and the thermodynamic properties of the alloy are then used as inputs to compute the solution to the Stefan problem of a moving phase boundary, thereby providing the through-thickness cooling curves at each chosen location of the casting. The local cooling rate is used to calculate the resulting grain size and skin thickness via established relationships. The prediction of skin thickness and average grain size of skin region determined from this method compares quite well with the experimental results. Due to the presence of externally solidified grains, this method underestimates the grain size value in the core region, as compared to the experiment. Finally, we predict the locally varying yield strength using a modified Hall-Petch equation.

  7. SPH based modelling of oxide and oxide film formation in gravity die castings

    NASA Astrophysics Data System (ADS)

    Ellingsen, K.; Coudert, T.; M'Hamdi, M.

    2015-06-01

    Gravity die casting is an important casting process which has the capability of making complicated, high-integrity components for e.g. the automotive industry. Oxides and oxide films formed during filling affect the cast product quality. The Smoothed particle hydrodynamics (SPH) method is particularly suited to follow complex flows. The SPH method has been used to study filling of a gravity die including the formation and transport of oxides and oxide films for two different filling velocities. A low inlet velocity leads to a higher amount of oxides and oxide films in the casting. The study demonstrates the usefulness of the SPH method for an increased understanding of the effect of different filling procedures on the cast quality.

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

    NASA Astrophysics Data System (ADS)

    Fiorese, Elena; Bonollo, Franco

    2016-07-01

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

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

    NASA Astrophysics Data System (ADS)

    Sce, Andrea; Caporale, Lorenzo

    2014-07-01

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

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

    SciTech Connect

    Madhav Rao Gonvindaraju

    1999-10-18

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-05-01

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

  12. Qualitative Reasoning for Additional Die Casting Applications

    SciTech Connect

    R. Allen Miller; Dehua Cui; Yuming Ma

    2003-05-28

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-06-01

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

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

    SciTech Connect

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

    1998-05-01

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

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

    SciTech Connect

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

    1998-05-01

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

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

    SciTech Connect

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

    2004-10-01

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

  17. Numerical simulation of mold-filling capability for a thin- walled aluminum die casting

    NASA Astrophysics Data System (ADS)

    Sun, L.; Subasic, E.; Jakumeit, J.

    2015-06-01

    Mold-filling capability is an important property of casting materials. Especially in thin-walled die casting, fast cooling of the melt by contact to the die makes complete filling difficult to ensure. Simulation is an important tool enabling investigation of filling problems, even before the die is manufactured. However, the prediction of misruns is challenging. Flow and solidification have to be computed as closely coupled. The effects of surface tension, the wetting angle and reduced melt flow due to solidification must be modeled with high precision. To meet these requirements, a finite-volume method using arbitrary polyhedral control volumes is used to solve flow and solidification as closely coupled. The Volume-of-Fluid approach is used to capture the phase separation between gas, melt and solid in connection with a High-Resolution Interface-Capturing scheme to obtain sharp interfaces between phases. To model the resistance of the dendrite network to the melt flow, an additional source term in the momentum equation was implemented. The Bolt test was performed for A356 alloys at a range of different casting temperatures. Numerical prediction of incomplete filling in the bottleneck regions agreed well with experimental findings using 3D camera scanning. The simulation enables derivation of the dependence of critical wall-thickness, i.e. the thickness which is fillable, on casting temperature and metallostatic pressure. This could prove useful in predicting filling problems ahead of casting.

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

    SciTech Connect

    Heestand, G.M.

    1996-02-02

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

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

    NASA Astrophysics Data System (ADS)

    Wu, Mengwu; Xiong, Shoumei

    2012-07-01

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

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

    SciTech Connect

    David Schwam

    2012-12-15

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

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

    NASA Astrophysics Data System (ADS)

    Hardro, Peter Jason

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

  2. Machining studies of die cast aluminum alloy-silicon carbide composites

    NASA Astrophysics Data System (ADS)

    Sornakumar, Thambu; Kathiresan, Marimuthu

    2010-10-01

    Metal matrix composites (MMCs) with high specific stiffness, high strength, improved wear resistance, and thermal properties are being increasingly used in advanced structural, aerospace, automotive, electronics, and wear applications. Aluminum alloy-silicon carbide composites were developed using a new combination of the vortex method and the pressure die-casting technique in the present work. Machining studies were conducted on the aluminum alloy-silicon carbide (SiC) composite work pieces using high speed steel (HSS) end-mill tools in a milling machine at different speeds and feeds. The quantitative studies on the machined work piece show that the surface finish is better for higher speeds and lower feeds. The surface roughness of the plain aluminum alloy is better than that of the aluminum alloy-silicon carbide composites. The studies on tool wear show that flank wear increases with speed and feed. The end-mill tool wear is higher on machining the aluminum alloy-silicon carbide composites than on machining the plain aluminum alloy.

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

    SciTech Connect

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

    2012-09-30

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

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

    SciTech Connect

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

    2007-03-15

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

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

    NASA Astrophysics Data System (ADS)

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

    2014-09-01

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

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

    SciTech Connect

    Zhang, X.

    1997-12-31

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

  7. Cast Aluminum Alloy for High Temperature Applications

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A.

    2003-01-01

    Originally developed by NASA as high performance piston alloys to meet U.S. automotive legislation requiring low exhaust emission, the novel NASA alloys now offer dramatic increase in tensile strength for many other applications at elevated temperatures from 450 F (232 C) to about 750 F (400 C). It is an ideal low cost material for cast automotive components such as pistons, cylinder heads, cylinder liners, connecting rods, turbo chargers, impellers, actuators, brake calipers and rotors. It can be very economically produced from conventional permanent mold, sand casting or investment casting, with silicon content ranging from 6% to 18%. At high silicon levels, the alloy exhibits excellent dimensional stability, surface hardness and wear resistant properties.

  8. A summary of special coatings projects conducted in support of the Die Casting Program

    SciTech Connect

    Selle, J.E.

    1988-09-12

    The usefulness of various kinds of coatings to the die casting program has been studied. This work includes heat transfer and fluid flow calculations, as well as experimental work, to examine the feasibility and characteristics of various types of coatings. Calculations include the effect of surface roughness on fluid flow, conductance as a function of coating thickness, conductivity as a function of coating porosity, and solidification and possible remelting of microspheres of metal. In each case, the model is described and the results are presented. Experimental work involved evaluating the relative insulating value of various coatings and an analysis of commercial flame-sprayed coatings, low-density coatings, and release coatings. In each case, description of the experimental arrangement is given and the results are described. 5 refs., 28 figs., 6 tabs.

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

    NASA Astrophysics Data System (ADS)

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

    2016-07-01

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

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

    NASA Astrophysics Data System (ADS)

    Lee, Soon Gi

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

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

    SciTech Connect

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

    2013-06-01

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

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

    NASA Technical Reports Server (NTRS)

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

    1996-01-01

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

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

    SciTech Connect

    1994-11-01

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

  14. Application of TRIZ Theory in Patternless Casting Manufacturing Technique

    NASA Astrophysics Data System (ADS)

    Yang, Weidong; Gan, Dequan; Jiang, Ping; Tian, Yumei

    The ultimate goal of Patternless Casting Manufacturing (referred to as PCM) is how to obtain the casts by casting the sand mold directly. In the previous PCM, the resin content of sand mold is much higher than that required by traditional resin sand, so the casts obtained are difficult to be sound and qualified products, which limits the application of this technique greatly. In this paper, the TRIZ algorithm is introduced to the innovation process in PCM systematically.

  15. 25 CFR 301.4 - Application of dies.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 25 Indians 2 2012-04-01 2012-04-01 false Application of dies. 301.4 Section 301.4 Indians INDIAN ARTS AND CRAFTS BOARD, DEPARTMENT OF THE INTERIOR NAVAJO, PUEBLO, AND HOPI SILVER AND TURQUOISE PRODUCTS; STANDARDS § 301.4 Application of dies. Dies are to be applied to the object with the aid...

  16. 25 CFR 301.4 - Application of dies.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 25 Indians 2 2014-04-01 2014-04-01 false Application of dies. 301.4 Section 301.4 Indians INDIAN ARTS AND CRAFTS BOARD, DEPARTMENT OF THE INTERIOR NAVAJO, PUEBLO, AND HOPI SILVER AND TURQUOISE PRODUCTS; STANDARDS § 301.4 Application of dies. Dies are to be applied to the object with the aid...

  17. 25 CFR 301.4 - Application of dies.

    Code of Federal Regulations, 2013 CFR

    2013-04-01

    ... 25 Indians 2 2013-04-01 2013-04-01 false Application of dies. 301.4 Section 301.4 Indians INDIAN ARTS AND CRAFTS BOARD, DEPARTMENT OF THE INTERIOR NAVAJO, PUEBLO, AND HOPI SILVER AND TURQUOISE PRODUCTS; STANDARDS § 301.4 Application of dies. Dies are to be applied to the object with the aid...

  18. 25 CFR 301.4 - Application of dies.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 25 Indians 2 2010-04-01 2010-04-01 false Application of dies. 301.4 Section 301.4 Indians INDIAN ARTS AND CRAFTS BOARD, DEPARTMENT OF THE INTERIOR NAVAJO, PUEBLO, AND HOPI SILVER AND TURQUOISE PRODUCTS; STANDARDS § 301.4 Application of dies. Dies are to be applied to the object with the aid...

  19. 25 CFR 301.4 - Application of dies.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... 25 Indians 2 2011-04-01 2011-04-01 false Application of dies. 301.4 Section 301.4 Indians INDIAN ARTS AND CRAFTS BOARD, DEPARTMENT OF THE INTERIOR NAVAJO, PUEBLO, AND HOPI SILVER AND TURQUOISE PRODUCTS; STANDARDS § 301.4 Application of dies. Dies are to be applied to the object with the aid...

  20. Microstructural Evolution and Solidification Behavior of Al-Mg-Si Alloy in High-Pressure Die Casting

    NASA Astrophysics Data System (ADS)

    Ji, Shouxun; Wang, Yun; Watson, D.; Fan, Z.

    2013-07-01

    Microstructural evolution and solidification behavior of Al-5 wt pct Mg-1.5 wt pct Si-0.6 wt pct Mn-0.2 wt pct Ti alloy have been investigated using high-pressure die casting. Solidification commences with the formation of primary α-Al phase in the shot sleeve and is completed in the die cavity. The average size of dendrites and fragmented dendrites of the primary α-Al phase formed in the shot sleeve is 43 μm, and the globular primary α-Al grains formed inside the die cavity is at a size of 7.5 μm. Solidification inside the die cavity also forms the lamellar Al-Mg2Si eutectic phase and the Fe-rich intermetallics. The size of the eutectic cells is about 10 μm, in which the lamellar α-Al phase is 0.41 μm thick. The Fe-rich intermetallic compound exhibits a compact morphology and is less than 2 μm with a composition of 1.62 at. pct Si, 3.94 at. pct Fe, and 2.31 at. pct Mn. A solute-enriched circular band is always observed parallel to the surface of the casting. The band zone separates the outer skin region from the central region of the casting. The solute concentration is consistent in the skin region and shows a general drop toward the center inside the band for Mg and Si. The peak of the solute enrichment in the band zone is much higher than the nominal composition of the alloy. The die casting exhibits a combination of brittle and ductile fracture. There is no significant difference on the fracture morphology in the three regions. The band zone is not significantly detrimental in terms of the fracture mechanism in the die casting. Calculations using the Mullins and Sekerka stability criterion reveal that the solidification of the primary α-Al phase inside the die cavity has been completed before the spherical α-Al globules begin to lose their stability, but the α-Al grains formed in the shot sleeve exceed the limit of spherical growth and therefore exhibit a dendritic morphology.

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

    SciTech Connect

    J. F. Wallace; D. Schwam

    1998-10-01

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

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

    NASA Astrophysics Data System (ADS)

    Kachold, Franziska; Singer, Robert

    2016-08-01

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

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

    SciTech Connect

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

    2012-05-02

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

  4. 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.

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

    NASA Astrophysics Data System (ADS)

    Cecchel, Silvia; Cornacchia, Giovanna; Panvini, Andrea

    2016-08-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2013-12-01

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

  7. Advanced Pattern Material for Investment Casting Applications

    SciTech Connect

    F. Douglas Neece Neil Chaudhry

    2006-02-08

    Cleveland Tool and Machine (CTM) of Cleveland, Ohio in conjunction with Harrington Product Development Center (HPDC) of Cincinnati, Ohio have developed an advanced, dimensionally accurate, temperature-stable, energy-efficient and cost-effective material and process to manufacture patterns for the investment casting industry. In the proposed technology, FOPAT (aFOam PATtern material) has been developed which is especially compatible with the investment casting process and offers the following advantages: increased dimensional accuracy; increased temperature stability; lower cost per pattern; less energy consumption per pattern; decreased cost of pattern making equipment; decreased tooling cost; increased casting yield. The present method for investment casting is "the lost wax" process, which is exactly that, the use of wax as a pattern material, which is then melted out or "lost" from the ceramic shell. The molten metal is then poured into the ceramic shell to produce a metal casting. This process goes back thousands of years and while there have been improvements in the wax and processing technology, the material is basically the same, wax. The proposed technology is based upon an established industrial process of "Reaction Injection Molding" (RIM) where two components react when mixed and then "molded" to form a part. The proposed technology has been modified and improved with the needs of investment casting in mind. A proprietary mix of components has been formulated which react and expand to form a foam-like product. The result is an investment casting pattern with smooth surface finish and excellent dimensional predictability along with the other key benefits listed above.

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

    NASA Technical Reports Server (NTRS)

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

    1981-01-01

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

  9. [Application to dental casting machine of the rapid heating infrared image furnace (author's transl)].

    PubMed

    Etchu, Y; Noguchi, H

    1980-10-01

    The authors tried to manufacture a casting machine in dentistry by application of the infrared image furnace with a high heating speed and an easy control of a heating temperature. This machine melts an alloy in a carbon crucible set in the furnace, held in the horizontal position. Then, the furnace is turned to the vertical position to drop a melted alloy on the casting mold, and the alloy is cast in the mold by the pressure of Argon gas. The functions of trial casting machine were follows. 1. The trial casting machine was capable of heating to 1250 degrees C within one minute under 4 kW electric power. 2. The castability of the 20% Au-Pd-Ag commercial alloy cast in all casting conditions by the trial casting machine was higher than that of Thermotrol D-2 automatic centrifugal casting machine. 3. Castings of the trial casting machine showed higher tensile strength and elongation than those of the centrifugal casting machine, and the deviation of values got by the trial casting machine was small. In particular, some casting of the trial casting machine showed three times or over elongation values as compared with those of the centrifugal casting machine. 4. When casting conditions (casting temperature, casting pressure) of the trial casting machine changed, the physical properties of castings did not change so much. However, when the mold was not prevented from heating by the furnace in casting, the elongation of castings increased.

  10. Optimization of cooling channel design and spray patterns in aluminum die casting using infrared thermography

    NASA Astrophysics Data System (ADS)

    Prystay, Mark; Loong, Chee A.; Nguyen, Ky T.

    1996-03-01

    A protocol for infrared thermal analysis of die surfaces is proposed. The most suitable infrared camera has a spectral response in the 8 - 10 micrometer of the infrared spectrum as the emissivity is higher and more uniform across the surface of the die than in the 3 - 5 micrometer region of the spectrum. Through the prudent use of shielding, die surface temperatures can be measured, thermal gradients are detected, the effectiveness of cooling lines can be evaluated and spray patterns are optimized. The technique is not suitable for examining aluminum parts as the emissivity of aluminum is low and the optical properties of the surface oxide layer change as the part cools.

  11. Effect of Hydrostatic Pressure on the 3D Porosity Distribution and Mechanical Behavior of a High Pressure Die Cast Mg AZ91 Alloy

    NASA Astrophysics Data System (ADS)

    Sket, Federico; Fernández, Ana; Jérusalem, Antoine; Molina-Aldareguía, Jon M.; Pérez-Prado, María Teresa

    2015-09-01

    A limiting factor of high pressure die cast (HPDC) Mg alloys is the presence of porosity, which has a detrimental effect on the mechanical strength and gives rise to a large variability in the ductility. The application of hydrostatic pressure after casting is known to be beneficial to improve the mechanical response of HPDC Mg alloys. In this study, a combined experimental and simulation approach has been developed in order to investigate the influence of pressurization on the 3D porosity distribution and on the mechanical behavior of an HPDC Mg AZ91 alloy. Examination of about 10,000 pores by X-ray computed microtomography allowed determining the effect of hydrostatic pressure on the bulk porosity volume fraction, as well as the change in volume and geometry of each individual pore. The evolution of the 3D porosity distribution and mechanical behavior of a sub-volume containing 200 pores was also simulated by finite element analysis. Both experiments and simulations consistently revealed a decrease in the bulk porosity fraction and a bimodal distribution of the individual volume changes after the application of the pressure. This observation is associated with pores containing internal pressure as a result of the HPDC process. Furthermore, a decrease in the complexity factor with increasing volume change is observed experimentally and predicted by simulations. The pressure-treated samples have consistently higher plastic flow strengths.

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

    SciTech Connect

    Schaefer, M.; Fournelle, R.A.

    1996-05-01

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

  13. Effect of Gas Pores on Mechanical Properties of High-Pressure Die-Casting AM50 Magnesium Alloy.

    PubMed

    Jiang, Wei; Cao, Zhanyi; Liu, Liping; Jiang, Bo

    2016-08-01

    High-pressure die-casting (HPDC) AM50 tensile specimens were used to investigate characteristics of gas pores and its effect on mechanical properties of HPDC AM50 magnesium alloy. Combining microstructure morphology gained from optical microscopy, scanning electron microscopy (SEM), and three-dimensional (3D) reconstruction with the experimental data from uniaxial tensile testing, we pursued the relationship between gas pores and the mechanical properties of HPDC AM50 Mg alloy. Results indicate that comparing with 3D reconstruction models, 2D images like optical metallography images and SEM images have one-sidedness. Furthermore, the size and maximum areal fraction of gas pores have negative effects on the mechanical properties of HPDC AM50 Mg alloy. With increase of the maximum size of gas pores in the specimen, the ultimate tensile strength (UTS) and elongation decrease. In addition, with the maximum areal fraction becoming larger, both the UTS and elongation decrease linearly.

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

    PubMed

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

    2016-03-24

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

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

    PubMed

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

    2016-01-01

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

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

    PubMed Central

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

    2016-01-01

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

  17. A comparative evaluation of application techniques of a paint-on die spacer in grooves: an in vitro study.

    PubMed

    Vaishali, K; Prasad, D Krishna; Shetty, Manoj

    2013-12-01

    The use of paint-on die spacer to improve the seating of casting has become quite popular in the recent years. The generally accepted range of paint-on die spacer is approximately 20-40 μm, which suggests a range of tolerance. The painting of the retentive grooves with die spacer has always been a subject of debate. The primary purpose of this study was to determine if there was a tendency for the paint-on die spacer to accumulate in grooves of tooth preparation in sufficient thickness to exceed this accepted range of tolerance when applied using two different techniques. Eight die stone blocks with three grooves each were prepared. Half the samples were painted in unidirectional method and the other halves were painted using the haphazard method of application. The thickness of the die spacer was measured at different positions using 200× magnification and the mean and standard deviations were calculated. On analysis it was seen that the thickness of the paint-on die spacer in grooves was in the range of 20-40 μm for unidirectional method of application, whereas in haphazard method of application the thickness of the paint-on die spacer was in the range of 28-132 μm. From the above study it was concluded that the method of application influenced the thickness of the paint-on die spacer. The recommended thickness of the die spacer was achieved on unidirectional method of application.

  18. SiC Die Attach for High-Temperature Applications

    NASA Astrophysics Data System (ADS)

    Drevin-Bazin, A.; Lacroix, F.; Barbot, J.-F.

    2013-11-01

    Eutectic solders AuIn19 and AuGe12 and nanosilver paste were investigated for SiC die attach in high-temperature (300°C) applications. The soldering or sintering conditions were optimized through die shear tests performed at room temperature. In particular, application of static pressure (3.5 MPa) during sintering resulted in greatly improved mechanical behavior of the nanosilver-based joint. Microstructural study of the eutectic solders showed formation of Au-rich grains in AuGe die attach and significant diffusion of Au and In through the Ni layer in AuIn19 die attach, which could lead to formation of intermetallic compounds. Die shear tests versus temperature showed that the behaviors of the studied die attaches are different; nevertheless they present suitable shear strengths required for high-temperature applications. The mechanical behavior of joints under various levels of thermal and mechanical stress was also studied. Creep experiments were carried out on the eutectic solders to describe the thermomechanical behavior of the complete module; only one creep mechanism was observed in the working range.

  19. Elasto-Plastic-Creep Constitutive Equation of an Al-Si-Cu High-Pressure Die Casting Alloy for Thermal Stress Analysis

    NASA Astrophysics Data System (ADS)

    Motoyama, Yuichi; Shiga, Hidetoshi; Sato, Takeshi; Kambe, Hiroshi; Yoshida, Makoto

    2016-11-01

    Accurate simulation of residual stress and deformation is necessary to optimize the design and lifetime of casting components. Therefore, the recovery and strain-rate dependence of the stress-strain curve have been incorporated into empirical constitutive equations to improve the thermal stress analysis accuracy. Nevertheless, these equations present several difficulties related to the determination of material constants and their physical bases. This study suggested an empirical elasto-plastic-creep constitutive equation incorporating these phenomena. To determine the material parameters used in this constitutive equation, this study investigated tensile test methods to obtain stress-strain curves that most closely resemble those during or immediately after casting for the Al-Si-Cu high-pressure die-casting alloy JIS ADC 12 (A383.0), which exhibits natural aging. Results show that solution heat treatment with subsequent cooling to the test temperature should be applied to obtain stress-strain curves used for the thermal stress analysis of high-pressure die casting process of this alloy. The yield stresses obtained using the conventional heating method were 50-64 pct higher than those of the method described above. Therefore, the conventional method is expected to overestimate the overestimation of the predicted residual stress in die castings. Evaluation of the developed equation revealed that it can represent alloy recovery and strain-rate dependence.

  20. Elasto-Plastic-Creep Constitutive Equation of an Al-Si-Cu High-Pressure Die Casting Alloy for Thermal Stress Analysis

    NASA Astrophysics Data System (ADS)

    Motoyama, Yuichi; Shiga, Hidetoshi; Sato, Takeshi; Kambe, Hiroshi; Yoshida, Makoto

    2016-08-01

    Accurate simulation of residual stress and deformation is necessary to optimize the design and lifetime of casting components. Therefore, the recovery and strain-rate dependence of the stress-strain curve have been incorporated into empirical constitutive equations to improve the thermal stress analysis accuracy. Nevertheless, these equations present several difficulties related to the determination of material constants and their physical bases. This study suggested an empirical elasto-plastic-creep constitutive equation incorporating these phenomena. To determine the material parameters used in this constitutive equation, this study investigated tensile test methods to obtain stress-strain curves that most closely resemble those during or immediately after casting for the Al-Si-Cu high-pressure die-casting alloy JIS ADC 12 (A383.0), which exhibits natural aging. Results show that solution heat treatment with subsequent cooling to the test temperature should be applied to obtain stress-strain curves used for the thermal stress analysis of high-pressure die casting process of this alloy. The yield stresses obtained using the conventional heating method were 50-64 pct higher than those of the method described above. Therefore, the conventional method is expected to overestimate the overestimation of the predicted residual stress in die castings. Evaluation of the developed equation revealed that it can represent alloy recovery and strain-rate dependence.

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

    NASA Astrophysics Data System (ADS)

    Prabhu, K. N.; Hemanna, P.

    2006-06-01

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

  2. 40 CFR 464.10 - Applicability; description of the aluminum casting subcategory.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... aluminum casting subcategory. 464.10 Section 464.10 Protection of Environment ENVIRONMENTAL PROTECTION... Aluminum Casting Subcategory § 464.10 Applicability; description of the aluminum casting subcategory. The... introduction of pollutants into publicly owned treatment works resulting from aluminum casting operations...

  3. 40 CFR 464.10 - Applicability; description of the aluminum casting subcategory.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... aluminum casting subcategory. 464.10 Section 464.10 Protection of Environment ENVIRONMENTAL PROTECTION... Aluminum Casting Subcategory § 464.10 Applicability; description of the aluminum casting subcategory. The... introduction of pollutants into publicly owned treatment works resulting from aluminum casting operations...

  4. 40 CFR 420.60 - Applicability; description of the continuous casting subcategory.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... continuous casting subcategory. 420.60 Section 420.60 Protection of Environment ENVIRONMENTAL PROTECTION... Continuous Casting Subcategory § 420.60 Applicability; description of the continuous casting subcategory. The... owned treatment works resulting from the continous casting of molten steel into intermediate or...

  5. 40 CFR 464.30 - Applicability; description of the ferrous casting subcategory.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... ferrous casting subcategory. 464.30 Section 464.30 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Ferrous Casting Subcategory § 464.30 Applicability; description of the ferrous casting subcategory....

  6. 40 CFR 464.30 - Applicability; description of the ferrous casting subcategory.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... ferrous casting subcategory. 464.30 Section 464.30 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS (CONTINUED) METAL MOLDING AND CASTING POINT SOURCE CATEGORY Ferrous Casting Subcategory § 464.30 Applicability; description of the ferrous casting...

  7. 40 CFR 464.20 - Applicability; description of the copper casting subcategory.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... copper casting subcategory. 464.20 Section 464.20 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Copper Casting Subcategory § 464.20 Applicability; description of the copper casting subcategory....

  8. 40 CFR 420.60 - Applicability; description of the continuous casting subcategory.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... continuous casting subcategory. 420.60 Section 420.60 Protection of Environment ENVIRONMENTAL PROTECTION... Continuous Casting Subcategory § 420.60 Applicability; description of the continuous casting subcategory. The... owned treatment works resulting from the continous casting of molten steel into intermediate or...

  9. 40 CFR 464.20 - Applicability; description of the copper casting subcategory.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... copper casting subcategory. 464.20 Section 464.20 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS (CONTINUED) METAL MOLDING AND CASTING POINT SOURCE CATEGORY Copper Casting Subcategory § 464.20 Applicability; description of the copper casting...

  10. 40 CFR 464.20 - Applicability; description of the copper casting subcategory.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... copper casting subcategory. 464.20 Section 464.20 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS (CONTINUED) METAL MOLDING AND CASTING POINT SOURCE CATEGORY Copper Casting Subcategory § 464.20 Applicability; description of the copper casting...

  11. 40 CFR 464.30 - Applicability; description of the ferrous casting subcategory.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... ferrous casting subcategory. 464.30 Section 464.30 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS (CONTINUED) METAL MOLDING AND CASTING POINT SOURCE CATEGORY Ferrous Casting Subcategory § 464.30 Applicability; description of the ferrous casting...

  12. 40 CFR 464.20 - Applicability; description of the copper casting subcategory.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... copper casting subcategory. 464.20 Section 464.20 Protection of Environment ENVIRONMENTAL PROTECTION... CATEGORY Copper Casting Subcategory § 464.20 Applicability; description of the copper casting subcategory... introduction of pollutants into publicly owned treatment works resulting from copper casting operations...

  13. 40 CFR 464.20 - Applicability; description of the copper casting subcategory.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... copper casting subcategory. 464.20 Section 464.20 Protection of Environment ENVIRONMENTAL PROTECTION... Copper Casting Subcategory § 464.20 Applicability; description of the copper casting subcategory. The... introduction of pollutants into publicly owned treatment works resulting from copper casting operations...

  14. 40 CFR 420.60 - Applicability; description of the continuous casting subcategory.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... continuous casting subcategory. 420.60 Section 420.60 Protection of Environment ENVIRONMENTAL PROTECTION... Continuous Casting Subcategory § 420.60 Applicability; description of the continuous casting subcategory. The... owned treatment works resulting from the continous casting of molten steel into intermediate or...

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

    NASA Astrophysics Data System (ADS)

    Zaki, Gergis Adel

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

  16. 21 CFR 888.5980 - Manual cast application and removal instrument.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 21 Food and Drugs 8 2014-04-01 2014-04-01 false Manual cast application and removal instrument... SERVICES (CONTINUED) MEDICAL DEVICES ORTHOPEDIC DEVICES Surgical Devices § 888.5980 Manual cast application and removal instrument. (a) Identification. A manual cast application and removal instrument is...

  17. 21 CFR 888.5980 - Manual cast application and removal instrument.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... 21 Food and Drugs 8 2011-04-01 2011-04-01 false Manual cast application and removal instrument... SERVICES (CONTINUED) MEDICAL DEVICES ORTHOPEDIC DEVICES Surgical Devices § 888.5980 Manual cast application and removal instrument. (a) Identification. A manual cast application and removal instrument is...

  18. 21 CFR 888.5980 - Manual cast application and removal instrument.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 21 Food and Drugs 8 2012-04-01 2012-04-01 false Manual cast application and removal instrument... SERVICES (CONTINUED) MEDICAL DEVICES ORTHOPEDIC DEVICES Surgical Devices § 888.5980 Manual cast application and removal instrument. (a) Identification. A manual cast application and removal instrument is...

  19. 21 CFR 888.5980 - Manual cast application and removal instrument.

    Code of Federal Regulations, 2010 CFR

    2010-04-01

    ... 21 Food and Drugs 8 2010-04-01 2010-04-01 false Manual cast application and removal instrument... SERVICES (CONTINUED) MEDICAL DEVICES ORTHOPEDIC DEVICES Surgical Devices § 888.5980 Manual cast application and removal instrument. (a) Identification. A manual cast application and removal instrument is...

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

    SciTech Connect

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

    1995-07-01

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

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

    SciTech Connect

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

    2013-06-10

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

  2. Simultaneous Effect of Plunger Motion Profile, Pressure, and Temperature on the Quality of High-Pressure Die-Cast Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Fiorese, Elena; Bonollo, Franco

    2016-10-01

    High-pressure die casting has been used widely to manufacture a large variety of products with high dimensional accuracy and productivity. Although this process has a considerably lower cycle time than the other metal forming processes, it is not yet optimized, due to the complexity of the process and the number of parameters to be controlled. Hence, the identification of the parameters affecting quality of castings is the current challenge toward efficient and effective production. In their previous work, the authors proposed and validated some novel kinematic parameters of the plunger, which explain and forecast both the static mechanical properties and the internal quality of castings. The present work extends such an approach by including two other meaningful parameters, which describe the effect of upset pressure and temperature on the final outcome. These parameters are here formulated and have been validated by means of a statistically significant sample manufactured with different plunger motion profiles, upset pressures, and temperatures of the melt and die. The quality of the castings was assessed through static mechanical properties and density measurements. As further proof, internal defects were analyzed on the fracture surfaces of some meaningful castings.

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

    SciTech Connect

    Prindiville, J; Lee, S; Gokhale, A

    2004-07-08

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

  4. 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.

  5. 40 CFR 464.40 - Applicability; description of the zinc casting subcategory.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 40 Protection of Environment 31 2012-07-01 2012-07-01 false Applicability; description of the zinc... Zinc Casting Subcategory § 464.40 Applicability; description of the zinc casting subcategory. The... introduction of pollutants into publicly owned treatment works resulting from zinc casting operations...

  6. 40 CFR 464.40 - Applicability; description of the zinc casting subcategory.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 40 Protection of Environment 30 2014-07-01 2014-07-01 false Applicability; description of the zinc... Zinc Casting Subcategory § 464.40 Applicability; description of the zinc casting subcategory. The... introduction of pollutants into publicly owned treatment works resulting from zinc casting operations...

  7. 40 CFR 464.40 - Applicability; description of the zinc casting subcategory.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 40 Protection of Environment 30 2011-07-01 2011-07-01 false Applicability; description of the zinc... (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Zinc Casting Subcategory § 464.40 Applicability; description of the zinc casting subcategory. The provisions of...

  8. 40 CFR 464.40 - Applicability; description of the zinc casting subcategory.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 40 Protection of Environment 31 2013-07-01 2013-07-01 false Applicability; description of the zinc... Zinc Casting Subcategory § 464.40 Applicability; description of the zinc casting subcategory. The... introduction of pollutants into publicly owned treatment works resulting from zinc casting operations...

  9. 40 CFR 464.40 - Applicability; description of the zinc casting subcategory.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 40 Protection of Environment 29 2010-07-01 2010-07-01 false Applicability; description of the zinc... (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Zinc Casting Subcategory § 464.40 Applicability; description of the zinc casting subcategory. The provisions of...

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

    SciTech Connect

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

    1993-08-01

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

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

    NASA Astrophysics Data System (ADS)

    Lu, You

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

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

    PubMed

    Kilburn, K H; Warshaw, R H

    1993-08-01

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

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

    SciTech Connect

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

    2013-12-15

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

  14. 40 CFR 464.10 - Applicability; description of the aluminum casting subcategory.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... aluminum casting subcategory. 464.10 Section 464.10 Protection of Environment ENVIRONMENTAL PROTECTION... CATEGORY Aluminum Casting Subcategory § 464.10 Applicability; description of the aluminum casting... the introduction of pollutants into publicly owned treatment works resulting from aluminum...

  15. 40 CFR 464.10 - Applicability; description of the aluminum casting subcategory.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... aluminum casting subcategory. 464.10 Section 464.10 Protection of Environment ENVIRONMENTAL PROTECTION... CATEGORY Aluminum Casting Subcategory § 464.10 Applicability; description of the aluminum casting... the introduction of pollutants into publicly owned treatment works resulting from aluminum...

  16. 40 CFR 464.10 - Applicability; description of the aluminum casting subcategory.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... aluminum casting subcategory. 464.10 Section 464.10 Protection of Environment ENVIRONMENTAL PROTECTION... CATEGORY Aluminum Casting Subcategory § 464.10 Applicability; description of the aluminum casting... the introduction of pollutants into publicly owned treatment works resulting from aluminum...

  17. 40 CFR 466.20 - Applicability; description of the cast iron basis material subcategory.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... iron basis material subcategory. 466.20 Section 466.20 Protection of Environment ENVIRONMENTAL... Cast Iron Basis Material Subcategory § 466.20 Applicability; description of the cast iron basis... of pollutants into publicly owned treatment works from porcelain enameling of cast iron...

  18. 40 CFR 466.20 - Applicability; description of the cast iron basis material subcategory.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... iron basis material subcategory. 466.20 Section 466.20 Protection of Environment ENVIRONMENTAL... Cast Iron Basis Material Subcategory § 466.20 Applicability; description of the cast iron basis... of pollutants into publicly owned treatment works from porcelain enameling of cast iron...

  19. 43 CFR 2883.14 - What happens to my application, grant, or TUP if I die?

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 43 Public Lands: Interior 2 2011-10-01 2011-10-01 false What happens to my application, grant, or TUP if I die? 2883.14 Section 2883.14 Public Lands: Interior Regulations Relating to Public Lands... happens to my application, grant, or TUP if I die? (a) If an applicant or grant or TUP holder dies,...

  20. 43 CFR 2883.14 - What happens to my application, grant, or TUP if I die?

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 43 Public Lands: Interior 2 2013-10-01 2013-10-01 false What happens to my application, grant, or TUP if I die? 2883.14 Section 2883.14 Public Lands: Interior Regulations Relating to Public Lands... happens to my application, grant, or TUP if I die? (a) If an applicant or grant or TUP holder dies,...

  1. 43 CFR 2803.12 - What happens to my application or grant if I die?

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 43 Public Lands: Interior 2 2014-10-01 2014-10-01 false What happens to my application or grant if I die? 2803.12 Section 2803.12 Public Lands: Interior Regulations Relating to Public Lands... What happens to my application or grant if I die? (a) If an applicant or grant holder dies,...

  2. 43 CFR 2883.14 - What happens to my application, grant, or TUP if I die?

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 43 Public Lands: Interior 2 2012-10-01 2012-10-01 false What happens to my application, grant, or TUP if I die? 2883.14 Section 2883.14 Public Lands: Interior Regulations Relating to Public Lands... happens to my application, grant, or TUP if I die? (a) If an applicant or grant or TUP holder dies,...

  3. 43 CFR 2803.12 - What happens to my application or grant if I die?

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 43 Public Lands: Interior 2 2013-10-01 2013-10-01 false What happens to my application or grant if I die? 2803.12 Section 2803.12 Public Lands: Interior Regulations Relating to Public Lands... What happens to my application or grant if I die? (a) If an applicant or grant holder dies,...

  4. 43 CFR 2883.14 - What happens to my application, grant, or TUP if I die?

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 43 Public Lands: Interior 2 2014-10-01 2014-10-01 false What happens to my application, grant, or TUP if I die? 2883.14 Section 2883.14 Public Lands: Interior Regulations Relating to Public Lands... happens to my application, grant, or TUP if I die? (a) If an applicant or grant or TUP holder dies,...

  5. 43 CFR 2803.12 - What happens to my application or grant if I die?

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 43 Public Lands: Interior 2 2012-10-01 2012-10-01 false What happens to my application or grant if I die? 2803.12 Section 2803.12 Public Lands: Interior Regulations Relating to Public Lands... What happens to my application or grant if I die? (a) If an applicant or grant holder dies,...

  6. 43 CFR 2803.12 - What happens to my application or grant if I die?

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 43 Public Lands: Interior 2 2011-10-01 2011-10-01 false What happens to my application or grant if I die? 2803.12 Section 2803.12 Public Lands: Interior Regulations Relating to Public Lands... What happens to my application or grant if I die? (a) If an applicant or grant holder dies,...

  7. 43 CFR 3202.13 - What happens if the applicant dies before the lease is issued?

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 43 Public Lands: Interior 2 2011-10-01 2011-10-01 false What happens if the applicant dies before...) GEOTHERMAL RESOURCE LEASING Lessee Qualifications § 3202.13 What happens if the applicant dies before the lease is issued? If the applicant dies before the lease is issued, BLM will issue the lease to...

  8. 43 CFR 3202.13 - What happens if the applicant dies before the lease is issued?

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 43 Public Lands: Interior 2 2013-10-01 2013-10-01 false What happens if the applicant dies before...) GEOTHERMAL RESOURCE LEASING Lessee Qualifications § 3202.13 What happens if the applicant dies before the lease is issued? If the applicant dies before the lease is issued, BLM will issue the lease to...

  9. 43 CFR 3202.13 - What happens if the applicant dies before the lease is issued?

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 43 Public Lands: Interior 2 2012-10-01 2012-10-01 false What happens if the applicant dies before...) GEOTHERMAL RESOURCE LEASING Lessee Qualifications § 3202.13 What happens if the applicant dies before the lease is issued? If the applicant dies before the lease is issued, BLM will issue the lease to...

  10. Vascular Corrosion Casting: Review of Advantages and Limitations in the Application of Some Simple Quantitative Methods.

    PubMed

    Hossler, Fred E.; Douglas, John E.

    2001-05-01

    Vascular corrosion casting has been used for about 40 years to produce replicas of normal and abnormal vasculature and microvasculature of various tissues and organs that could be viewed at the ultrastructural level. In combination with scanning electron microscopy (SEM), the primary application of corrosion casting has been to describe the morphology and anatomical distribution of blood vessels in these tissues. However, such replicas should also contain quantitative information about that vasculature. This report summarizes some simple quantitative applications of vascular corrosion casting. Casts were prepared by infusing Mercox resin or diluted Mercox resin into the vasculature. Surrounding tissues were removed with KOH, hot water, and formic acid, and the resulting dried casts were observed with routine SEM. The orientation, size, and frequency of vascular endothelial cells were determined from endothelial nuclear imprints on various cast surfaces. Vascular volumes of heart, lung, and avian salt gland were calculated using tissue and resin densities, and weights. Changes in vascular volume and functional capillary density in an experimentally induced emphysema model were estimated from confocal images of casts. Clearly, corrosion casts lend themselves to quantitative analysis. However, because blood vessels differ in their compliances, in their responses to the toxicity of casting resins, and in their response to varying conditions of corrosion casting procedures, it is prudent to use care in interpreting this quantitative data. Some of the applications and limitations of quantitative methodology with corrosion casts are reviewed here.

  11. 38 CFR 11.128 - Veteran dies without having filed application for final settlement.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 1 2012-07-01 2012-07-01 false Veteran dies without... Amended (pub. L. 120, 68th Cong.) § 11.128 Veteran dies without having filed application for final settlement. If the veteran dies without having filed application for final settlement under the...

  12. 38 CFR 11.128 - Veteran dies without having filed application for final settlement.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 1 2013-07-01 2013-07-01 false Veteran dies without... Amended (pub. L. 120, 68th Cong.) § 11.128 Veteran dies without having filed application for final settlement. If the veteran dies without having filed application for final settlement under the...

  13. 38 CFR 11.128 - Veteran dies without having filed application for final settlement.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 1 2010-07-01 2010-07-01 false Veteran dies without... Amended (pub. L. 120, 68th Cong.) § 11.128 Veteran dies without having filed application for final settlement. If the veteran dies without having filed application for final settlement under the...

  14. 38 CFR 11.128 - Veteran dies without having filed application for final settlement.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 1 2011-07-01 2011-07-01 false Veteran dies without... Amended (pub. L. 120, 68th Cong.) § 11.128 Veteran dies without having filed application for final settlement. If the veteran dies without having filed application for final settlement under the...

  15. 38 CFR 11.128 - Veteran dies without having filed application for final settlement.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 1 2014-07-01 2014-07-01 false Veteran dies without... Amended (pub. L. 120, 68th Cong.) § 11.128 Veteran dies without having filed application for final settlement. If the veteran dies without having filed application for final settlement under the...

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

    NASA Astrophysics Data System (ADS)

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

    2016-04-01

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

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

    SciTech Connect

    Wallace, J.F.; Schwam, D.

    1995-03-01

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

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

    PubMed

    Chun, Sung-Yong

    2015-07-01

    Chromium nitride coatings for the surface modified die casting molds with various ICP powers have been prepared using ICP assisted magnetron sputtering. The applied ICP power was varied from 0 to 300 W. The deposited coatings were characterized post-deposition using X-ray diffractometry (XRD) and atomic force microscopy (AFM). Single CrN phased coatings with nano-grain sized (< 20 nm) were identified. The corrosion resistance and hardness of each coating were evaluated from potentiost at and nanoindentator. Superior corrosion protective coatings in excess of 20 GPa were deposited with assistance of ICP plasma during sputtering.

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

    PubMed

    Chun, Sung-Yong

    2016-02-01

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

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

    PubMed

    Chun, Sung-Yong

    2016-02-01

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

  1. Clean Metal Casting

    SciTech Connect

    Makhlouf M. Makhlouf; Diran Apelian

    2002-02-05

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

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

    SciTech Connect

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

    2006-08-25

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

  3. 78 FR 38682 - Information Collection; Application for Payment of Amounts Due Persons Who Have Died, Disappeared...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-06-27

    ...; Application for Payment of Amounts Due Persons Who Have Died, Disappeared, or Have Been Declared Incompetent... Amounts Due Persons Who Have Died, Disappeared, or Have Been Declared Incompetent. OMB Control Number... to claim payments earned, but not yet paid to a person who has died, disappeared, or has...

  4. The application of quality criteria for the prediction of porosity in the design of casting processes

    SciTech Connect

    Viswanathan, S.; Sikka, V.K.; Brody, H.D.

    1993-12-31

    Solidification parameters calculated from temperature measurements and experimentally determined distributions of porosity in gain- refined Al-4.5% Cu alloy castings are linked to provide quality criteria for the prediction of porosity in the computer-aided design and analysis of casting processes. The quality criteria applicable to a particular casting process are dependent on the thermal conditions and the solidification mode of the alloy. Accordingly, casting processes and alloy types are divided into four groups according to whether porosity distribution is dominated by liquid transport, dendrite structure, or bubble pressure, and a different set of quality criteria is obtained for each group. Results from test castings of Al-4.5% Cu alloy cast in a variety of configurations and mold media are used to develop models and extract quality criteria. The results obtained on Al-4.5% Cu alloy are tested on data on Al-7% Si-0.3% Mg alloy castings reported in the literature. The results show that the quality criteria developed for USSR Cu alloy are also applicable to other alloy systems. The procedure for applying quality criteria for the prediction of microporosity distributions in commercial casting processes is outlined.

  5. The application of quality criteria for the prediction of porosity in the design of casting processes

    SciTech Connect

    Viswanathan, S.; Sikka, V.K. ); Brody, H.D. . School of Engineering)

    1993-01-01

    Solidification parameters calculated from temperature measurements and experimentally determined distributions of porosity in gain- refined Al-4.5% Cu alloy castings are linked to provide quality criteria for the prediction of porosity in the computer-aided design and analysis of casting processes. The quality criteria applicable to a particular casting process are dependent on the thermal conditions and the solidification mode of the alloy. Accordingly, casting processes and alloy types are divided into four groups according to whether porosity distribution is dominated by liquid transport, dendrite structure, or bubble pressure, and a different set of quality criteria is obtained for each group. Results from test castings of Al-4.5% Cu alloy cast in a variety of configurations and mold media are used to develop models and extract quality criteria. The results obtained on Al-4.5% Cu alloy are tested on data on Al-7% Si-0.3% Mg alloy castings reported in the literature. The results show that the quality criteria developed for USSR Cu alloy are also applicable to other alloy systems. The procedure for applying quality criteria for the prediction of microporosity distributions in commercial casting processes is outlined.

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

    SciTech Connect

    Sabau, Adrian S

    2005-09-01

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

  7. Fastcast: Integration and application of rapid prototyping and computational simulation to investment casting

    SciTech Connect

    Maguire, M.C.; Baldwin, M.D.; Atwood, C.L.

    1996-09-01

    The emergence of several rapid prototyping and manufacturing (RP and M) technologies is having a dramatic impact on investment casting. While the most successful of the rapid prototyping technologies are almost a decade old, relatively recent process advances in their application have produced some remarkable success in utilizing their products as patterns for investment castings. Sandia National Laboratories has been developed highly coupled experimental and computational capabilities to examine the investment casting process with the intention of reducing the amount of time required to manufacture castings, and to increase the quality of the finished product. This presentation will begin with process aspects of RP and M pattern production and handling, shell fabrication, burnout, and casting. The emphasis will be on how the use of Stereolithography (SL) or Selective Laser Sintered (SLS) patterns differs from more traditional wax pattern processes. Aspects of computational simulation to couple design, thermal analysis, and mold filling will be discussed. Integration of these topics is probably the greatest challenge to the use of concurrent engineering principles with investment casting. Sandia has conducted several experiments aimed at calibrating computer codes and providing data for input into these simulations. Studies involving materials as diverse as stainless steel and gold have been conducted to determine liquid metal behavior in molds via real time radiography. The application of these experiments to predictive simulations will be described.

  8. Improved ceramic slip casting technique. [application to aircraft model fabrication

    NASA Technical Reports Server (NTRS)

    Buck, Gregory M. (Inventor); Vasquez, Peter (Inventor)

    1993-01-01

    A primary concern in modern fluid dynamics research is the experimental verification of computational aerothermodynamic codes. This research requires high precision and detail in the test model employed. Ceramic materials are used for these models because of their low heat conductivity and their survivability at high temperatures. To fabricate such models, slip casting techniques were developed to provide net-form, precision casting capability for high-purity ceramic materials in aqueous solutions. In previous slip casting techniques, block, or flask molds made of plaster-of-paris were used to draw liquid from the slip material. Upon setting, parts were removed from the flask mold and cured in a kiln at high temperatures. Casting detail was usually limited with this technique -- detailed parts were frequently damaged upon separation from the flask mold, as the molded parts are extremely delicate in the uncured state, and the flask mold is inflexible. Ceramic surfaces were also marred by 'parting lines' caused by mold separation. This adversely affected the aerodynamic surface quality of the model as well. (Parting lines are invariably necessary on or near the leading edges of wings, nosetips, and fins for mold separation. These areas are also critical for flow boundary layer control.) Parting agents used in the casting process also affected surface quality. These agents eventually soaked into the mold, the model, or flaked off when releasing the case model. Different materials were tried, such as oils, paraffin, and even an algae. The algae released best, but some of it remained on the model and imparted an uneven texture and discoloration on the model surface when cured. According to the present invention, a wax pattern for a shell mold is provided, and an aqueous mixture of a calcium sulfate-bonded investment material is applied as a coating to the wax pattern. The coated wax pattern is then dried, followed by curing to vaporize the wax pattern and leave a shell

  9. Numerical simulation of the interface molten metal air in the shot sleeve chambre and mold cavity of a die casting machine

    NASA Astrophysics Data System (ADS)

    Korti, Abdel Illah Nabil; Abboudi, Said

    2011-11-01

    The objective of this study relates to the numerical simulation of the free surface during the two-dimensional flow and solidification of aluminum in the horizontal cylinder and mold cavity of the high pressure die casting HPDC machine with cold chamber. The flow is governed by the Navier-Stokes equations (the mass and the momentum conservations) and solved in the two phase's liquid aluminum and air. The tracking of the free surface is ensured by the VOF method. The equivalent specific heat method is used to solve the phase change heat transfer problem in the solidification process. Considering the displacement of the plunger, the geometry of the problem is variable and the numerical resolution uses a dynamic grid. The study examines the influence of the plunger speed on the evolution of the interface aluminum liquid-air profile, the mass of air imprisoned and the stream function contours versus time. Filling of a mold is an essential part of HPDC process and affects significantly the heat transfer and solidification of the melt. For this reason, accurate prediction of the temperature field in the system can be achieved only by including simulation of filling in the analysis.

  10. Commercialization of NASA's High Strength Cast Aluminum Alloy for High Temperature Applications

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A.

    2003-01-01

    In this paper, the commercialization of a new high strength cast aluminum alloy, invented by NASA-Marshall Space Flight Center, for high temperature applications will be presented. Originally developed to meet U.S. automotive legislation requiring low- exhaust emission, the novel NASA aluminum alloy offers dramatic improvement in tensile and fatigue strengths at elevated temperatures (450 F-750 F), which can lead to reducing part weight and cost as well as improving performance for automotive engine applications. It is an ideal low cost material for cast components such as pistons, cylinder heads, cylinder liners, connecting rods, turbo chargers, impellers, actuators, brake calipers and rotors. NASA alloy also offers greater wear resistance, dimensional stability, and lower thermal expansion compared to conventional aluminum alloys, and the new alloy can be produced economically from sand, permanent mold and investment casting. Since 2001, this technology was licensed to several companies for automotive and marine internal combustion engines applications.

  11. The application of cast SiC/Al to rotary engine components

    NASA Technical Reports Server (NTRS)

    Stoller, H. M.; Carluccio, J. R.; Norman, J. P.

    1986-01-01

    A silicon carbide reinforced aluminum (SiC/Al) material fabricated by Dural Aluminum Composites Corporation was tested for various components of rotary engines. Properties investigated included hardness, high temperature strength, wear resistance, fatigue resistance, thermal conductivity, and expansion. SiC/Al appears to be a viable candidate for cast rotors, and may be applicable to other components, primarily housings.

  12. 40 CFR 420.60 - Applicability; description of the continuous casting subcategory.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... 40 Protection of Environment 28 2010-07-01 2010-07-01 true Applicability; description of the continuous casting subcategory. 420.60 Section 420.60 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS IRON AND STEEL MANUFACTURING POINT SOURCE...

  13. Cast CF8C-Plus Stainless Steel for Turbocharger Applications

    SciTech Connect

    Maziasz, P.J.; Shyam, A.; Evans, N.D.; Pattabiraman, K. (Honeywell Turbo Technologies

    2010-06-30

    The purpose of this Cooperative Research and Development Agreement (CRADA) project is to provide the critical test data needed to qualify CF8C-Plus cast stainless steel for commercial production and use for turbocharger housings with upgraded performance and durability relative to standard commercial cast irons or stainless steels. The turbocharger technologies include, but are not limited to, heavy-duty highway diesel engines, and passenger vehicle diesel and gasoline engines. This CRADA provides additional critical high-temperature mechanical properties testing and data analysis needed to quality the new CF8C-Plus steels for turbocharger housing applications.

  14. Feasibility Assessment for Pressure Casting of Ceramic-Aluminum Composites for NASA's Propulsion Applications

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A.

    2005-01-01

    Feasibility assessment of pressure casting of ceramic-aluminum composites for NASA% propulsion applications is summarized. A combination of several demonstration projects to produce three unique components for liquid hydrogen-oxygen rocket engine% flanges, valves and turbo-pump housing are conducted. These components are made from boron carbide, silicon carbide and alumina powders fabricated into complex net shaped parts using dry green powder compaction, slip casting or a novel 3D ink-jet printing process, followed by sintering to produce performs that can be pressure cast by infiltration with molten aluminum. I n addition, joining techniques are also explored to insure that these components can be assembled into a structure without degrading their highly tailored properties. The feasibility assessment was made to determine if these new materials could provide a significant weight savings, thereby reducing vehicle launch costs, while being durable materials to increase safety and performance for propulsion system.

  15. Cast Aluminum Alloys for High Temperature Applications Using Nanoparticles Al2O3 and Al3-X Compounds (X = Ti, V, Zr)

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A.

    2009-01-01

    In this paper, the effect of nanoparticles Al2O3 and Al3-X compounds (X = Ti, V, Zr) on the improvement of mechanical properties of aluminum alloys for elevated temperature applications is presented. These nanoparticles were selected based on their low cost, chemical stability and low diffusions rates in aluminum at high temperatures. The strengthening mechanism at high temperature for aluminum alloy is based on the mechanical blocking of dislocation movements by these nanoparticles. For Al2O3 nanoparticles, the test samples were prepared from special Al2O3 preforms, which were produced using ceramic injection molding process and then pressure infiltrated by molten aluminum. In another method, Al2O3 nanoparticles can also be homogeneously mixed with fine aluminum powder and consolidated into test samples through hot pressing and sintering. With the Al3-X nanoparticles, the test samples are produced as precipitates from in-situ reactions with molten aluminum using conventional permanent mold or die casting techniques. It is found that cast aluminum alloy using nanoparticles Al3-X is the most cost effective method to produce high strength aluminum alloys for high temperature applications in comparison to nanoparticles Al2O3. Furthermore, significant mechanical properties retention in high temperature environment could be achieved with Al3-X nanoparticles, resulting in tensile strength of nearly 3 times higher than most 300- series conventional cast aluminum alloys tested at 600 F.

  16. 43 CFR 3202.13 - What happens if the applicant dies before the lease is issued?

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 43 Public Lands: Interior 2 2014-10-01 2014-10-01 false What happens if the applicant dies before the lease is issued? 3202.13 Section 3202.13 Public Lands: Interior Regulations Relating to Public Lands (Continued) BUREAU OF LAND MANAGEMENT, DEPARTMENT OF THE INTERIOR MINERALS MANAGEMENT (3000) GEOTHERMAL RESOURCE LEASING Lessee Qualifications...

  17. Ni3Al-based alloys for die and tool application

    DOEpatents

    Liu, Chain T.; Bloom, Everett E.

    2001-01-01

    A novel Ni.sub.3 Al-based alloy exhibits strengths and hardness in excess of the standard base alloy IC-221M at temperatures of up to about 1000.degree. C. The alloy is useful in tool and die applications requiring such temperatures, and for structural elements in engineering systems exposed to such temperatures.

  18. Matched metal die compression molded structural random fiber sheet molding compound flywheel. [Patent application

    DOEpatents

    Kulkarni, S.V.; Christensen, R.M.; Toland, R.H.

    1980-09-24

    A flywheel is described that is useful for energy storage in a hybrid vehicle automotive power system or in some stationary applications. The flywheel has a body of essentially planar isotropic high strength structural random fiber sheet molding compound (SMC-R). The flywheel may be economically produced by a matched metal die compression molding process. The flywheel makes energy intensive efficient use of a fiber/resin composite while having a shape designed by theory assuming planar isotropy.

  19. Compaction die for forming a solid annulus on a right circular cylinder. [Patent application

    DOEpatents

    Harlow, J.L.

    1981-09-14

    A compacting die is disclosed wherein the improvement comprises providing a screen in the die cavity, the screen being positioned parallel to the side walls of said die and dividing the die cavity into center and annular compartments. In addition, the use of this die in a method for producing an annular clad ceramic fuel material is disclosed.

  20. Urinary casts

    MedlinePlus

    ... the urine; Fatty casts; Red blood cell casts; White blood cell casts ... with advanced kidney disease and chronic kidney failure . White blood cell (WBC) casts are more common with acute kidney ...

  1. Cryogenic Fracture Toughness Evaluation of an Investment Cast Al-Be Alloy for Structural Applications

    NASA Technical Reports Server (NTRS)

    Gamwell, W. R.; McGill, P. B.

    2006-01-01

    Aluminum-Beryllium metal matrix composite materials are useful due to their desirable performance characteristics for aerospace applications. Desirable characteristics of this material includes light-weight, dimensional stability, stiffness, good vibration damping characteristics, low coefficient of thermal expansion, and workability, This material is 3.5 times stiffer and 22% lighter than conventional aluminum alloys. electro-optical systems, advanced sensor and guidance components for flight and satellite systems, components for light-weight high-performance aircraft engines, and structural components for helicopters. Aluminum-beryllium materials are now available in the form of near net shape investment castings. In this materials properties characterization study, the cryogenic tensile and fracture properties of an investment casting alloy, Beralcast 363, were determined. Tensile testing was performed at 21 C (70 F), -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F), and fracture (K(sub lc) and da/dN) testing was performed at -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F). Their use is attractive for weight critical structural applications such as advanced

  2. Contactless inductive flow tomography: basic principles and first applications in the experimental modelling of continuous casting

    NASA Astrophysics Data System (ADS)

    Stefani, F.; Eckert, S.; Ratajczak, M.; Timmel, K.; Wondrak, T.

    2016-07-01

    Contactless inductive flow tomography (CIFT) aims at reconstructing the flow structure of a liquid metal from the magnetic fields measured at various positions outside the fluid body which are induced by the flow under the influence of one or multiple applied magnetic fields. We recap the basic mathematical principles of CIFT and the results of an experiment in which the propeller-driven three-dimensional flow in a cylindrical had been reconstructed. We also summarize the recent activities to utilize CIFT in various problems connected with the experimental simulation of the continuous casting process. These include flow reconstructions in single-phase and two-phase flow problems in the Mini-LIMMCAST model of slab-casting, studies of the specific effects of an electromagnetic stirrer attached to the Submerged Entry Nozzle (SEN), as well as first successful applications of CIFT on the background of a strong electromagnetic brake field. We conclude by discussing some remaining obstacles for the deployment of CIFT in a real caster.

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

    SciTech Connect

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

    1996-06-01

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

  4. Laser assisted die bending: a new application of high power diode lasers

    NASA Astrophysics Data System (ADS)

    Schuöcker, D.; Schumi, T.; Spitzer, O.; Bammer, F.; Schuöcker, G.; Sperrer, G.

    2015-02-01

    Nowadays high power lasers are mainly used for cutting of sheet metals, for welding, hardening and rapid prototyping. In the forming of sheet metals as bending or deep drawing lasers are not used. Nevertheless a few years ago a new application of high power lasers has been invented, where bending of materials that break at room temperature becomes possible by heating them along the bending edge with high power lasers thus allowing their treatment without cracks and rupture. For this purpose a large number of diode lasers are arranged in the bottom tool of a bending machine (a V-shaped die) which heat up the initially flat sheet metal during the bending process what is performed by pressing it into the die with a knife shaped upper tool where due to the laser heating the material is softened and thus cracks are avoided. For the technical realization of the new process of laser assisted die bending, modules equipped with numerous laser diodes and a total beam power of 2,5 kW are used. The light emitted by these modules enters a tool with a length of 15cm and is deflected towards the workpiece. By using ten of these modules with adjacent dies and by integrating those in a bending press a bending edge of sheet metals with a length of 1500mm can be realized. Such a bending press with laser assistance also needs energization with a power of practically 50kW, a respective water flow, a heat exchanger system and also a control for all functions of this system. Special measures have also been developed to avoid radiating of those tools that are not covered by a workpiece in the case of bending edges shorter than the full length of the bending tools whereas individual short circuiting of diode modules can be performed. Specific measures to ensure a safe operation without any harm to the operational person have been realized. Exploitation of the bending process has been carried out for titanium, where material thicknesses up to 3mm have been bent successfully.

  5. 40 CFR 466.20 - Applicability; description of the cast iron basis material subcategory.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS (CONTINUED) PORCELAIN ENAMELING POINT SOURCE... of pollutants into publicly owned treatment works from porcelain enameling of cast iron...

  6. 40 CFR 466.20 - Applicability; description of the cast iron basis material subcategory.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS (CONTINUED) PORCELAIN ENAMELING POINT SOURCE... of pollutants into publicly owned treatment works from porcelain enameling of cast iron...

  7. 40 CFR 466.20 - Applicability; description of the cast iron basis material subcategory.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS (CONTINUED) PORCELAIN ENAMELING POINT SOURCE... of pollutants into publicly owned treatment works from porcelain enameling of cast iron...

  8. The improvement of aluminium casting process control by application of the new CRIMSON process

    NASA Astrophysics Data System (ADS)

    Dai, X.; Jolly, M.; Zeng, B.

    2012-07-01

    All The traditional foundry usually not only uses batch melting where the aluminium alloys are melted and held in a furnace for long time, but also uses the gravity filling method in both Sand Casting Process (SCP) and Investment Casting Process (ICP). In the gravity filling operation, the turbulent behaviour of the liquid metal causes substantial entrainment of the surface oxide films which are subsequently trapped into the liquid and generate micro cracks and casting defects. In this paper a new CRIMSON process is introduced which features instead of gravity filling method, using the single shot up-casting method to realize the rapid melting and rapid filling mould operations which reduce the contact time between the melt and environment thus reducing the possibility of defect generation. Another advantage of the new process is the drastic reduction of energy consumption due to shortened melting and filling time. Two types of casting samples from SCP and ICP were compared with the new process. The commercial software was used to simulate the filling and solidification processes of the casting samples. The results show that the new process has a more improved behaviour during filling a mould and solidification than the two conventional casting processes.

  9. Low-gravity solidification of cast iron and space technology applications

    NASA Technical Reports Server (NTRS)

    Graham, J. A.

    1984-01-01

    Two types of analyses relating to cast iron solidification were conducted. A theoretical analysis using a computer to predict the cooling versus time relationship throughout the test specimen was performed. Tests were also conducted in a ground-based laboratory to generate a cooling time curve for cast iron. In addition, cast iron was cooled through the solidification period on a KC-135 and an F-104 aircraft while these aircraft were going through a period of low gravity. Future subjects for low gravity tests are enumerated.

  10. Application of Internal Fusible Chills in Thick-Walled Castings Made of EN-GJS with an Optimized Microstructure

    NASA Astrophysics Data System (ADS)

    Krupa, Wojciech; Tonn, Babette

    2011-01-01

    permanent moulds using fusible cooling plates at Gontermann-Peipers GmbH. Homogenous microstructures as well as higher mechanical properties were achieved. This new method shows good perspectives for further applications in composite casting technologies.

  11. [Application of analytical pyrolysis in air pollution control for green sand casting industry].

    PubMed

    Wang, Yu-jue; Zhao, Qi; Chen, Ying; Wang, Cheng-wen

    2010-02-01

    Analytic pyrolysis was conducted to simulate the heating conditions that the raw materials of green sand would experience during metal casting process. The volatile organic compound (VOC) and hazardous air pollutant (HAP) emissions from analytical pyrolysis were analyzed by gas chromatograph-flame ionization detector/mass spectrometry (GC-FID/MS). The emissions from analytical pyrolysis exhibited some similarity in the compositions and distributions with those from actual casting processes. The major compositions of the emissions included benzene, toluene and phenol. The relative changes of emission levels that were observed in analytical pyrolysis of the various raw materials also showed similar trends with those observed in actual metal casting processes. The emission testing results of both analytic pyrolysis and pre-production foundry have shown that compared to the conventional phenolic urethane binder, the new non-naphthalene phenolic urethane binder diminished more than 50% of polycyclic aromatic hydrocarbon emissions, and the protein-based binder diminished more than 90% of HAP emissions. The similar trends in the two sets of tests offered promise that analytical pyrolysis techniques could be a fast and accurate way to establish the emission inventories, and to evaluate the relative emission levels of various raw materials of casting industry. The results of analytical pyrolysis could provide useful guides for the foundries to select and develop proper clean raw materials for the casting production. PMID:20391731

  12. Drop-casted polyaniline thin films on flexible substrates for supercapacitor applications

    NASA Astrophysics Data System (ADS)

    Kim, Jongmin; Sohn, J.; Jo, Yongcheol; Woo, Hyeonseok; Han, Jaeseok; Cho, Sangeun; Inamdar, A. I.; Kim, Hyungsang; Im, Hyunsik

    2014-11-01

    The PANI (polyaniline) thin films are synthesized on flexible ITO/PET (indium tin oxide/polyethylene terephthalate) substrates by using the drop-casting method. The amount of the PANI for the drop casting varies from 0.04 to 0.16 g. The morphology of the drop-casted PANI films shows a porous vermicular shape. The electrochemical supercapacitor properties of the PANI films are examined in a 0.5-M LiClO4 + PC electrolyte. The PANI films with 0.08 g of PANI show higher current density and considerably higher specific capacitance and capacity retention, compared with other PANI films. The highest specific capacitance of the films with 0.08 g of PANI is found to be ˜120 F/g, and the capacity retention is found to be as high as 70.51% after 100 charge-discharge cycles.

  13. Sensitivity comparison of fast integrated die-to-die T+R pattern inspection, standard database inspection, and STARlight2 contamination mode for application in mask production

    NASA Astrophysics Data System (ADS)

    Schmalfuss, Heiko; Schulmeyer, Thomas; Heumann, Jan; Lang, Michael; Sier, Jean-Paul

    2007-10-01

    'Fast Integrated Die-to-Die T+R' pattern inspection (DDTR), reflected tritone database inspection (DBRt) and STARlight2 TM (SL2) contamination inspection are employed by mask makers in order to detect pattern defects and contamination defects on photomasks for in process inspection steps. In this paper we compare the detection capabilities of these modes on real production masks with a representative set of contamination and pattern defects. Currently, SL2 inspection is used to find contamination defects and die-to-die and die-to-database are used for pattern defects. In this paper we will show that the new introduced 'Fast Integrated Die-to-Die T+R' pattern inspection (DDTR)1 in combination with the DBRt can be used in production environment, instead of SL2 without any loss in the sensitivity. During the study, we collected and analyzed inspection data on critical layers such as lines & spaces and contact holes. Besides, performance of the modes on product plates characterization was done using a test mask with programmed defects.

  14. Attitudes of elderly Korean patients toward death and dying: an application of Q-methodology.

    PubMed

    Yeun, Eunja

    2005-11-01

    The aim of this study was to identify the attitudes of elderly Korean patients toward death and dying using Q-methodology to aid in the development of basic strategies for nursing care of elderly Koreans. Thirty participants at a university hospital sorted 40 selected Q-statements on a nine-point scale. Data analysis identified three types of attitudes toward death and dying in elderly patients in Korea: religion-dependent, science-adherent, and sardonic. Religion-dependent elders are highly dependent upon religion as evidenced by their reply that they would like to rely on God and a minister the most. Science-adherent elders have great affection for life and believe in modern medical advancements. The sardonic elders regard death as the dispensation of nature so there is no need to be afraid of death and dying. This study will contribute to the understanding that nurses and other health professionals have of the perceptions of elderly Koreans about death and dying. Also, the findings may provide the basis for the development of more appropriate strategies to improve death and dying education programs of health professionals.

  15. Application of the Billet Casting Method to Determine the Onset of Incipient Melting of 319 Al Alloy Engine Blocks

    NASA Astrophysics Data System (ADS)

    Lombardi, A.; Ravindran, C.; MacKay, R.

    2015-06-01

    The increased use of Al for automotive applications has resulted from the need to improve vehicle fuel efficiency. Aluminum alloy engine blocks fulfil the need of lightweighting. However, there are many challenges associated with thermo-mechanical mismatch between Al and the gray cast iron cylinder liners, which result in large tensile residual stress along the cylinder bores. This requires improced mechanical properties in this region to prevent premature engine failure. In this study, replicating billet castings were used to simulate the engine block solution heat treatment process and determine the onset of incipient melting. Microstructural changes during heat treatment were assessed with SEM and EDX, while thermal analysis was carried out using differential scanning calorimetry. The results suggest that solution heat treatment at 500 °C was effective in dissolving secondary phase particles, while solutionizing at 515 or 530 °C caused incipient melting of Al2Cu and Al5Mg8Cu2Si6. Incipient melting caused the formation ultra-fine eutectic clusters consisting of Al, Al2Cu, and Al5Mg8Cu2Si6 on quenching. In addition, DSC analysis found that incipient melting initiated at 507 °C for all billets, although the quantity of local melting reduced with microstructural refinement as evidenced by smaller endothermic peaks and energy absorption. The results from this study will assist in improving engine block casting integrity and process efficiency.

  16. Overview of the ToxCast Research Program: Applications to Predictive Toxicology and Chemical Prioritization

    EPA Science Inventory

    EPA’s ToxCast program, the NTP’s HTS initiative, and the NCGC’s Molecular Libraries Initiative into a collaborative research program focused on identifying toxicity pathways and developing in vitro assays to characterize the ability of chemicals to perturb those pathways. The go...

  17. The Second Phase of ToxCast and Initial Applications to Chemical Prioritization

    EPA Science Inventory

    Tens of thousands of chemicals and other contaminants exist in our environment, but only a fraction of these have been characterized for their potential hazard to humans. ToxCast is focused on closing this data gap and improving the management of chemical risk through a high thro...

  18. Overview of the ToxCast Research Program: Applications to Predictive Toxicology and Chemical Prioritization (SETAC)

    EPA Science Inventory

    Understanding the potential health risks posed by environmental chemicals is a significant challenge driven by the large number of diverse chemicals with generally uncharacterized exposures, mechanisms and toxicities. The U.S. EPA’s ToxCast chemical prioritization research projec...

  19. 43 CFR 3502.40 - What happens if an applicant or successful bidder for a permit or lease dies before the permit or...

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 43 Public Lands: Interior 2 2014-10-01 2014-10-01 false What happens if an applicant or successful bidder for a permit or lease dies before the permit or lease is issued? 3502.40 Section 3502.40 Public... successful bidder for a permit or lease dies before the permit or lease is issued? (a) If probate of...

  20. 43 CFR 3502.40 - What happens if an applicant or successful bidder for a permit or lease dies before the permit or...

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 43 Public Lands: Interior 2 2012-10-01 2012-10-01 false What happens if an applicant or successful bidder for a permit or lease dies before the permit or lease is issued? 3502.40 Section 3502.40 Public... successful bidder for a permit or lease dies before the permit or lease is issued? (a) If probate of...

  1. 43 CFR 3502.40 - What happens if an applicant or successful bidder for a permit or lease dies before the permit or...

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 43 Public Lands: Interior 2 2013-10-01 2013-10-01 false What happens if an applicant or successful bidder for a permit or lease dies before the permit or lease is issued? 3502.40 Section 3502.40 Public... successful bidder for a permit or lease dies before the permit or lease is issued? (a) If probate of...

  2. 43 CFR 3502.40 - What happens if an applicant or successful bidder for a permit or lease dies before the permit or...

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 43 Public Lands: Interior 2 2011-10-01 2011-10-01 false What happens if an applicant or successful bidder for a permit or lease dies before the permit or lease is issued? 3502.40 Section 3502.40 Public... successful bidder for a permit or lease dies before the permit or lease is issued? (a) If probate of...

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

    NASA Astrophysics Data System (ADS)

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

    2014-09-01

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

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

    SciTech Connect

    David Schwam; John F. Wallace; Quanyou Zhou

    2002-01-30

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

  5. 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. PMID:6846144

  6. Microstructure and Corrosion Characterization of Squeeze Cast AM50 Magnesium Alloys

    NASA Astrophysics Data System (ADS)

    Sachdeva, Deepika; Tiwari, Shashank; Sundarraj, Suresh; Luo, Alan A.

    2010-12-01

    Squeeze casting of magnesium alloys potentially can be used in lightweight chassis components such as control arms and knuckles. This study documents the microstructural analysis and corrosion behavior of AM50 alloys squeeze cast at different pressures between 40 and 120 MPa and compares them with high-pressure die cast (HPDC) AM50 alloy castings and an AM50 squeeze cast prototype control arm. Although the corrosion rates of the squeeze cast samples are slightly higher than those observed for the HPDC AM50 alloy, the former does produce virtually porosity-free castings that are required for structural applications like control arms and wheels. This outcome is extremely encouraging as it provides an opportunity for additional alloy and process development by squeeze casting that has remained relatively unexplored for magnesium alloys compared with aluminum. Among the microstructural parameters analyzed, it seems that the β-phase interfacial area, indicating a greater degree of β network, leads to a lower corrosion rate. Weight loss was the better method for determining corrosion behavior in these alloys that contain a large fraction of second phase, which can cause perturbations to an overall uniform surface corrosion behavior.

  7. Thermal investigation of compound cast steel tools

    NASA Astrophysics Data System (ADS)

    Schaper, Mirko; Haferkamp, Heinz; Niemeyer, Matthias; Pelz, Christoph; Viets, Roman

    1999-03-01

    Tools for hot forging are exposed to complex stresses during their life-cycle. Therefore, forging dies should have a high wear resistance and toughness on the surface, combined with excellent thermal conductivity in the die body. Hot-work tool steel is appropriate for this application except from its thermal conductance. Hence, a tool consisting of hot-work tool steel in the area of contact and heat-treatable steel as die body is favorable. A smoothly graded microstructure in the joint zone between the two steel alloys is needed to match with the requirements. Fabrication of such functionally graded dies by sand casting exhibits high sensitivity to temperature and geometry dependent parameters. To melt on the inlay's surface must be ensured without destroying this region according to overheat coarsening and mixing of alloying elements. Instead of empirical methods to optimize the process parameters, a thermographic CCD-device is used for visualization of the heat flow while pouring the melt on the inlay. In fact the molten metal flow can be directed homogeneously across the bonding surface at adequate temperatures after evaluation of thermography data. The use of a silica-aerogel sheet as opaque window beneath the inlay in the mold enables systematic development of gating and risering, whereas undesirable scaling of the inlay due to the change of emissivity is retarded. Infrared image sequences clearly demonstrate the influence of different ring gating systems concerning the filling properties. Non-joined cavities may even be classified from image data. Compound cast steel tools have been manufactured and examined in forging trials validating life-cycle prolongation.

  8. Processing of Advanced Cast Alloys for A-USC Steam Turbine Applications

    NASA Astrophysics Data System (ADS)

    Jablonski, Paul D.; Hawk, Jeffery A.; Cowen, Christopher J.; Maziasz, Philip J.

    2012-02-01

    The high-temperature components within conventional supercritical coal-fired power plants are manufactured from ferritic/martensitic steels. To reduce greenhouse-gas emissions, the efficiency of pulverized coal steam power plants must be increased to as high a temperature and pressure as feasible. The proposed steam temperature in the DOE/NETL Advanced Ultra Supercritical power plant is high enough (760°C) that ferritic/martensitic steels will not work for the majority of high-temperature components in the turbine or for pipes and tubes in the boiler due to temperature limitations of this class of materials. Thus, Ni-based superalloys are being considered for many of these components. Off-the-shelf forged nickel alloys have shown good promise at these temperatures, but further improvements can be made through experimentation within the nominal chemistry range as well as through thermomechanical processing and subsequent heat treatment. However, cast nickel-based superalloys, which possess high strength, creep resistance, and weldability, are typically not available, particularly those with good ductility and toughness that are weldable in thick sections. To address those issues related to thick casting for turbine casings, for example, cast analogs of selected wrought nickel-based superalloys such as alloy 263, Haynes 282, and Nimonic 105 have been produced. Alloy design criteria, melt processing experiences, and heat treatment are discussed with respect to the as-processed and heat-treated microstructures and selected mechanical properties. The discussion concludes with the prospects for full-scale development of a thick section casting for a steam turbine valve chest or rotor casing.

  9. Low Frequency Phased Array Application for Crack Detection in Cast Austenitic Piping

    SciTech Connect

    Anderson, Michael T.; Cumblidge, Stephen E.; Doctor, Steven R.

    2006-10-01

    As part of a multi-year program funded by the United States Nuclear Regulatory Commission (US NRC) to address nondestructive examination (NDE) reliability of inservice inspection (ISI) programs, studies conducted at the Pacific N¬orthwest National Laboratory (PNNL) in Richland, Washington, have focused on assessing novel NDE approaches for the inspection of coarse-grained, cast stainless steel reactor components. The primary objective of this work is to provide information to the US NRC on the utility, effec¬tiveness and reliability of ultrasonic testing (UT) as related to the ISI of primary piping components in US commercial nuclear power plants. This paper describes progress, recent developments and results from an assessment of a portion of the work relating to the ultrasonic low frequency phased array inspection technique. Westinghouse Owner’s Group (WOG) cast stainless steel pipe segments with thermal and mechanical fatigue cracks, PNNL samples containing thermal fatigue cracks and several blank vintage specimens having very coarse grains that are representative of early centrifugally cast piping installed in PWRs, were used for assessing the inspection method. The phased array approach was implemented using an R/D Tech Tomoscan III system operating at 1.0 MHz and 500 kHz, providing composite volumetric images of the samples. Several dual, transmit-receive, custom designed low-frequency arrays were employed in laboratory trials. Results from laboratory studies for assessing detection, localization and length sizing effectiveness are discussed.

  10. Effect of Titanium on the Mechanical Properties and Microstructure of Gray Cast Iron for Automotive Applications

    NASA Astrophysics Data System (ADS)

    Gelfi, M.; Gorini, D.; Pola, A.; La Vecchia, G. M.

    2016-07-01

    Lamellar gray cast iron, with a mainly pearlitic microstructure, is widely used in the automotive industry, mostly in the manufacturing of brake disks. This work analyzes in depth the effects of small variations of titanium content on the microstructure and mechanical properties of cast iron brake disks. For this purpose, eight different heats of EN-GJL-250 cast iron were selected, with a similar chemical composition but with different titanium contents, varying from 0.013 to 0.031%. The drops in mechanical strength and hardness values measured on the high-Ti samples were correlated to microstructural variations quantitatively observed by means of optical and scanning electron microscope. It was found that titanium combines to form titanium nitrides, suppressing the beneficial microstructural effects of nitrogen at solidification. Residual nitrogen, if present in sufficient quantity, promotes the nucleation of primary austenite from the liquid and the formation of a fine microstructure, with small eutectic cells and lower graphite content. Such a microstructure provides brake disks with better mechanical properties. The interpretation of results was further supported by thermal analysis and thermodynamic calculations.

  11. Effect of Titanium on the Mechanical Properties and Microstructure of Gray Cast Iron for Automotive Applications

    NASA Astrophysics Data System (ADS)

    Gelfi, M.; Gorini, D.; Pola, A.; La Vecchia, G. M.

    2016-09-01

    Lamellar gray cast iron, with a mainly pearlitic microstructure, is widely used in the automotive industry, mostly in the manufacturing of brake disks. This work analyzes in depth the effects of small variations of titanium content on the microstructure and mechanical properties of cast iron brake disks. For this purpose, eight different heats of EN-GJL-250 cast iron were selected, with a similar chemical composition but with different titanium contents, varying from 0.013 to 0.031%. The drops in mechanical strength and hardness values measured on the high-Ti samples were correlated to microstructural variations quantitatively observed by means of optical and scanning electron microscope. It was found that titanium combines to form titanium nitrides, suppressing the beneficial microstructural effects of nitrogen at solidification. Residual nitrogen, if present in sufficient quantity, promotes the nucleation of primary austenite from the liquid and the formation of a fine microstructure, with small eutectic cells and lower graphite content. Such a microstructure provides brake disks with better mechanical properties. The interpretation of results was further supported by thermal analysis and thermodynamic calculations.

  12. PREFACE: International Conference on Advancement in Science and Technology 2012 (iCAST): Contemporary Mathematics, Mathematical Physics and their Applications

    NASA Astrophysics Data System (ADS)

    Ganikhodjaev, Nasir; Mukhamedov, Farrukh; Hee, Pah Chin

    2013-04-01

    The 4th International Conference on the Advancement of Science and Technology 2012 (iCAST 2012), with theme 'Contemporary Mathematics, Mathematical Physics and their Applications', took place in Kuantan, Malaysia, from Wednesday 7 to Friday 9 November 2012. The conference was attended by more than 100 participants, and hosted about 160 oral and poster papers by more than 140 pre-registered authors. The key topics of the 4th iCAST 2012 include Pure Mathematics, Applied Mathematics, Theoretical/Mathematical Physics, Dynamical Systems, Statistics and Financial Mathematics. The scientific program was rather full since after the Keynote and Invited Talks in the morning, four parallel sessions ran every day. However, according to all attendees, the program was excellent with a high level of talks and the scientific environment was fruitful; thus all attendees had a creative time. The conference aimed to promote the knowledge and development of high-quality research in mathematical fields concerned with the application of other scientific fields as well as modern technological trends in physics, chemistry, biology, medicine, economics, sociology and environmental sciences. We would like to thank the Keynote and the Invited Speakers for their significant contributions to 4th iCAST 2012. We would also like to thank the members of the International Scientific Committee and the members of the Organizing Committee. We cannot end without expressing our many thanks to International Islamic University Malaysia and our sponsors for their financial support . This volume presents selected papers which have been peer-reviewed. The editors hope that it may be useful and fruitful for scholars, researchers, and advanced technical members of the industrial laboratory facilities for developing new tools and products. Guest Editors Nasir Ganikhodjaev, Farrukh Mukhamedov and Pah Chin Hee The PDF contains the committee lists, board list and biographies of the plenary speakers.

  13. 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.

  14. Initial billet and forging dies shape optimization: Application on an axisymetrical forging with a hammer

    NASA Astrophysics Data System (ADS)

    Meng, Fanjuan; Labergere, Carl; Lafon, Pascal

    2011-05-01

    In metal forming process, the forging die design is the most important step for products quality control. Reasonable dies shape can not only reduce raw material cost but also improving material flow and eliminating defects. The main objective of this paper is to obtain some optimal parameters of the initial billet and forging dies shape according to the simulation results of a two-step metal forming process (platting step and forging step). To develop this metal forming process optimization system several numerical tools are required: geometric modelling (CATIA V5™), FEM analysis (ABAQUS®), work-flow control and optimization computation (MODEFRONTIER®). This study is done in three stages: simulating the two-step metal forming process, building surrogate meta-models to relate response and variables and optimizing the process by using advanced optimization algorithms. In this paper, a two-step axisymmetric metal forming project was studied as an example. By using our simulation model, we get 581 correct real simulation results totally. According to all these real values, we build the surrogate meta-models and obtain Pareto points for a two-objective optimization process. The choice of a solution in all Pareto points will be done by the engineer who can choose his best values according to their criterions of project.

  15. Application of the cost-per-good-die metric for process design co-optimization

    NASA Astrophysics Data System (ADS)

    Jhaveri, Tejas; Arslan, Umut; Rovner, Vyacheslav; Strojwas, Andrzej; Pileggi, Larry

    2010-03-01

    The semiconductor industry has pursued a rapid pace of technology scaling to achieve an exponential component cost reduction. Over the years the goal of technology scaling has been distilled down to two discrete targets. Process engineers focus on sustaining wafer costs, while manufacturing smaller dimensions whereas design engineers work towards creating newer IC designs that can feed the next generation of electronic products. In doing so, the impact of process choices made by manufacturing community on the design of ICs and vice-versa were conveniently ignored. Hoever, with the lack of cost effective lithography solutions at the forefront, the process and design communities are struggling to minimize IC die costs by following the described traditional scaling practices. In this paper we discuss a framework for quantifying the economic impact of design and process decisions on the overall product by comparing the cost-per-good-die. We discuss the intricacies involved in computing the cost-per-good-die as we make design and technology choices. We also discuss the impact of design and lithography choices for the 32nm and 22nm technology node. The results demonstrate a strong volume dependence on the optimum design style and corresponding lithography and strategy. Most importantly, using this framework process and design engineers can collaborate to define design style and lithography solutions that will lead to continued IC cost scaling.

  16. Application of statistical methods for analyzing the relationship between casting distortion, mold filling, and interfacial heat transfer in sand molds

    SciTech Connect

    Y. A. Owusu

    1999-03-31

    This report presents a statistical method of evaluating geometric tolerances of casting products using point cloud data generated by coordinate measuring machine (CMM) process. The focus of this report is to present a statistical-based approach to evaluate the differences in dimensional and form variations or tolerances of casting products as affected by casting gating system, molding material, casting thickness, and casting orientation at the mold-metal interface. Form parameters such as flatness, parallelism, and other geometric profiles such as angularity, casting length, and height of casting products were obtained and analyzed from CMM point cloud data. In order to relate the dimensional and form errors to the factors under consideration such as flatness and parallelism, a factorial analysis of variance and statistical test means methods were performed to identify the factors that contributed to the casting distortion at the mold-metal interface.

  17. SPHERICAL DIE

    DOEpatents

    Livingston, J.P.

    1959-01-27

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

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

    SciTech Connect

    Nick Cannell; Adrian S. Sabau

    2005-09-30

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

  19. Melting and casting of FeAl-based cast alloy

    SciTech Connect

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

    1998-11-01

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

  20. Micromechanical die attachment surcharge

    DOEpatents

    Filter, William F.; Hohimer, John P.

    2002-01-01

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

  1. The application of integrated computational material engineering (ICME) in metal castings simulation

    NASA Astrophysics Data System (ADS)

    Guo, Jianzheng; Cao, Weisheng; Samonds, Mark

    2012-07-01

    Integrated Computational Materials Engineering (ICME) is emerging as a methodology for developing advanced materials, manufacturing processing, and engineering components in a faster and more cost effective way. For casting processes, ICME involves many physical phenomena such as thermodynamics, heat transfer, fluid flow, stress, defect formation, microstructure evaluation, and thermophysical and mechanical properties. In this paper, the integration of thermodynamic calculations, thermophysical and mechanical property predictions, and the prediction of microstructure and defects during solidification and heat treatment will be presented. Such integration is helpful to understand the effects of alloy chemistry and processing conditions, and their relationship to microstructure, defect formation, and the final mechanical properties from solidification to heat treatment. Eventually the alloy chemistry and processing parameters can be optimized with the help of the integrated computational modelling.

  2. Magnesium for automotive applications

    SciTech Connect

    VanFleteren, R.

    1996-05-01

    Die cast magnesium parts are rapidly replacing steel and aluminum structural components in automotive applications, as design engineers seek to reduce assembly costs, raise fuel efficiency, and improve safety. Dozens of automotive components are now die cast from magnesium alloys, including seat stanchions, valve covers, steering wheels, and a variety of steering column components. Because of their excellent castability, complex magnesium die castings can sometimes consolidate several components and eliminate assembly steps. Highly ductile magnesium alloys such as AM60B (6% aluminum) and AM50A (5% aluminum) are important in helping to meet automotive industry crash-energy requirements for car seating and steering components. AZ91D (9% aluminum, 1% zinc) alloys are making removable rear seats in new minivans much easier to handle.

  3. Pigmented casts.

    PubMed

    Miteva, Mariya; Romanelli, Paolo; Tosti, Antonella

    2014-01-01

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

  4. Rapid Tooling via Investment Casting and Rapid Prototype Patterns

    SciTech Connect

    Baldwin, Michael D.

    1999-06-01

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

  5. High density tape casting system

    NASA Technical Reports Server (NTRS)

    Collins, Earl R., Jr. (Inventor)

    1989-01-01

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

  6. ShakeCast Manual

    USGS Publications Warehouse

    Lin, Kuo-Wan; Wald, David J.

    2008-01-01

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

  7. Project CAST.

    ERIC Educational Resources Information Center

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

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

  8. Prototype casting fabrication by stereolithography

    SciTech Connect

    Cromwell, W.E.

    1992-03-01

    The evolution of the new technology of producing CAD models by ultraviolet solidification of resin materials (``STEREOLITHOGRAPHY``) continues to progress. The potential application area of rigid fabrication of prototype investment castings is becoming more feasible as we continue to successfully yield experimental castings by the ``SHELL`` processing method. This supplemental (to 11/90 publication) report briefly reviews the original project objectives, activities related to these objectives since November 1990, and progress made through December 1991. We discuss several new case studies involving new resin materials (and other materials) tested along with investment casting processing results. The most recent success, the processing of the highly complex ``C`` HOUSING design by the ``shell`` mold process in both aluminum and steel, will be discussed. This is considered a major breakthrough toward establishing this new technology as a viable approach to the rapid development of prototype investment castings, employing the most common aerospace (precision) cast process. Our future planning calls for expanding the study to help the investment casting industry in refining related processing techniques and to continue our evaluation of new resins suitable for the casting process. Present project planning calls for the completion of this study by the third quarter FY93 or sooner. We believe that with the continued excellent cooperation of our casting supplier study team and an accelerated effort by resin materials producers to further refine related materials, we can achieve all objectives during the planned time frame.

  9. Prototype casting fabrication by stereolithography

    SciTech Connect

    Cromwell, W.E.

    1992-03-01

    The evolution of the new technology of producing CAD models by ultraviolet solidification of resin materials ( STEREOLITHOGRAPHY'') continues to progress. The potential application area of rigid fabrication of prototype investment castings is becoming more feasible as we continue to successfully yield experimental castings by the SHELL'' processing method. This supplemental (to 11/90 publication) report briefly reviews the original project objectives, activities related to these objectives since November 1990, and progress made through December 1991. We discuss several new case studies involving new resin materials (and other materials) tested along with investment casting processing results. The most recent success, the processing of the highly complex C'' HOUSING design by the shell'' mold process in both aluminum and steel, will be discussed. This is considered a major breakthrough toward establishing this new technology as a viable approach to the rapid development of prototype investment castings, employing the most common aerospace (precision) cast process. Our future planning calls for expanding the study to help the investment casting industry in refining related processing techniques and to continue our evaluation of new resins suitable for the casting process. Present project planning calls for the completion of this study by the third quarter FY93 or sooner. We believe that with the continued excellent cooperation of our casting supplier study team and an accelerated effort by resin materials producers to further refine related materials, we can achieve all objectives during the planned time frame.

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

    SciTech Connect

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

    2011-09-13

    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

  11. Casting methods

    DOEpatents

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

    2012-12-18

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

  12. CASTING APPARATUS

    DOEpatents

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

    1958-09-23

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

  13. Alloy Design and Development of Cast Cr-W-V Ferritic Steels for Improved High-Temperature Strength for Power Generation Applications

    SciTech Connect

    Klueh, R L; Maziasz, P J; Vitek, J M; Evans, N D; Hashimoto, N

    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 additional 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

  14. A comparison of the accuracy of three removable die systems and two die materials.

    PubMed

    Sivakumar, I; Mohan, J; Arunachalam, K S; Zankari, V

    2013-09-01

    The purpose of this study was to evaluate the dimensional shift of three commonly used die systems (Conventional system, Pindex system, Di-Lok tray system) with two commercially available type IV die stones (Ultra rock and Pearl stone). Under controlled conditions, ten casts, each with two removable dies, were constructed for each system for a total of 30 casts and 60 removable dies. Before and after sectioning measurements to within 0.01 mm in horizontal and vertical planes were recorded and differences calculated. Data were analyzed with 't' tests, one way analysis of variance and post hoc Tukey test. The results demonstrated that among the die systems compared, no single system was superior to the others in all respects. But among the die materials, dies poured in Pearl stone exhibited more dimensional changes than Ultra rock (p<0.05). Selection of die material is as critical as selection of any particular die system for successful fabrication of fixed partial denture and implant prosthesis.

  15. USGS ShakeCast

    USGS Publications Warehouse

    Wald, David; Lin, Kuo-Wan

    2007-01-01

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

  16. Casting materials

    DOEpatents

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

    2011-06-14

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

  17. Casting the Spirit: A Handmade Legacy

    ERIC Educational Resources Information Center

    Rutenberg, Mona

    2008-01-01

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

  18. Modeling of cast systems using smoothed-particle hydrodynamics

    NASA Astrophysics Data System (ADS)

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

    2004-03-01

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

  19. 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.

  20. Thin Wall Iron Castings

    SciTech Connect

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

    2001-10-31

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

  1. Optimization of Squeeze Casting for Aluminum Alloy Parts

    SciTech Connect

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

    2002-07-30

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

  2. Microstructure and mechanical properties of as-cast Ti-Mo-xCr alloy for biomedical application

    NASA Astrophysics Data System (ADS)

    Senopati, Galih; Sutowo, Cahya; P. A., I. Nyoman Gede; Utomo, Edy Priyanto; Amal, M. Ikhlasul

    2016-02-01

    Beta Ti alloys is one of the most attractive biomaterials due to their better corrosion resistance, biocompatibility, greater specific strength and lower elastic modulus than stainless steels and Co-Cr based alloys. Cr is the strong beta Ti stabilizer and has lower density than Nb, Sn and Ta. In this study As cast Ti-12Mo and Ti-12-xCr with Cr content range 1, 3, 5, and 10 wt.% prepared by using arc melting vacuum-pressure casting were investigated. The as cast Ti-Mo and Ti-Mo-xCr examined using X-ray diffraction (XRD), optical microscope (OM) and Vickers hardness tester. Experimental result indicate Ti-12Mo-xNb match for β phase peaks but TiO2 phase occurred in all alloys. The vickers hardness values of all the Ti-12Mo-xCr alloys are higher than HV 1000. The optical microscope investigation indicate Cr content influence Ti-Mo-xCr microstructure.

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

    NASA Astrophysics Data System (ADS)

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

    2015-08-01

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

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

    SciTech Connect

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

    2005-01-30

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

  5. DIE Deflection Modeling: Empirical Validation and Tech Transfer

    SciTech Connect

    R. Allen Miller

    2003-05-28

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

  6. Task 7: Die soldering during host site testing. Final report, January1--December 31, 1997

    SciTech Connect

    Goodwin, F.E.; Walkington, W.G.

    1998-01-31

    To provide industrial confirmation of laboratory results produced in Task 6 of this project, five industrial trials were organized with cooperative die casters in the USA. Components cast during these trials ranged from functional electronic heat sinks to decorative household plumbing components. Whereas laboratory work indicated that die temperature and draft angle were the most important process factors influencing solder accumulation, it was not possible to vary draft angle on the established production dies used for these trials. Substantial variations in die temperature were realized however and also die surface conditions were varied, confirming the influence of a secondary variable in the laboratory investigation. Substantial evidence from the trials indicated that die surface temperature is the most important factor for controlling solder build up. The surface roughness of the die casting die greatly influenced the number of castings that could be run before solder initially appeared. Development of careful thermal management techniques, now judged to be beyond the capabilities of most US die casters, will be necessary to control incidences of die soldering found in typical production. Thermal control will involve both control of the bulk die temperature through use of thermally controlled cooling lines, and also regulation of surface temperature by well controlled cooling lines, and also regulation of surface temperature by well controlled die spraying (lubrication) techniques. Further research, development and technology transfer to enhance thermal control capabilities of US die casters is recommended.

  7. The effect of four sprue shapes on the quality of cobalt-chromium cast removable partial denture frame-works

    PubMed Central

    Viswambaran, M.; Agarwal, S. K.

    2013-01-01

    Statement of Problem: Sprue design is a factor that controls the velocity and adequate supply of metal to the mould. Currently various manufacturers recommend different shapes of sprue, which have not been advocated in textbooks and literature is lacking for their routine applications. Purpose: This in vitro study was carried out to determine the efficacy of four sprue shapes in producing complete, void free cobalt-chrome removable partial denture frameworks. Materials and Methods: A brass metal die with a Kennedy class III, modification 1, partially edentulous arch was used and four sprue shapes (Group A-Ribbon, Group B-Square, Group C-Round and Group D- Round with reservoir) were evaluated. 40 refractory casts were made, 10 wax patterns for each sprue design were waxed up, invested with phosphate bonded investment material and castings done with induction casting machine by the same operator under standardized protocols. The cast frameworks were evaluated for 1. The defects observed visually before finishing and polishing procedures, 2. Fit on the master die as seen with naked eye and 3. Defects on radiographic evaluation. Data were tabulated and statistically analyzed with 1-way ANOVA followed by Student ‘t’ test. Results: The results differed significantly (P < 0.0001) between the Groups with maximum defects in the castings of Group A followed in decreasing order by Group B, Group C and Group D. When comparing between the Groups (P < 0.05), the defects in Groups C and D was significantly lower than Group A and Group B. Conclusions: Round sprues with reservoir produced most satisfactory fit of castings with minimum number of internal and external defects. PMID:24014998

  8. A Benchmark Study on Casting Residual Stress

    SciTech Connect

    Johnson, Eric M.; Watkins, Thomas R; Schmidlin, Joshua E; Dutler, S. A.

    2012-01-01

    Stringent regulatory requirements, such as Tier IV norms, have pushed the cast iron for automotive applications to its limit. The castings need to be designed with closer tolerances by incorporating hitherto unknowns, such as residual stresses arising due to thermal gradients, phase and microstructural changes during solidification phenomenon. Residual stresses were earlier neglected in the casting designs by incorporating large factors of safety. Experimental measurement of residual stress in a casting through neutron or X-ray diffraction, sectioning or hole drilling, magnetic, electric or photoelastic measurements is very difficult and time consuming exercise. A detailed multi-physics model, incorporating thermo-mechanical and phase transformation phenomenon, provides an attractive alternative to assess the residual stresses generated during casting. However, before relying on the simulation methodology, it is important to rigorously validate the prediction capability by comparing it to experimental measurements. In the present work, a benchmark study was undertaken for casting residual stress measurements through neutron diffraction, which was subsequently used to validate the accuracy of simulation prediction. The stress lattice specimen geometry was designed such that subsequent castings would generate adequate residual stresses during solidification and cooling, without any cracks. The residual stresses in the cast specimen were measured using neutron diffraction. Considering the difficulty in accessing the neutron diffraction facility, these measurements can be considered as benchmark for casting simulation validations. Simulations were performed using the identical specimen geometry and casting conditions for predictions of residual stresses. The simulation predictions were found to agree well with the experimentally measured residual stresses. The experimentally validated model can be subsequently used to predict residual stresses in different cast

  9. [Application of gypsum-bonded investment containing niobium carbide on casting of alloy for metal-ceramic restoration].

    PubMed

    Tsuruta, S; Ban, S; Hasegawa, J; Hayashi, S; Iiyama, K; Yamamura, Y

    1990-07-01

    Experimental gypsum-bonded investments containing 0.5-5.0 wt% NbC were prepared by mechanical mixing of each powder. Setting and thermal expansion measurement, compressive strength and casting accuracy for Ni-Cr alloy for metal-ceramic restoration were investigated. Analysis of NbC during heating was carried out by X-ray diffraction, TG-DTA and SEM. NbC was oxidized to Nb2O5 with a volume change between 300-600 degrees C, as in the following equation: 2NbC + 4 1/2O2----Nb2O5 + 2CO2 The theoretical volume of 1/2Nb2O5 calculated from the lattice constants according to JCPDS file was approximately 4 times larger than that of NbC. The experimental investments of 70 wt% cristobalite and 30 wt% gypsum containing 2.0, 3.0 and 5.0 wt% NbC showed large thermal expansion of 7.0, 10.0 and 13.0% respectively. The investment containing 2.0 wt% NbC showed nearly the same casting accuracy for Ni-Cr alloys for metal-ceramic restoration as the commercial phosphate-bonded investment.

  10. Modified soft tissue cast for fixed partial denture: a technique

    PubMed Central

    2011-01-01

    In process of fabrication of a fixed partial denture, dies are trimmed to expose margins of the preparations. The need for the soft tissue cast is quite evident as the soft tissue emergence profile that surrounds the prepared tooth is destroyed in the process of fabrication. This article describes a modified technique to fabricate the soft tissue cast for the conventional fixed partial denture. The impression made with the polyvinylsiloxane was first poured to prepare the die cast. After retrieval of the cast, the same impression was poured second time with the resin based resilient material to cover the facial and proximal gingival areas. The remaining portion of the impression was poured with the gypsum material. This technique does not require additional clinical appointment, second impression procedure, technique sensitive manipulations with impression, or cumbersome laboratory procedures. The simplicity of this technique facilitates and justifies its routine use in fabrication of the fixed partial denture. PMID:21503191

  11. Plastic casting resin poisoning

    MedlinePlus

    Epoxy poisoning; Resin poisoning ... Epoxy and resin can be poisonous if they are swallowed or their fumes are breathed in. ... Plastic casting resins are found in various plastic casting resin products.

  12. Cool Cast Facts

    MedlinePlus

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

  13. Electromagnetic Casting of Copper Alloys

    NASA Astrophysics Data System (ADS)

    Tyler, D. E.; Lewis, B. G.; Renschen, P. D.

    1985-09-01

    Electromagnetic (EMC) casting technology has been successfully developed for copper base alloys. This casting technique eliminates the mold related defects normally encountered in direct chill (DC) mold casting, and provides castings with greatly improved hot workability.

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

    NASA Astrophysics Data System (ADS)

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

    2016-10-01

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

  15. LLNL casting technology

    SciTech Connect

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

    1994-01-01

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

  16. LLNL casting technology

    NASA Astrophysics Data System (ADS)

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

    1994-01-01

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

  17. Computer simulation applied to jewellery casting: challenges, results and future possibilities

    NASA Astrophysics Data System (ADS)

    Tiberto, Dario; Klotz, Ulrich E.

    2012-07-01

    Computer simulation has been successfully applied in the past to several industrial processes (such as lost foam and die casting) by larger foundries and direct automotive suppliers, while for the jewelry sector it is a procedure which is not widespread, and which has been tested mainly in the context of research projects. On the basis of a recently concluded EU project, the authors here present the simulation of investment casting, using two different softwares: one for the filling step (Flow-3D®), the other one for the solidification (PoligonSoft®). A work on material characterization was conducted to obtain the necessary physical parameters for the investment (used for the mold) and for the gold alloys (through thermal analysis). A series of 18k and 14k gold alloys were cast in standard set-ups to have a series of benchmark trials with embedded thermocouples for temperature measurement, in order to compare and validate the software output in terms of the cooling curves for definite test parts. Results obtained with the simulation included the reduction of micro-porosity through an optimization of the feeding channels for a controlled solidification of the metal: examples of the predicted porosity in the cast parts (with metallographic comparison) will be shown. Considerations on the feasibility of applying the casting simulation in the jewelry sector will be reached, underlining the importance of the software parametrization necessary to obtain reliable results, and the discrepancies found with the experimental comparison. In addition an overview on further possibilities of application for the CFD in jewellery casting, such as the modeling of the centrifugal and tilting processes, will be presented.

  18. Vacuum casting of thick polymeric films

    NASA Technical Reports Server (NTRS)

    Cuddihy, E. F.; Moacanin, J.

    1979-01-01

    Bubble formation and layering, which often plague vacuum-evaporated films, are prevented by properly regulating process parameters. Vacuum casting may be applicable to forming thick films of other polymer/solvent solutions.

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

    SciTech Connect

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

    1995-11-01

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

  20. Materials processing threshold report: 2. Use of low gravity for cast iron process development

    NASA Technical Reports Server (NTRS)

    Frankhouser, W. L.

    1980-01-01

    Potential applications of a low gravity environment of interest to the commercial producers of cast iron were assessed to determine whether low gravity conditions offer potential opportunities to producers for improving cast iron properties and expanding the use of cast irons. The assessment is limited to the gray and nodular types of iron, however, the findings are applicable to all cast irons. The potential advantages accrued through low gravity experiments with cast irons are described.

  1. Methods and apparatus for manufacturing monocrystalline cast silicon and monocrystalline cast silicon bodies for photovoltaics

    SciTech Connect

    Stoddard, Nathan G

    2014-01-14

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.

  2. Methods and apparatuses for manufacturing monocrystalline cast silicon and monocrystalline cast silicon bodies for photovoltaics

    DOEpatents

    Stoddard, Nathan G.

    2011-11-01

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.

  3. Shrinkage Prediction for the Investment Casting of Stainless Steels

    SciTech Connect

    Sabau, Adrian S

    2007-01-01

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

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

    SciTech Connect

    Sabau, Adrian S

    2006-01-01

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

  5. Processing of IN-718 Lattice Block Castings

    NASA Technical Reports Server (NTRS)

    Hebsur, Mohan G.

    2002-01-01

    Recently a low cost casting method known as lattice block casting has been developed by JAM Corporation, Wilmington, Massachusetts for engineering materials such as aluminum and stainless steels that has shown to provide very high stiffness and strength with only a fraction of density of the alloy. NASA Glenn Research Center has initiated research to investigate lattice block castings of high temperature Ni-base superalloys such as the model system Inconel-718 (IN-718) for lightweight nozzle applications. Although difficulties were encountered throughout the manufacturing process , a successful investment casting procedure was eventually developed. Wax formulation and pattern assembly, shell mold processing, and counter gravity casting techniques were developed. Ten IN-718 lattice block castings (each measuring 15-cm wide by 30-cm long by 1.2-cm thick) have been successfully produced by Hitchiner Gas Turbine Division, Milford, New Hampshire, using their patented counter gravity casting techniques. Details of the processing and resulting microstructures are discussed in this paper. Post casting processing and evaluation of system specific mechanical properties of these specimens are in progress.

  6. Formation of blade and slot die coated small molecule multilayers for OLED applications studied theoretically and by XPS depth profiling

    NASA Astrophysics Data System (ADS)

    Peters, Katharina; Raupp, Sebastian; Hummel, Helga; Bruns, Michael; Scharfer, Philip; Schabel, Wilhelm

    2016-06-01

    Slot die coaters especially designed for low material consumption and doctor blades were used to process small molecule solutions for organic light-emitting diodes (OLEDs). Optimum process parameters were developed for the large-scale coating techniques to generate stable single and multiple layers only a few nanometers thick. Achieving a multilayer architecture for solution-processed OLEDs is the most challenging step. X-ray photoelectron spectroscopy sputter depth profiling was performed to determine defined interfaces between coated organic layers. Commercially available small molecules NPB (N,N'-Di(1-naphthyl)-N,N'-diphenyl-(1,1'-biphenyl)-4,4'-diamine) and BAlq (Bis(8-hdroxy-2methylquinoline)-(4-phenylphenoxy)aluminum), originally developed for vacuum deposition, were used as hole, respectively electron transport material. Defined double-layers were processed with both scalable coating methods using the orthogonal solvent approach. The use of non-orthogonal solvents resulted in complete intermixing of the material. The results are explained by calculations of solubilities and simulating drying and diffusion kinetics of the small molecule solutions.

  7. Displaced capillary dies

    DOEpatents

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

    1984-01-01

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

  8. Displaced capillary dies

    DOEpatents

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

    1982-01-01

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

  9. Packaged die heater

    SciTech Connect

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

    2011-06-21

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

  10. Expandable pattern casting research

    NASA Astrophysics Data System (ADS)

    1993-09-01

    The Expandable Pattern Casting (EPC) Process is a developing foundry technology that allows designers the opportunity to consolidate parts, reduce machining, and minimize assembly operations. An air gauging system was developed for measuring foam patterns; exact shrinkage depended on type and density of the foam. Compaction studies showed that maximum sand densities in cavities and under overhangs are achieved with vibrational amplitudes 0.001-0.004 in., and that sand moved most freely within a few inches of the top free surface. Key to complete mold filling while minimizing casting defects lies in removing the foam decomposition products. The most precise iron castings were made by EPC in four commercial EPC foundries, with attention paid to molding and compaction. EP cast 60-45-12 ductile iron had yield strengths, ultimate strengths, and elastic modulus similar to conventionally cast ductile iron cast from the same ladle.

  11. Study of protective coatings for aluminum die casting molds

    NASA Astrophysics Data System (ADS)

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

    2015-12-01

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

  12. SLIP CASTING METHOD

    DOEpatents

    Allison, A.G.

    1959-09-01

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

  13. Application of the ToxMiner Database: Network Analysis of Linkage between ToxCast Phase I Chemicals and Thyroid Related Disease Outcomes

    EPA Science Inventory

    The US EPA ToxCast program is using in vitro HTS (High-Throughput Screening) methods to profile and model bioactivity of environmental chemicals. The main goals of the ToxCast program are to generate predictive signatures of toxicity, and ultimately provide rapid and cost-effecti...

  14. Application of the ToxMiner Database: Network Analysis Linking the ToxCast Chemicals to Known Disease-Gene Associations

    EPA Science Inventory

    The US EPA ToxCast program is using in vitro HTS (High-Throughput Screening) methods to profile and model bioactivity of environmental chemicals. The main goals of the ToxCast program are to generate predictive signatures of toxicity, and ultimately provide rapid and cost-effecti...

  15. HIGH PRESSURE DIES

    DOEpatents

    Wilson, W.B.

    1960-05-31

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

  16. [Harmony in dying].

    PubMed

    Meyer, H

    1990-02-13

    Dying and death have scarcely before our time preoccupied so many. Some even seem to thrive from thanatology. Do we physicians however consecrate patience and time to the dying of our next or our patients? Did we learn in medical school or with our patients to assist a dying person? Did we search for answers to death and dying by asking philosophers, physicians or musicians? Can we follow their reasoning in profit for our patients or for ourselves? Harmony in death can possibly be found in a harmonious life in our splendid and humane profession. Modest personal experience enriched by reflections tries imperfectly to bring harmony as hope to our dying.

  17. Cast Metals Coalition Technology Transfer and Program Management Final Report

    SciTech Connect

    Gwyn, Mike

    2009-03-31

    , new technologies enabling energy efficiencies and environment-friendly improvements are slow to develop, and have trouble obtaining a broad application. The CMC team was able to effectively and efficiently transfer the results of DOE's metalcasting R&D projects to industry by utilizing and delivering the numerous communication vehicles identified in the proposal. The three metalcasting technical associations achieved significant technology transition results under this program. In addition to reaching over 23,000 people per year through Modern Casting and 28,000 through Engineered Casting Solutions, AFS had 84 national publications and reached over 1,200 people annually through Cast Metals Institute (CMI) education courses. NADCA's education department reached over 1,000 people each year through their courses, in addition to reaching over 6,000 people annually through Die Casting Engineer, and publishing 58 papers. The SFSA also published 99 research papers and reached over 1,000 people annually through their member newsletters. In addition to these communication vehicles, the CMC team conducted numerous technical committee meetings, project reviews, and onsite visits. All of these efforts to distribute the latest metalcasting technologies contributed to the successful deployment of DOE's R&D projects into industry. The DOE/CMC partnership demonstrated significant success in the identification and review of relevant and easy-to-implement metalcasting energy-saving processes and technologies so that the results are quickly implemented and become general practice. The results achieved in this program demonstrate that sustained technology transfer efforts are a critical step in the deployment of R&D projects to industry.

  18. Metallic Fuel Casting Development and Parameter Optimization Simulations

    SciTech Connect

    R.S. Fielding; J. Crapps; C. Unal; J.R. Kennedy

    2013-03-01

    One of the advantages of metallic fuel is the abilility to cast the fuel slugs to near net shape with little additional processing. However, the high aspect ratio of the fuel is not ideal for casting. EBR-II fuel was cast using counter gravity injection casting (CGIC) but, concerns have been raised concerning the feasibility of this process for americium bearing alloys. The Fuel Cycle Research and Development program has begun developing gravity casting techniques suitable for fuel production. Compared to CGIC gravity casting does not require a large heel that then is recycled, does not require application of a vacuum during melting, and is conducive to re-usable molds. Development has included fabrication of two separate benchscale, approximately 300 grams, systems. To shorten development time computer simulations have been used to ensure mold and crucible designs are feasible and to identify which fluid properties most affect casting behavior and therefore require more characterization.

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

    ERIC Educational Resources Information Center

    Niklas, Frank; Schneider, Wolfgang

    2014-01-01

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

  20. X-ray computed tomography for casting development

    NASA Astrophysics Data System (ADS)

    Georgeson, Gary E.; Crews, Alan R.; Bossi, Richard H.

    1992-09-01

    Computed tomography (CT) has been used to evaluate specific sand casting product examples for technical and economic benefits. The representative results are applicable to other casting technologies as well. CT has been shown to be cost effective in the development of new castings. The areas which would benefit include internal dimensional measurements (eliminating destructive sectioning), specific region inspections, flaw characterization in critical regions (to allow passing or informed repair of castings), and geometric acquisition for CAD/CAM. The quantitative capability of CT allows an engineering evaluation of castings based upon a correlation with performance. This quantitative measurement capability has also been used to measure the benefit of hot isostatic pressing in casting production. CT is also cost effective for engineering design and analysis by providing rapid geometry acquisition for input to computer aided design systems. This is particularly beneficial for components that do not have existing drawings or cannot be adequately defined until they are made for any reason. Presently CT can serve as an engineering aid to casting manufacturing. In order for CT evaluation to become routine in foundry applications, however, casting designers need to call it out as a measurement technique in the original casting design drawings, specifications on the application of CT must be written, contracts must include CT evaluation as a means for accepting casting quality, and lower cost CT systems must be available.

  1. Expendable Pattern Casting Technology

    NASA Astrophysics Data System (ADS)

    1990-07-01

    The expendable pattern casting (EPC) process is a potential casting process breakthrough which could dramatically improve the competitiveness of the U.S. foundry industry. Cooperatively supported by U.S. Industry and the Department of Energy and managed by the American Foundrymen's Society, a project was started in May 1989 to develop and optimize expendable pattern casting technology. Four major tasks were conducted in the first phase of the project. Those tasks involved: (1) reviewing published literature to determine the major problems in the EPC process; (2) evaluating factors influencing sand flow and compaction; (3) evaluating and comparing casting precision obtained in the EPC process with that obtained in other processes; and (4) identifying critical parameters that control dimensional precision and defect formation in EP castings.

  2. Impact of Simulation Technology on Die and Stamping Business

    NASA Astrophysics Data System (ADS)

    Stevens, Mark W.

    2005-08-01

    Over the last ten years, we have seen an explosion in the use of simulation-based techniques to improve the engineering, construction, and operation of GM production tools. The impact has been as profound as the overall switch to CAD/CAM from the old manual design and construction methods. The changeover to N/C machining from duplicating milling machines brought advances in accuracy and speed to our construction activity. It also brought significant reductions in fitting sculptured surfaces. Changing over to CAD design brought similar advances in accuracy, and today's use of solid modeling has enhanced that accuracy gain while finally leading to the reduction in lead time and cost through the development of parametric techniques. Elimination of paper drawings for die design, along with the process of blueprinting and distribution, provided the savings required to install high capacity computer servers, high-speed data transmission lines and integrated networks. These historic changes in the application of CAE technology in manufacturing engineering paved the way for the implementation of simulation to all aspects of our business. The benefits are being realized now, and the future holds even greater promise as the simulation techniques mature and expand. Every new line of dies is verified prior to casting for interference free operation. Sheet metal forming simulation validates the material flow, eliminating the high costs of physical experimentation dependent on trial and error methods of the past. Integrated forming simulation and die structural analysis and optimization has led to a reduction in die size and weight on the order of 30% or more. The latest techniques in factory simulation enable analysis of automated press lines, including all stamping operations with corresponding automation. This leads to manufacturing lines capable of running at higher levels of throughput, with actual results providing the capability of two or more additional strokes per

  3. Japanese R&D on new cast alloys and materials

    SciTech Connect

    Hayden, H.W.

    1996-05-01

    On the basis of observations of the JTEC team, it appears that Japanese universities and research institutes are leading long-term R&D thrusts for development of new materials casting technologies. Significant efforts include amorphous metals, intermetallics, application of MHD in continuous casting of steel, and energy efficient furnace technology. Industrial R&D seems focused more on process improvements than on new product technologies, but significant efforts in new cast materials included cast metal matrix composites, materials substitutions for thinner wall products, and advanced ceramic products for foundry industry applications.

  4. Die singulation method

    DOEpatents

    Swiler, Thomas P [Albuquerque, NM; Garcia, Ernest J [Albuquerque, NM; Francis, Kathryn M [Rio Rancho, NM

    2014-01-07

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

  5. Die singulation method

    DOEpatents

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

    2013-06-11

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

  6. Effects of chromium and nitrogen content on the microstructures and mechanical properties of as-cast Co-Cr-Mo alloys for dental applications.

    PubMed

    Yoda, Keita; Suyalatu; Takaichi, Atsushi; Nomura, Naoyuki; Tsutsumi, Yusuke; Doi, Hisashi; Kurosu, Shingo; Chiba, Akihiko; Igarashi, Yoshimasa; Hanawa, Takao

    2012-07-01

    The microstructure and mechanical properties of as-cast Co-(20-33)Cr-5Mo-N alloys were investigated to develop ductile Co-Cr-Mo alloys without Ni addition for dental applications that satisfy the requirements of the type 5 criteria in ISO 22674. The effects of the Cr and N contents on the microstructure and mechanical properties are discussed. The microstructures were evaluated using scanning electron microscopy with energy-dispersive X-ray spectroscopy (EDS), X-ray diffractometry (XRD), and electron back-scattered diffraction pattern analysis. The mechanical properties were evaluated using tensile testing. The proof strength and elongation of N-containing 33Cr satisfied the type 5 criteria in ISO 22674. ε-phase with striations was formed in the N-free (20-29)Cr alloys, while there was slight formation of ε-phase in the N-containing (20-29)Cr alloys, which disappeared in N-containing 33Cr. The lattice parameter of the γ-phase increased with increasing Cr content (i.e. N content) in the N-containing alloys, although the lattice parameter remained almost the same in the N-free alloys because of the small atomic radius difference between Co and Cr. Compositional analyses by EDS and XRD revealed that in the N-containing alloys Cr and Mo were concentrated in the cell boundary, which became enriched in N, stabilizing the γ-phase. The mechanical properties of the N-free alloys were independent of the Cr content and showed low strength and limited elongation. Strain-induced martensite was formed in all the N-free alloys after tensile testing. On the other hand, the proof strength, ultimate tensile strength, and elongation of the N-containing alloys increased with increasing Cr content (i.e. N content). Since formation of ε-phase after tensile testing was confirmed in the N-containing alloys the deformation mechanism may change from strain-induced martensite transformation to another form, such as twinning or dislocation slip, as the N content increases. Thus the N

  7. Extrusion die and method

    DOEpatents

    Lipp, G. Daniel

    1994-04-26

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

  8. The Ambiguous Dying Syndrome

    ERIC Educational Resources Information Center

    Bern-Klug, Mercedes

    2004-01-01

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

  9. Acquired localised hypertrichosis in a Chinese child after cast immobilisation.

    PubMed

    Yuen, M W; Lai, Loretta K P; Chan, P F; Chao, David V K

    2015-08-01

    Hypertrichosis refers to excessive hair growth that is independent of any androgen effect. Hypertrichosis could be congenital or acquired, localised or generalised. The phenomenon of acquired localised hypertrichosis following cast application for a fracture is well known to orthopaedic surgeons, but is rarely encountered by primary care physicians. We describe a 28-month-old Chinese boy who had fracture of right leg as a result of an injury. He had a cast applied by an orthopaedic surgeon as treatment. On removal of the cast 6 weeks later, he was noticed to have significant hair growth on his right leg compared with the left leg. The patient was reassessed 3 months after removal of the cast. The hypertrichosis resolved completely with time. This patient was one of the youngest among the reported cases of acquired localised hypertrichosis after cast application. We illustrate the significance of management of post-cast-acquired localised hypertrichosis in the primary care setting.

  10. 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.

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

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

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

  12. Symptomatic stent cast.

    PubMed

    Keohane, John; Moore, Michael; O'Mahony, Seamus; Crosbie, Orla

    2008-02-01

    Biliary stent occlusion is a major complication of endoscopic stent insertion and results in repeat procedures. Various theories as to the etiology have been proposed, the most frequently studied is the attachment of gram negative bacteria within the stent. Several studies have shown prolongation of stent patency with antibiotic prophylaxis. We report the case of stent occlusion from a cast of a previously inserted straight biliary stent; a "stent cast" in an 86-year-old woman with obstructive jaundice. This was retrieved with the lithotrypter and she made an uneventful recovery. This is the first reported case of a biliary stent cast.

  13. CASTING METHOD AND APPARATUS

    DOEpatents

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

    1958-10-01

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

  14. CENTRIFUGAL CASTING MACHINE

    DOEpatents

    Shuck, A.B.

    1958-04-01

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

  15. Is Dying Young Worse than Dying Old?

    ERIC Educational Resources Information Center

    Jecker, Nancy S.; Schneiderman, Lawrence J.

    1994-01-01

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

  16. Extrusion die and method

    DOEpatents

    Lipp, G. Daniel

    1994-05-03

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

  17. Method of casting aerogels

    SciTech Connect

    Poco, J.F.

    1993-09-07

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

  18. MOLDS FOR CASTING PLUTONIUM

    DOEpatents

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

    1962-02-27

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

  19. Method of casting aerogels

    DOEpatents

    Poco, John F.

    1993-01-01

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

  20. A Winning Cast

    NASA Technical Reports Server (NTRS)

    2001-01-01

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

  1. Viability changes: Microbiological analysis of dental casts

    PubMed Central

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

    2014-01-01

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

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

    DOEpatents

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

    2002-01-01

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

  3. A Comparison of Creep-Rupture Tested Cast Alloys HR282, IN740 and 263 for Possible Application in Advanced Ultrasupercritical Steam Turbine and Boiler

    SciTech Connect

    Jablonski, P D; Evens, N; Yamamoto, Y; Maziasz, P

    2011-02-27

    Cast forms of traditionally wrought Ni-base precipitation-strengthened superalloys are being considered for service in the ultra-supercritical conditions (760°C, 35MPa) of next-generation steam boilers and turbines. After casting and homogenization, these alloys were given heat-treatments typical for each in the wrought condition to develop the gamma-prime phase. Specimens machined from castings were creep-rupture tested in air at 800°C. In their wrought forms, alloy 282 is expected to precipitate M23C6 within grain boundaries, alloy 740 is expected to precipitate several grain boundary phases including M23C6, G Phase, and η phase, and alloy 263 has M23C6 and MC within its grain boundaries. This presentation will correlate the observed creep-life of these cast alloys with the microstructures developed during creep-rupture tests, with an emphasis on the phase identification and chemistry of precipitated grain boundary phases. The suitability of these cast forms of traditionally wrought alloys for turbine and boiler components will also be discussed.

  4. Two from One Casting. Art Education: 6681.20.

    ERIC Educational Resources Information Center

    Hilf, Anne

    Two From One Casting is a studio course dealing with exploratory applications of casting methods and materials for students in grades 7 through 12 who wish to make permanent those creations easily destroyed by time or negligence. Course rationale, enrollment guidelines, objectives, outline of content, descriptions of activities and procedures,…

  5. Methods and apparatuses for manufacturing geometric multicrystalline cast silicon and geometric multicrystalline cast silicon bodies for photovoltaics

    DOEpatents

    Stoddard, Nathan G

    2015-02-10

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of geometrically ordered multi-crystalline silicon may be formed that is free or substantially free of radially-distributed impurities and defects and having at least two dimensions that are each at least about 10 cm is provided.

  6. When Somebody Dies

    MedlinePlus

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

  7. Spray casting project final report

    SciTech Connect

    Churnetski, S.R.; Thompson, J.E.

    1996-08-01

    Lockheed Martin Energy Systems, Inc. (Energy Systems), along with other participating organizations, has been exploring the feasibility of spray casting depleted uranium (DU) to near-net shape as a waste minimization effort. Although this technology would be useful in a variety of applications where DU was the material of choice, this effort was aimed primarily at gamma-shielding components for use in storage and transportation canisters for high-level radioactive waste, particularly in the Multipurpose Canister (MPC) application. In addition to the waste-minimization benefits, spray casting would simplify the manufacturing process by allowing the shielding components for MPC to be produced as a single component, as opposed to multiple components with many fabrication and assembly steps. In earlier experiments, surrogate materials were used to simulate the properties (specifically reactivity and density) of DU. Based on the positive results from those studies, the project participants decided that further evaluation of the issues and concerns that would accompany spraying DU was warranted. That evaluation occupied substantially all of Fiscal Year 1995, yielding conceptual designs for both an intermediate facility and a production facility and their associated engineering estimates. An intermediate facility was included in this study to allow further technology development in spraying DU. Although spraying DU to near-net shape seems to be feasible, a number of technical, engineering, and safety issues would need to be evaluated before proceeding with a production facility. This report is intended to document the results from the spray-casting project and to provide information needed by anyone interested in proceeding to the next step.

  8. Extending the Derek-Meteor Workflow to Predict Chemical-Toxicity Space Impacted by Metabolism: Application to ToxCast and Tox21 Chemical Inventories

    EPA Science Inventory

    A central aim of EPA’s ToxCast project is to use in vitro high-throughput screening (HTS) profiles to build predictive models of in vivo toxicity. Where assays lack metabolic capability, such efforts may need to anticipate the role of metabolic activation (or deactivation). A wo...

  9. Application of Targeted Functional Assays to Assess a Putative Vascular Disruption Developmental Toxicity Pathway Informed By ToxCast High-Throughput Screening Data

    EPA Science Inventory

    Chemical perturbation of vascular development is a putative toxicity pathway which may result in developmental toxicity. EPA’s high-throughput screening (HTS) ToxCast program contains assays which measure cellular signals and biological processes critical for blood vessel develop...

  10. Cheminformatics Analysis of EPA ToxCast Chemical Libraries to Identify Domains of Applicability for Predictive Toxicity Models and Prioritize Compounds for Toxicity Testing

    EPA Science Inventory

    An important goal of toxicology research is the development of robust methods that use in vitro and chemical structure information to predict in vivo toxicity endpoints. The US EPA ToxCast program is addressing this goal using ~600 in vitro assays to create bioactivity profiles o...

  11. 20150323 - The U.S. EPA ToxCast Program: Moving from Data Generation to Application (SOT Tox21 update symposium presentation)

    EPA Science Inventory

    The U.S. EPA ToxCast program is entering its tenth year. Significant learning and progress have occurred towards collection, analysis, and interpretation of the data. The library of ~1,800 chemicals has been subject to ongoing characterization (e.g., identity, purity, stability...

  12. Tox21 and ToxCast Chemical Landscapes: Laying the Foundation for 21st Century Toxicology - Application of the Strategy to Chemical Testing

    EPA Science Inventory

    The U.S. Environmental Protection Agency’s ToxCast project and the related, multi-Agency Tox21 project are employing high-throughput technologies to screen hundreds to thousands of chemicals in hundreds of assays, probing a wide diversity of biological targets, pathways and mecha...

  13. 78 FR 15048 - Johnstown Specialty Castings, Inc., a Subsidiary of WHEMCO, Johnstown, Pennsylvania; Notice of...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-03-08

    ... Employment and Training Administration Johnstown Specialty Castings, Inc., a Subsidiary of WHEMCO, Johnstown... Assistance (TAA) applicable to workers and former workers of Johnstown Specialty Castings, Inc., a subsidiary.... The workers' ] firm is engaged in activities related to the production of steel castings, slag...

  14. Microporosity Prediction and Validation for Ni-based Superalloy Castings

    NASA Astrophysics Data System (ADS)

    Guo, J.; Beckermann, C.; Carlson, K.; Hirvo, D.; Bell, K.; Moreland, T.; Gu, J.; Clews, J.; Scott, S.; Couturier, G.; Backman, D.

    2015-06-01

    Microporosityin high performance aerospace castings can reduce mechanical properties and consequently degrade both component life and durability. Therefore, casting engineers must be able to both predict and reduce casting microporosity. A dimensionless Niyama model has been developed [1] that predicts local microporosity by accounting for local thermal conditions during casting as well as the properties and solidification characteristics of the cast alloy. Unlike the well-known Niyama criterion, application of the dimensionless Niyama model avoids the need to find a threshold Niyama criterion below which shrinkage porosity forms - a criterion which can be determined only via extensive alloy dependent experimentation. In the present study, the dimensionless Niyama model is integrated with a commercial finite element casting simulation software, which can now more accurately predict the location-specific shrinkage porosity volume fraction during solidification of superalloy castings. These microporosity predictions are validated by comparing modelled results against radiographically and metallographically measured porosity for several Ni-based superalloy equiaxed castings that vary in alloy chemistry with a focus on plates of changing draft angle and thickness. The simulation results agree well with experimental measurements. The simulation results also show that the dimensionless Niyama model can not only identify the location but also the average volume fraction of microporosity distribution in these equiaxed investment cast Ni-based superalloy experiments of relatively simple geometry.

  15. Is dying young worse than dying old?

    PubMed

    Jecker, N S; Schneiderman, L J

    1994-02-01

    In contemporary Western society, people experience the deaths of older and younger persons differently. We are disposed to feel that the death of a small child is a greater injustice than the death of an older adult, and we experience correspondingly greater sorrow, anger, regret or bitterness when a very young person dies. This article examines these responses critically to determine whether they are backed by ethical considerations that reason can discern and defend. We contrast contemporary attitudes with those of ancient Greece and show the relevance that different attitudes toward death have for health care decision making.

  16. Killing, letting die and euthanasia.

    PubMed

    Husak, D N

    1979-12-01

    Medical ethicists debate whether or not the moral assessment of cases of euthanasia should depend on whether the patient is 'killed' or 'allowed to die'. The usual presupposition is that a clear distinction between killing and letting die can be drawn so that this substantive question is not begged. I contend that the categorisation of cases of instances of killing rather than as instances of letting die depends in part on a prior moral assessment of the case. Hence is it trivially rather than substantively true that the distinction has moral significance. But even if a morally neutral (ie non-question begging) distinction could be drawn, its application to the euthanasia controversy is problematic. I illustrate the difficulties of employing this distinction to reach moral conclusions by critically discussing Philippa Foot's recent treatment of euthanasia. I conclude that even if an act of euthanasia is an instance of killing, and there exists a prima facie moral duty not to kill, and no more stringent duty overrides this duty, one still cannot determine such an act to be morally impermissible.

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

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

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

  18. A new casting defect healing technology

    SciTech Connect

    Hodge, E.S.; Reddoch, T.W.; Viswanathan, S.

    1997-01-01

    A new technology is presented for healing of defects in 356 aluminium alloys that provides economic upgrading of these cast alloys. It uses pneumatic isostatic forging (PIF) to produce high quality Al alloys products with enhanced mechanical properties uniform throughout the part, allowing higher design allowables and increased usage of Al alloy castings. The fundamental mechanism underlying PIF is a single mode plastic deformation process that uses isostatic application of pressures for 10-30 seconds at temperature. The process can be integrated in-line with other production operations, i.e., using the latent heat from the previous casting step. Results of applying the PIF process indicate lower cost and significant improvement in mechanical properties that rival and often exceed corresponding properties of other technologies like hot isostatic pressing and related processes. This process offers many advantages that are described in this paper in addition to presenting case histories of property enhancement by PIF and the mechanism responsible for property enhancement.

  19. Composites for Advanced Space Transportation Systems (CASTS)

    NASA Technical Reports Server (NTRS)

    Davis, J. G., Jr. (Compiler)

    1979-01-01

    A summary is given of the in-house and contract work accomplished under the CASTS Project. In July 1975 the CASTS Project was initiated to develop graphite fiber/polyimide matrix (GR/PI) composite structures with 589K (600 F) operational capability for application to aerospace vehicles. Major tasks include: (1) screening composites and adhesives, (2) developing fabrication procedures and specifications, (3) developing design allowables test methods and data, and (4) design and test of structural elements and construction of an aft body flap for the Space Shuttle Orbiter Vehicle which will be ground tested. Portions of the information are from ongoing research and must be considered preliminary. The CASTS Project is scheduled to be completed in September 1983.

  20. Method for casting polyethylene pipe

    NASA Technical Reports Server (NTRS)

    Elam, R. M., Jr.

    1973-01-01

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

  1. Casting Of Multilayer Ceramic Tapes

    NASA Technical Reports Server (NTRS)

    Collins, Earl R., Jr.

    1991-01-01

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

  2. Bioinspired Design: Magnetic Freeze Casting

    NASA Astrophysics Data System (ADS)

    Porter, Michael Martin

    Nature is the ultimate experimental scientist, having billions of years of evolution to design, test, and adapt a variety of multifunctional systems for a plethora of diverse applications. Next-generation materials that draw inspiration from the structure-property-function relationships of natural biological materials have led to many high-performance structural materials with hybrid, hierarchical architectures that fit form to function. In this dissertation, a novel materials processing method, magnetic freeze casting, is introduced to develop porous scaffolds and hybrid composites with micro-architectures that emulate bone, abalone nacre, and other hard biological materials. This method uses ice as a template to form ceramic-based materials with continuously, interconnected microstructures and magnetic fields to control the alignment of these structures in multiple directions. The resulting materials have anisotropic properties with enhanced mechanical performance that have potential applications as bone implants or lightweight structural composites, among others.

  3. Casting and Angling.

    ERIC Educational Resources Information Center

    Smith, Julian W.

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

  4. Extrusion cast explosive

    DOEpatents

    Scribner, Kenneth J.

    1985-01-01

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

  5. Mix/Cast Contamination Control

    NASA Technical Reports Server (NTRS)

    Wallentine, M.

    2005-01-01

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

  6. Composite Materials Processing of Cast Iron and Ceramics Using Compo-Casting Technology

    NASA Astrophysics Data System (ADS)

    Tomita, Yoshihiro; Sumimoto, Haruyoshi

    The compo-casting technology of ceramics and cast iron is expected to be one of the major casting technologies that can expand the application fields of cast iron. This technique allows the heat energy of the molten metal to be utilized to produce cast iron products which are added with functions of ceramic materials. The largest problem in compo-casting technology is generation of cracks caused by thermal shock. Although this crack generation can be prevented by reducing the thermal stress by means of preheating ceramics, the necessary preheating temperature is considerably high and its precise controlling is difficult at the practical foundry working sites. In this study, we tried to numerically predict the critical preheating temperature of ceramics using the thermal stress analysis in unsteady heat transfer and the Newman's diagram, and found that the preheating of ceramics to reduce thermal stress could be substituted with placing an appropriate cast iron cover around the ceramics. Excellent results were obtained by using a method whereby a ceramic bar was covered with a flake graphite cast iron cover and fixed in a sand mold and then molten metal was poured. Then, two or three ceramics were examined at the same time under the compocasting condition. As a result, three specimens could be done at the same time by adjusting the cover space to 15mm. Moreover, irregular shape ceramics were examined under the compocasting condition. As a result, the compocasting could be done by devising the cover shape. In each condition, it was confirmed that the cover shape made from the analytical result was effective to the compocasting by doing the thermometry of the specimens.

  7. Experiences of the dying.

    PubMed

    Schoenbeck, Susan L

    2011-01-01

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

  8. [Human dying has changed].

    PubMed

    Llano Escobar, A

    1990-01-01

    In the modern era, the act of dying, at least in the West, presents a series of new characteristics resulting from scientific and technological progress and social changes. More and more frequently, humans die in the strange surroundings of medical establishments without the support of their loved ones and without the opportunity of taking part in decisions related to their own deaths. In the light of the serious personal and social problems caused by this transformation of human death, bioethics emerges as an attempt to uncover options that are more humane.

  9. Creep Behavior at 1273 K (1000 °C) in Nb-Bearing Austenitic Heat-Resistant Cast Steels Developed for Exhaust Component Applications

    NASA Astrophysics Data System (ADS)

    Zhang, Yinhui; Li, Mei; Godlewski, Larry A.; Zindel, Jacob W.; Feng, Qiang

    2016-07-01

    A series of Nb-bearing austenitic heat-resistant cast steels with variations of N/C ratios were investigated, and the morphological change of Nb(C,N) from faceted blocks, mixed flake-blocks to "Chinese-script" was observed as N/C ratios decreased. The creep behavior of these alloys was studied at 1273 K (1000 °C), and the longest creep life and lowest creep rate occurred in model alloys with script Nb(C,N). Residual δ-ferrites and (Cr,Fe)23C6 were adverse to creep properties. This work indicates that the control of N/C ratio is required for the as-cast microstructural strengthening.

  10. AMCC casting development, volume 2

    NASA Technical Reports Server (NTRS)

    1995-01-01

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

  11. Die andere Revolution

    NASA Astrophysics Data System (ADS)

    Kippenhahn, Rudolf

    2005-05-01

    War Kopernikus der größte Revolutionär des naturwissenschaftlichen Weltbildes? Seine Erkenntnisse waren der Beginn eines jahrhundertelangen Denkprozesses, welcher zur Einsicht führte, dass im Weltall die gleichen physikalischen Gesetze gelten wie auf der Erde.

  12. Die Kosmologie der Griechen.

    NASA Astrophysics Data System (ADS)

    Mittelstraß, J.

    Contents: 1. Mythische Eier. 2. Thales-Welten. 3. "Alles ist voller Götter". 4. Griechische Astronomie. 5. "Rettung der Phänomene". 6. Aristotelische Kosmololgie. 7. Aristoteles-Welt und Platon-Welt. 8. Noch einmal: die Göttlichkeit der Welt. 9. Griechischer Idealismus.

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

    NASA Astrophysics Data System (ADS)

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

    1997-07-01

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

  14. Energy Saving Melting andRevert Reduction Technology (E0SMARRT): Predicting Pattern Tooling and Casting Dimension for Investment Casting

    SciTech Connect

    Nick Cannell; Dr. Mark Samonds; Adi Sholapurwalla; Sam Scott

    2008-11-21

    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 shrinkage 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

  15. Properties of a hybrid plaster-fibreglass cast

    PubMed Central

    Charles, Mark N.; Yen, David

    2000-01-01

    Objective To examine the suitability of a plaster-fibreglass hybrid cast for orthopedic applications, comparing them to plaster of Paris (POP) and fibreglass constructs. Method Groups of 10 standardized hybrid, POP and fibreglass casts were studied. An Instron servo-hydraulic system was used to test the casts in 3-point bending and shear. Outcome measures Strength, stiffness, weight, thickness and cost of the 3 types of cast, and shear strength at the interface between the POP and fibreglass in the hybrid casts. Results The hybrid casts were twice as strong as the POP constructs, were stiffer and weighed 14% less but were thicker and cost 2.5 times more. They were almost as strong as and less than half the cost of the fibreglass constructs but were thicker, not as stiff, and weighed 42% more. The shear strength of the POP–fibreglass interface in the hybrid casts was higher than the 3-point bending strength of this construct by a factor of 3. Conclusions Plaster-fibreglass hybrid casts should be considered for orthopedic use on the basis of their strength, stiffness, weight and cost, combined with their acknowledged advantages of good moulding ability and water resistance. PMID:11045095

  16. Navigating "Assisted Dying".

    PubMed

    Schipper, Harvey

    2016-02-01

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

  17. Volume MLS ray casting.

    PubMed

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

    2008-01-01

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

  18. Herausforderungen durch die deutsche Wiedervereinigung

    NASA Astrophysics Data System (ADS)

    Stäglin, Reiner

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

  19. Extrusion cast explosive

    DOEpatents

    Scribner, K.J.

    1985-11-26

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

  20. Extrusion cast explosive

    DOEpatents

    Scribner, K.J.

    1985-01-29

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

  1. Casting larger polycrystalline silicon ingots

    SciTech Connect

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

    1995-08-01

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

  2. Advanced Line Die Forming Simulation Technology and Its Impact on Stamping Automotive Body Panels

    NASA Astrophysics Data System (ADS)

    Zhang, Jimmy; Wang, Chuantao; Xu, Siguang; Joshi, Ramesh; Goan, Norman

    2005-08-01

    Line die forming simulation and validation create tremendous business values for automotive die developments and production stamping while they pose a great technological challenge to stamping CAE community. GM Manufacturing Engineering Die Center has developed an integrated line die analysis technology to validate die lines as a productionized business process. In this process, a finished stamping body panel can be streamline analyzed with required time, accuracy, and quality. This paper presents critical issues in line die analysis, discusses technical challenges in production applications and software development, and finally demonstrates the impact of line die forming simulation and validations on automotive body styling and tooling developments.

  3. Solidification science in cast MMCs: The influence of merton flemings

    NASA Astrophysics Data System (ADS)

    Rohatgi, Pradeep; Asthana, Rajiv

    2001-09-01

    The solidification science of cast metalmatrix composites (MMC) evolved as a subset of the broad field of solidification of monolithic alloys pioneered by Merton Flemings and his students. As a result of advances in solidification, the cast MMC field has evolved from its early incarnation—employing empirical research to engineer novel materials using versatile and cost-effective casting techniques—to using solidification-science-based approaches to tailor advanced materials for application-specific needs. The current and emerging applications of cast MMCs in a variety of automotive, aerospace, electronic packaging, and consumer-good industries exemplify the maturity of the field and the materials. Innovations in composite-forming techniques and efforts at wider industrial acceptance of MMCs will undoubtedly continue. However, the scientific principles underlying the solidification microstructure evolution that governs the composite properties have become well established, to a great extent, due to Flemings’ early, pioneering work on monolithic alloys and some of his more recent studies on solidification of reinforced metals. This paper reviews some aspects of solidification of discontinuously reinforced cast metals that owe their current understanding to Flemings’ contributions, in particular, the scientific understanding of macro- and microsegregation, fluidity and rheology of multiphase slurries, and stircasting, semi-solid casting, and preform infiltration. Current research to develop and test prototype components made from cast composites, including Al-flyash, Cu-graphite, Al-graphite, Al-alumina, and SiC-Al, is also presented, along with directions for future research.

  4. The application of a probabilistic particle model for turbulent combustion modelling in combustors. (German Title: Die Anwendung eines probabilistischen Partikelmodells für die Modellierung der turbulenten Verbrennung in Brennkammern)

    NASA Astrophysics Data System (ADS)

    Aumeier, Thomas

    2011-12-01

    The modeling of combustion phenomena in turbulent flows is an important requirement to calculate the effects on the underlying flow field and thus to use the results for design studies and optimization processes in technical applications. Complex chemical systems arise due to the large amount of species participating in combustion reactions as well as multiple reaction paths which are represented by a set of reaction equations. These systems have to be solved with suitable numerical techniques and must consider the influence of turbulence in the mean transport equations, respectively. Compared to the time scales in the flow, chemical reactions occur on a more expanded range of time at a molecular level. This effect reflects in the formulation of the equations for the calculation of chemical reaction rates, which are given in a Lagrangian formulation and therefore only depends on time. In practical cases specific combustion models are used depending on the combustion regime which is associated within an application. In this thesis a combustion model for turbulence chemistry interactions is presented, which can be used, independently of the combustion regime, for both diffusion and premixed flames as well as for partially premixed flames in realistic combustors. With the aid of the model the mean chemical source terms can be coupled to the species transport equations and the energy equation of the commercial CFD - solver FLUENT®. This is done within the solver by a user-friendly interface, the so-called User Defined Functions (UDF). Transport equations for each specie progressing in the chemical reactions are solved and its source terms are calculated with the aid of a detailed reaction mechanism. In the presented model the calculation of the mean values is performed by coupling a Lagrangian solution procedure with an Eulerian finite volume solver. A very large amount of individual particles are considered where for each particle additional Lagrangian equations

  5. Heated die facilitates tungsten forming

    NASA Technical Reports Server (NTRS)

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

    1966-01-01

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

  6. Care of the Dying: A Swedish Perspective

    ERIC Educational Resources Information Center

    Feigenberg, Loma; Fulton, Robert

    1977-01-01

    This article illustrates various aspects of terminal care, and shows that rules and norms for such care do not exist today. The authors advocate the formulation of an aim for humane treatment of dying patients, and its application in a manner appropriate to Swedish medical concepts and Swedish conditions. (Author)

  7. Die kalte Zunge

    NASA Astrophysics Data System (ADS)

    Bartels, Sören; Müller, Rüdiger

    Gefühlte Temperaturen. Ist ein Null Grad Celsius kalter Metallstab eigentlich kälter als ein Holzstab mit der selben Temperatur? Rein physikalisch gesehen natürlich nicht, aber wenn wir beide Stäbe anfassen, kommt uns der Metallstab deutlich kälter vor. Und wer kennt nicht die Szene aus dem Film Dumm und Dümmer in der Harry mit seiner Zunge am Metallrahmen des Skilifts hängen bleibt.Würde das auch passieren, wenn man an einem eiskalten Stück Holz lecken würde? Wohl kaum, doch woran liegt das eigentlich? Unterschiedliche Materialien haben verschiedene Fähigkeiten, Wärme zu übertragen und zu leiten. So transportiert Metall die von der Zunge ausgehende Wärme sehr schnell weiter und verändert seine Temperatur kaum, während die Zunge abkühlt. Holz hingegen leitet Wärme fast gar nicht und daher wird der Teil, der von der Zunge berührt wird, aufgewärmt.

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

    SciTech Connect

    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 in 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.

  9. Characterization of Ni-Cr alloys using different casting techniques and molds.

    PubMed

    Chen, Wen-Cheng; Teng, Fu-Yuan; Hung, Chun-Cheng

    2014-02-01

    This study differentiated the mechanical properties of nickel-chromium (Ni-Cr) alloys under various casting techniques (different casting molds and casting atmospheres). These techniques were sampled by a sand mold using a centrifugal machine in ambient air (group I) and electromagnetic induction in an automatic argon castimatic casting machine (group II). The specimen casting used a graphite mold by a castimatic casting machine (group III). The characteristics of the Ni-Cr alloys, yield and ultimate tensile strength, bending modulus, microhardness, diffraction phase, grindability, ability to spring back, as well as ground microstructure and pattern under different casting conditions were evaluated. The group III specimens exhibited the highest values in terms of strength, modulus, hardness, and grindability at a grind rate of 500 rpm. Moreover, group III alloys exhibited smaller grain sizes, higher ability to spring back, and greater ductility than those casted by sand investment (groups I and II). The main factor, "casting mold," significantly influenced all mechanical properties. The graphite mold casting of the Ni-Cr dental alloys in a controlled atmosphere argon casting system provided an excellent combination of high mechanical properties and good ability to spring back, and preserved the ductile properties for application in Ni-Cr porcelain-fused system. The results can offer recommendations to assist a prosthetic technician in selecting the appropriate casting techniques to obtain the desired alloy properties. PMID:24411373

  10. Improvement in Mechanical Properties of A356 Tensile Test Bars Cast in a Permanent Mold by Application of a Knife Ingate

    NASA Astrophysics Data System (ADS)

    Wang, Yaou; Schwam, David; Neff, David V.; Chen, Chai-Jung; Zhu, Xuejun

    2012-03-01

    As a standard test-bar permanent mold, the "Stahl" Mold has been widely used in foundries to assess the properties of cast alloys. However, inferior mechanical properties are often obtained with this mold due to shrinkage-induced microporosity in the gage section. In order to improve the mechanical properties, a design modification comprising a thin knife ingate between the feeder and test-bar cavity was evaluated in this work. The new design was studied by computer-aided simulation. Simulations predicted that the knife ingate improved the metal feeding capability and reduced the shrinkage microporosity at the gage section from 3 to 1 pct. Experimental verification work has been undertaken with aluminum alloy A356, and the results were analyzed by a statistics theory-based factorial analysis method. The new design resulted in main effects with ultimate tensile strength (UTS) improvement of 20 MPa (relative 12 pct) and elongation increment of 2 pct (relative 45 pct) for the as-cast test bars.

  11. Psychotherapy with Older Dying Persons.

    ERIC Educational Resources Information Center

    Dye, Carol J.

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

  12. Psychotherapy with the dying patient.

    PubMed

    Schwartz, A M; Karasu, T B

    1977-01-01

    This paper develops and describes encounters with dying patients and their families and looks for consesus of patterns and responses of possible help in confronting this situation. It offers positive suggestions for those providing care for dying patients but also acknowledges that only an intellectual grasp of the situation is not sufficient qualification for caring for the dying.

  13. LOST FOAM CASTING OF MAGNESIUM ALLOYS

    SciTech Connect

    Han, Qingyou; Dinwiddie, Ralph Barton; Sklad, Philip S; Currie, Kenneth; Abdelrahman, Mohamed; Vondra, Fred; Walford, Graham; Nolan, Dennis J

    2007-01-01

    The lost foam casting process has been successfully used for making aluminum and cast iron thin walled castings of complex geometries. Little work has been carried out on cast magnesium alloys using the lost foam process. The article describes the research activities at Oak Ridge National Laboratory and Tennessee Technological University on lost foam casting of magnesium alloys. The work was focused on castings of simple geometries such as plate castings and window castings. The plate castings were designed to investigate the mold filling characteristics of magnesium and aluminum alloys using an infrared camera. The pate castings were then characterized for porosity distribution. The window castings were made to test the castability of the alloys under lost foam conditions. Significant differences between lost foam aluminum casting and lost foam magnesium casting have been observed.

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

    SciTech Connect

    Pepelnjak, Tomaz; Kuzman, Karl; Kokol, Anton

    2011-05-04

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

  15. Cast dielectric composite linear accelerator

    DOEpatents

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

    2009-11-10

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

  16. Replacing London's cast iron mains

    SciTech Connect

    Thorne, A. ); Mathews, P. )

    1992-07-01

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

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

    SciTech Connect

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

    1981-10-01

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

  18. The Configurable Aperture Space Telescope (CAST)

    NASA Astrophysics Data System (ADS)

    Ennico, Kimberly; Bendek, Eduardo A.; Lynch, Dana H.; Vassigh, Kenny K.; Young, Zion

    2016-07-01

    The Configurable Aperture Space Telescope, CAST, is a concept that provides access to a UV/visible-infrared wavelength sub-arcsecond imaging platform from space, something that will be in high demand after the retirement of the astronomy workhorse, the 2.4 meter diameter Hubble Space Telescope. CAST allows building large aperture telescopes based on small, compatible and low-cost segments mounted on autonomous cube-sized satellites. The concept merges existing technology (segmented telescope architecture) with emerging technology (smartly interconnected modular spacecraft, active optics, deployable structures). Requiring identical mirror segments, CAST's optical design is a spherical primary and secondary mirror telescope with modular multi-mirror correctors placed at the system focal plane. The design enables wide fields of view, up to as much as three degrees, while maintaining aperture growth and image performance requirements. We present a point design for the CAST concept based on a 0.6 meter diameter (3 x 3 segments) growing to a 2.6 meter diameter (13 x 13 segments) primary, with a fixed Rp=13,000 and Rs=8,750 mm curvature, f/22.4 and f/5.6, respectively. Its diffraction limited design uses a two arcminute field of view corrector with a 7.4 arcsec/mm platescale, and can support a range of platescales as fine as 0.01 arcsec/mm. Our paper summarizes CAST, presents a strawman optical design and requirements for the underlying modular spacecraft, highlights design flexibilities, and illustrates applications enabled by this new method in building space observatories.

  19. A new freeze casting technique for ceramics

    NASA Astrophysics Data System (ADS)

    Araki, Kiyoshi

    A new freeze casting technique for ceramics capable of manufacturing near room temperature with a sublimable vehicle has been developed in order to eliminate expensive processes under extremely cold temperatures in the conventional freeze casting. Fluid concentrated slurries of Al2O 3 powder in molten camphene (C10H16) were successfully prepared at 55°C with a small amount of a dispersant. These slurries were quickly solidified (frozen) at room temperature to yield a rigid solid green body, where the frozen camphene was easily removed by sublimation (freeze-drying) with negligible shrinkage. Sintering was successfully conducted without any special binder burnout process to yield dense sintered bodies (over 98% T.D). An organic alloy with a eutectic composition in the naphthalene (C 10H8)-camphor (C10H16O) binary system with a eutectic temperature of 31°C was also found to be a successful vehicle for the new ceramic freeze casting. The fabrication processes are almost the same as those with camphene. It was found that vehicles with off-eutectic compositions resulted in large voids in the sintered body due to the ceramic particle rejection by pro-eutectic crystals during freezing. At the eutectic composition, fine lamellar microstructure in the solidified vehicle inhibits the particle rejection. The proposed advantages of the new freeze casting technique with a sublimable vehicle include; (1) elimination of extremely cold temperatures used in conventional freeze casting; (2) elimination of troublesome binder burnout process; and (3) fast manufacturing cycle due to quick solidification. Porous ceramic bodies with unique interconnected pore channels were fabricated by the new freeze casting with lower solid content. The unique channels surrounded by fully dense walls have nearly circular cross-sections unlike conventional aqueous freeze casting. The porosity and the channel diameters are controllable by the solid content in the slurry. The unique channels are

  20. Milling strategies evaluation when simulating the forming dies' functional surfaces production

    NASA Astrophysics Data System (ADS)

    Ižol, Peter; Tomáš, Miroslav; Beňo, Jozef

    2016-05-01

    The paper deals with selection and evaluation of milling strategies, available in CAM systems and applicable when complicated shape parts are produced, such as forming dies. A method to obtain samples is proposed and this stems from real forming die surface machined by proper strategies. The strategy applicability for the whole part - forming die - is reviewed by the particular specimen evaluation. The presented methodology has been verified by machining model die and comparing it to the production procedure proposed in other CAM systems.

  1. 40 CFR 63.5820 - What are my options for meeting the standards for continuous lamination/casting operations?

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... standards for continuous lamination/casting operations? 63.5820 Section 63.5820 Protection of Environment... options for meeting the standards for continuous lamination/casting operations? You must use one or more... each continuous lamination line and each continuous casting line complies with the applicable...

  2. 40 CFR 63.5820 - What are my options for meeting the standards for continuous lamination/casting operations?

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... standards for continuous lamination/casting operations? 63.5820 Section 63.5820 Protection of Environment... options for meeting the standards for continuous lamination/casting operations? You must use one or more... each continuous lamination line and each continuous casting line complies with the applicable...

  3. 40 CFR 63.5820 - What are my options for meeting the standards for continuous lamination/casting operations?

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... standards for continuous lamination/casting operations? 63.5820 Section 63.5820 Protection of Environment... meeting the standards for continuous lamination/casting operations? You must use one or more of the... continuous lamination line and each continuous casting line complies with the applicable standard....

  4. 40 CFR 63.5820 - What are my options for meeting the standards for continuous lamination/casting operations?

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... standards for continuous lamination/casting operations? 63.5820 Section 63.5820 Protection of Environment... meeting the standards for continuous lamination/casting operations? You must use one or more of the... continuous lamination line and each continuous casting line complies with the applicable standard....

  5. Study of Grain-Growth Kinetics in Delta-Ferrite and Austenite with Application to Thin-Slab Cast Direct-Rolling Microalloyed Steels

    NASA Astrophysics Data System (ADS)

    Zhou, Tihe; O'Malley, Ronald J.; Zurob, Hatem S.

    2010-08-01

    The high-temperature grain-growth kinetics in delta-ferrite and austenite is investigated. The delta-ferrite growth kinetics was observed directly on a model alloy that contained 2.5 wt pct aluminum in order to stabilize delta-ferrite down to room temperature. The gamma grain-growth kinetics was by etching the former austenite grain boundaries in a precipitate-free variant of APIX60 steel. At high temperatures and in the absence of precipitation, the growth kinetics in both delta-ferrite and austenite appeared to follow a simple parabolic growth law. The findings are applied to the problem of grain-size control during the process of thin-slab casting direct rolling (TSCDR).

  6. When Your Child Needs a Cast

    MedlinePlus

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

  7. Lost-Soap Aluminum Casting.

    ERIC Educational Resources Information Center

    Mihalow, Paula

    1980-01-01

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

  8. Education and Caste in India

    ERIC Educational Resources Information Center

    Chauhan, Chandra Pal Singh

    2008-01-01

    This paper analyses the policy of reservation for lower castes in India. This policy is similar to that of affirmative action in the United States. The paper provides a brief overview of the caste system and discusses the types of groups that are eligible for reservation, based on data from government reports. The stance of this paper is that…

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

    NASA Astrophysics Data System (ADS)

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

    2010-04-01

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

  10. Flexible, Ultra-Thin, Embedded Die Packaging

    NASA Astrophysics Data System (ADS)

    McPherson, Ryan J.

    As thin, flexible electronics solutions become more robust, their integration into everyday life becomes more likely. With possible applications in wearable electronics, biomedical sensors, or 'peel and stick' sensors, the reliability of these ultra-thin packages becomes paramount. Likewise, the density achievable with stacked packages benefits greatly from thinner die stacks. To this end, techniques previously developed have demonstrated packages with die thinned to approximately 20mum. Covered in this work are methods for thinning and packaging silicon die, as well as information on common materials used in these processes. The author's contribution is a fabrication process for embedding ultra-thin (approximately 10mum) silicon die in polyimide substrates. This method is fully illustrated in Chapter 3 and enumerated in the Appendix as a quick reference. Additionally, thermal cycle testing of passive daisy chain assemblies has shown promising reliability data. Packages were mounted in three alignments: flat, concave, and convex, and placed into thermal shock testing. Finally, the author discusses possible applications for this fabrication process, including the fabrication of multi-chip-modules.

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

    NASA Astrophysics Data System (ADS)

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

    2015-10-01

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

  12. Low Background Micromegas in CAST

    NASA Astrophysics Data System (ADS)

    Garza, J. G.; Aune, S.; Aznar, F.; Calvet, D.; Castel, J. F.; Christensen, F. E.; Dafni, T.; Davenport, M.; Decker, T.; Ferrer-Ribas, E.; Galán, J.; García, J. A.; Giomataris, I.; Hill, R. M.; Iguaz, F. J.; Irastorza, I. G.; Jakobsen, A. C.; Jourde, D.; Mirallas, H.; Ortega, I.; Papaevangelou, T.; Pivovaroff, M. J.; Ruz, J.; Tomás, A.; Vafeiadis, T.; Vogel, J. K.

    2015-11-01

    Solar axions could be converted into x-rays inside the strong magnetic field of an axion helioscope, triggering the detection of this elusive particle. Low background x-ray detectors are an essential component for the sensitivity of these searches. We report on the latest developments of the Micromegas detectors for the CERN Axion Solar Telescope (CAST), including technological pathfinder activities for the future International Axion Observatory (IAXO). The use of low background techniques and the application of discrimination algorithms based on the high granularity of the readout have led to background levels below 10-6 counts/keV/cm2/s, more than a factor 100 lower than the first generation of Micromegas detectors. The best levels achieved at the Canfranc Underground Laboratory (LSC) are as low as 10-7 counts/keV/cm2/s, showing good prospects for the application of this technology in IAXO. The current background model, based on underground and surface measurements, is presented, as well as the strategies to further reduce the background level. Finally, we will describe the R&D paths to achieve sub-keV energy thresholds, which could broaden the physics case of axion helioscopes.

  13. Volatile species retention during metallic fuel casting

    NASA Astrophysics Data System (ADS)

    Fielding, Randall S.; Porter, Douglas L.

    2013-10-01

    Metallic nuclear fuels are candidate transmutation fuel forms for advanced fuel cycles. Through the operation of the Experimental Breeder Reactor II metallic nuclear fuels have been shown to be robust and easily manufactured. However, concerns have been raised concerning loss of americium during the casting process because of its high vapor pressure. In order to address these concerns a gaseous diffusion model was developed and a series of experiments using both manganese and samarium as surrogates for americium were conducted. The modeling results showed that volatility losses can be controlled to essentially no losses with a modest overpressure. Experimental results also showed volatile species retention down to no detectable losses through overpressure, and although the loss values varied from the model results the same trend was seen. Based on these results it is very probable that americium losses through volatility can be controlled to no detectable losses through application of a modest overpressure during casting.

  14. Volatile Species Retention During Metallic Fuel Casting

    SciTech Connect

    Randall S. Fielding; Douglas L. Proter

    2013-10-01

    Metallic nuclear fuels are candidate transmutation fuel forms for advanced fuel cycles. Through the operation of the Experimental Breeder Reactor II metallic nuclear fuels have been shown to be robust and easily manufactured. However, concerns have been raised concerning loss of americium during the casting process because of its high vapor pressure. In order to address these concerns a gaseous diffusion model was developed and a series of experiments using both manganese and samarium as surrogates for americium were conducted. The modeling results showed that volatility losses can be controlled to essentially no losses with a modest overpressure. Experimental results also showed volatile species retention down to no detectable losses through overpressure, although the loss values varied from the model results the same trend was seen. Bases on these results it is very probably that americium losses through volatility can be controlled to no detectable losses through application of a modest overpressure during casting.

  15. Molten metal processing of advanced cast aluminum alloys

    NASA Astrophysics Data System (ADS)

    Shivkumar, S.; Wang, L.; Apelian, D.

    1991-01-01

    Premium quality aluminum alloy castings are used extensively in various applications requiring a high strength-to-weight ratio, such as aerospace, automotive and other structural components. The mechanical properties in these structure-sensitive alloys are determined primarily by the secondary dendrite arm spacing and the morphology of interdendritic phases. In addition, the amount of porosity in the casting and the inclusion concentration have a strong influence on fracture, fatigue and impact properties. During the production of the casting, various molten metal processing techniques can be implemented to control these microstructural parameters. These melt treatments include grain refinement with Ti-B, eutectic modification with strontium or sodium, degassing with purge gases and filtration of inclusions. The efficiency of these treatments determines the quality of the cast component.

  16. Cardiovascular cast model fabrication and casting effectiveness evaluation in fetus with severe congenital heart disease or normal heart.

    PubMed

    Wang, Yu; Cao, Hai-yan; Xie, Ming-xing; He, Lin; Han, Wei; Hong, Liu; Peng, Yuan; Hu, Yun-fei; Song, Ben-cai; Wang, Jing; Wang, Bin; Deng, Cheng

    2016-04-01

    To investigate the application and effectiveness of vascular corrosion technique in preparing fetal cardiovascular cast models, 10 normal fetal heart specimens with other congenital disease (control group) and 18 specimens with severe congenital heart disease (case group) from induced abortions were enrolled in this study from March 2013 to June 2015 in our hospital. Cast models were prepared by injecting casting material into vascular lumen to demonstrate real geometries of fetal cardiovascular system. Casting effectiveness was analyzed in terms of local anatomic structures and different anatomical levels (including overall level, atrioventricular and great vascular system, left-sided and right-sided heart), as well as different trimesters of pregnancy. In our study, all specimens were successfully casted. Casting effectiveness analysis of local anatomic structures showed a mean score from 1.90±1.45 to 3.60±0.52, without significant differences between case and control groups in most local anatomic structures except left ventricle, which had a higher score in control group (P=0.027). Inter-group comparison of casting effectiveness in different anatomical levels showed no significant differences between the two groups. Intra-group comparison also revealed undifferentiated casting effectiveness between atrioventricular and great vascular system, or left-sided and right-sided heart in corresponding group. Third-trimester group had a significantly higher perfusion score in great vascular system than second-trimester group (P=0.046), while the other anatomical levels displayed no such difference. Vascular corrosion technique can be successfully used in fabrication of fetal cardiovascular cast model. It is also a reliable method to demonstrate three-dimensional anatomy of severe congenital heart disease and normal heart in fetus.

  17. Laser-Ultrasonic Inspection of MG/AL Castings

    SciTech Connect

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

    2005-04-09

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

  18. Casting process modeling using ProCAST and CAST2D

    SciTech Connect

    Shapiro, A.; Stein, W.; Raboin, P.

    1990-12-01

    Correctly modeling the fluid flow and heat transfer during the filling of a mold with a molten metal, and the thermal-mechanical physics of solidification and cooldown is important in predicting the quality of a cast part. Determining the dynamics of the flow and the free surface shape during filling are essential in establishing the temperature gradients in the melt and in the mold. Correctly modeling the physics of volume change on solidification, shrinkage on cooling, and contact resistance across the part-mold interface directly affects the cooling rate and ultimately the final cast shape and stress state of the cast part. In this paper we describe our current research efforts on modeling fluid fill using the commercial code ProCAST by UES, and thermal-mechanical solidification modeling using the code CAST2D by LLNL.

  19. Graphite/Thermoplastic-Pultrusion Die

    NASA Technical Reports Server (NTRS)

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

    1990-01-01

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

  20. Die Milchstraße.

    NASA Astrophysics Data System (ADS)

    Henbest, N.; Couper, H.

    This book is a German translation, by M. Röser, from the English original "The guide to the Galaxy", published in 1994 (see Abstr. 61.003.065). Contents: 1. Die Entdeckung unserer Galaxis. 2. Die Lokale Gruppe. 3. Die Geographie der Galaxis. 4. Der Perseus-Arm. 5. Der Orion-Arm. 6. Unsere lokale Nachbarschaft: ein typischer Winkel der Galaxis. 7. Der Sagittarius-Arm: innerhalb der Sonnenumlaufbahn. 8. Das Zentrum der Galaxis.

  1. Where people die.

    PubMed

    Katz, B P; Zdeb, M S; Therriault, G D

    1979-01-01

    Death certificates for 1977 filed with the New York State Department of Health were studied to determine where people died. Data were examined by the location and cause of death and by the age, sex, race, and marital status of the decedent. Comparisons were made with a similar study in which U.S. data were used for 1958 events. Approximately 60 percent of all the 1977 deaths in upstate New York occurred in hospitals; only 27 percent occurred outside an institution. The location of death varied by all the factors studied. Within all age categories, males had a higher percentage of hospital deaths. In those age categories in which nursing home deaths comprised a significant proportion of total deaths, females had a higher percentage of such deaths than males. Differences in the location of death according to its cause reflect the nature of the cause of death, for example, whether it was of sudden onset or the result of chronic disease. Most people do not consider in advance where they might die. The idea that age, sex, and marital status, as well as the more obvious cause, all play a part in the location may seem surprising. Yet all these factors were found to be associated withe location of deaths in upstate New York, and there is no reason to believe that this association does not hold true for the entire nation. More research, however, needs to be done based on more years and other geographic artal stutus may be instructive as to the present state of health resources.

  2. Physicochemical and mechanical properties of freeze cast hydroxyapatite-gelatin scaffolds with dexamethasone loaded PLGA microspheres for hard tissue engineering applications.

    PubMed

    Ghorbani, Farnaz; Nojehdehian, Hanieh; Zamanian, Ali

    2016-12-01

    Hydroxyapatite (HA)-gelatin scaffolds incorporated with dexamethasone-loaded polylactic-co-glycolic acid (PLGA) microspheres were synthesized by freeze casting technique. Scanning electron microscopy (SEM) micrographs demonstrated a unidirectional microstructure and a decrease in the pore size as a function of temperature gradient. Higher amounts of HA resulted in a decrease in the pore size. According to the results, at lower cooling rates, the formation of a lamellar structure decreased the mechanical strength, but at the same time, enhanced the swelling ratio, biodegradation rate and drug release level. On the other hand, higher weight ratios of HA increased the compressive strength, and reduced the swelling ratio, biodegradation rate and drug release level. The results obtained by furrier transform infrared spectroscopy (FTIR) and bioactivity analysis illustrated that the interactions of the materials support the apatite formation in the simulated body fluid (SBF) solution. Based on the obtained results, the synthesized composite scaffolds have the necessary mechanical and physicochemical features to support the regeneration of defects and to maintain their stability during the neo-tissue formation.

  3. A New Method For Advanced Virtual Design Of Stamping Tools For Automotive Industry: Application To Nodular Cast Iron EN-GJS-600-3

    NASA Astrophysics Data System (ADS)

    Ben-Slima, Khalil; Penazzi, Luc; Mabru, Catherine; Ronde-Oustau, François; Rezaï-Aria, Farhad

    2011-05-01

    This contribution presents an approach combining the stamping numerical processing simulations and structure analysis in order to improve the design for optimizing the tool fatigue life. The method consists in simulating the stamping process via AutoForm® (or any FEM Code) by considering the tool as a perfect rigid body. The estimated contact pressure is then used as boundary condition for FEM structure loading analysis. The result of this analysis is used for life prediction of the tool using S-N fatigue curve. If the prescribed tool life requirements are not satisfied, then the critical region of the tool is redesigned and the whole simulation procedures are reactivated. This optimization method is applied for a cast iron EN-GJS-600-3 as candidate stamping tool materiel. The room temperature fatigue S-N curves of this alloy are established in laboratory under uniaxial push/pull cyclic experiments on cylindrical specimens under a load ratio of R (σmin/σmax) = -2.

  4. Effect of microstructure on the mechanical properties of as-cast Ti-Nb-Al-Cu-Ni alloys for biomedical application.

    PubMed

    Okulov, I V; Pauly, S; Kühn, U; Gargarella, P; Marr, T; Freudenberger, J; Schultz, L; Scharnweber, J; Oertel, C-G; Skrotzki, W; Eckert, J

    2013-12-01

    The correlation between the microstructure and mechanical behavior during tensile loading of Ti68.8Nb13.6Al6.5Cu6Ni5.1 and Ti71.8Nb14.1Al6.7Cu4Ni3.4 alloys was investigated. The present alloys were prepared by the non-equilibrium processing applying relatively high cooling rates. The microstructure consists of a dendritic bcc β-Ti solid solution and fine intermetallic precipitates in the interdendritic region. The volume fraction of the intermetallic phases decreases significantly with slightly decreasing the Cu and Ni content. Consequently, the fracture mechanism in tension changes from cleavage to shear. This in turn strongly enhances the ductility of the alloy and as a result Ti71.8Nb14.1Al6.7Cu4Ni3.4 demonstrates a significant tensile ductility of about 14% combined with the high yield strength of above 820 MPa already in the as-cast state. The results demonstrate that the control of precipitates can significantly enhance the ductility and yet maintaining the high strength and the low Young's modulus of these alloys. The achieved high bio performance (ratio of strength to Young's modulus) is comparable (or even superior) with that of the recently developed Ti-based biomedical alloys.

  5. Physicochemical and mechanical properties of freeze cast hydroxyapatite-gelatin scaffolds with dexamethasone loaded PLGA microspheres for hard tissue engineering applications.

    PubMed

    Ghorbani, Farnaz; Nojehdehian, Hanieh; Zamanian, Ali

    2016-12-01

    Hydroxyapatite (HA)-gelatin scaffolds incorporated with dexamethasone-loaded polylactic-co-glycolic acid (PLGA) microspheres were synthesized by freeze casting technique. Scanning electron microscopy (SEM) micrographs demonstrated a unidirectional microstructure and a decrease in the pore size as a function of temperature gradient. Higher amounts of HA resulted in a decrease in the pore size. According to the results, at lower cooling rates, the formation of a lamellar structure decreased the mechanical strength, but at the same time, enhanced the swelling ratio, biodegradation rate and drug release level. On the other hand, higher weight ratios of HA increased the compressive strength, and reduced the swelling ratio, biodegradation rate and drug release level. The results obtained by furrier transform infrared spectroscopy (FTIR) and bioactivity analysis illustrated that the interactions of the materials support the apatite formation in the simulated body fluid (SBF) solution. Based on the obtained results, the synthesized composite scaffolds have the necessary mechanical and physicochemical features to support the regeneration of defects and to maintain their stability during the neo-tissue formation. PMID:27612706

  6. 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.

  7. Strip casting with fluxing agent applied to casting roll

    DOEpatents

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

    1997-01-01

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

  8. Strip casting with fluxing agent applied to casting roll

    DOEpatents

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

    1997-07-29

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

  9. Strip casting apparatus and method

    DOEpatents

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

    1988-09-20

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

  10. Biomimetic Materials by Freeze Casting

    NASA Astrophysics Data System (ADS)

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

    2013-06-01

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

  11. Pressure Rig for Repetitive Casting

    NASA Technical Reports Server (NTRS)

    Vasquez, P.; Hutto, W. R.

    1986-01-01

    Equipment life increased by improved insulation. New design cuts time of preparation for casting from several days to about 1 hour. Savings due to elimination of lengthy heating and drying operations associated with preparation of ceramic mold. Quality of casting improved because moisture in cavity eliminated by use of insulating material, and more uniform pressure applied to process. Commercial blanket insulator protects components from heat, increasing life of pressure rig and enabling repeated use. Improved heat protection allows casting of brass and other alloys with higher melting temperatures in pressure rig.

  12. Strip casting apparatus and method

    DOEpatents

    Williams, Robert S.; Baker, Donald F.

    1988-01-01

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

  13. Automated multiple view inspection of metal castings

    NASA Astrophysics Data System (ADS)

    Mery, Domingo; Carrasco, Miguel

    2007-01-01

    Automated visual inspection of metal castings is defined as a quality control task that determines automatically if a casting deviates from a given set of specifications using visual data. Many research directions in this field have been exploited, some very different principles have been adopted and a wide variety of algorithms have been appeared in the literature. However, the developed approaches are tailored to the inspection task, i.e., there is no common approach applicable to all cases because the development is an ad hoc process. Additionally, detection accuracy should be improved, because there is a fundamental trade off between false alarms and miss detections. For these reasons, we proposed a novel methodology, called Automated Multiple View Inspection, that uses redundant views of the test object to perform the inspection task. The method is opening up new possibilities in inspection field by taking into account the useful information about the correspondence between the different views. It is very robust because in first step it identifies potential defects in each view and in second step it finds correspondences between potential defects, and only those that are matched in different views are detected as real defects. In this paper, we review the advances done in this field giving an overview of the multiple view inspection and showing experimental results obtained on metal castings.

  14. Will the UK Supreme Court allow assisted dying?

    PubMed

    Griffith, Richard

    MPs overwhelmingly voted against passing the Assisted Dying Bill into law in September 2015. The Bill was defeated by a majority of 212, despite the heartfelt pleas of many MPs to pass it into law. The size of the defeat means that it is unlikely that Parliament will consider a similar law for many years. Yet many considered the Bill their last opportunity to make assisted dying lawful. There is, however, one further possible way assisted dying could become lawful in the UK--and that would be where the Supreme Court allowed it. In this article, the author reviews the Supreme Court's decision in R (on the application of Nicklinson v Ministry of Justice [2014] and considers how likely it is that the Supreme Court will now sanction assisted dying following Parliament's refusal to enact an assisted dying law. PMID:26500128

  15. Will the UK Supreme Court allow assisted dying?

    PubMed

    Griffith, Richard

    MPs overwhelmingly voted against passing the Assisted Dying Bill into law in September 2015. The Bill was defeated by a majority of 212, despite the heartfelt pleas of many MPs to pass it into law. The size of the defeat means that it is unlikely that Parliament will consider a similar law for many years. Yet many considered the Bill their last opportunity to make assisted dying lawful. There is, however, one further possible way assisted dying could become lawful in the UK--and that would be where the Supreme Court allowed it. In this article, the author reviews the Supreme Court's decision in R (on the application of Nicklinson v Ministry of Justice [2014] and considers how likely it is that the Supreme Court will now sanction assisted dying following Parliament's refusal to enact an assisted dying law.

  16. 21 CFR 888.5940 - Cast component.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 21 Food and Drugs 8 2014-04-01 2014-04-01 false Cast component. 888.5940 Section 888.5940 Food and... ORTHOPEDIC DEVICES Surgical Devices § 888.5940 Cast component. (a) Identification. A cast component is a device intended for medical purposes to protect or support a cast. This generic type of device...

  17. 21 CFR 880.6185 - Cast cover.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... 21 Food and Drugs 8 2011-04-01 2011-04-01 false Cast cover. 880.6185 Section 880.6185 Food and....6185 Cast cover. (a) Identification. A cast cover is a device intended for medical purposes that is made of waterproof material and placed over a cast to protect it from getting wet during a shower or...

  18. 21 CFR 880.6185 - Cast cover.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 21 Food and Drugs 8 2012-04-01 2012-04-01 false Cast cover. 880.6185 Section 880.6185 Food and....6185 Cast cover. (a) Identification. A cast cover is a device intended for medical purposes that is made of waterproof material and placed over a cast to protect it from getting wet during a shower or...

  19. 21 CFR 880.6185 - Cast cover.

    Code of Federal Regulations, 2014 CFR

    2014-04-01

    ... 21 Food and Drugs 8 2014-04-01 2014-04-01 false Cast cover. 880.6185 Section 880.6185 Food and....6185 Cast cover. (a) Identification. A cast cover is a device intended for medical purposes that is made of waterproof material and placed over a cast to protect it from getting wet during a shower or...

  20. 21 CFR 888.5940 - Cast component.

    Code of Federal Regulations, 2011 CFR

    2011-04-01

    ... 21 Food and Drugs 8 2011-04-01 2011-04-01 false Cast component. 888.5940 Section 888.5940 Food and... ORTHOPEDIC DEVICES Surgical Devices § 888.5940 Cast component. (a) Identification. A cast component is a device intended for medical purposes to protect or support a cast. This generic type of device...

  1. 21 CFR 888.5940 - Cast component.

    Code of Federal Regulations, 2012 CFR

    2012-04-01

    ... 21 Food and Drugs 8 2012-04-01 2012-04-01 false Cast component. 888.5940 Section 888.5940 Food and... ORTHOPEDIC DEVICES Surgical Devices § 888.5940 Cast component. (a) Identification. A cast component is a device intended for medical purposes to protect or support a cast. This generic type of device...

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

    SciTech Connect

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

    2003-04-30

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

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

    SciTech Connect

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

    2003-04-01

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

  4. Continuous Casting for Aluminum Sheet: a Product Perspective

    NASA Astrophysics Data System (ADS)

    Sanders, Robert E.

    2012-02-01

    Continuous casting processes have been used successfully for more than 50 years to reduce the cost of manufacturing a variety of aluminum rolled products. Approximately 25% of North American flat-rolled sheet and foil is sourced from twin-roll cast or slab cast processes. Twin roll-casters provide a cost-effective solution for producing foil and light-gauge sheet from relatively low-alloyed aluminum (1xxx and 8xxx alloys). Slab casters, particularly Hazelett twin-belt machines, are well utilized in the production of 3xxx or 5xxx painted building products which require moderate strength and good corrosion resistance. Both foil and painted sheet are cost-sensitive commodity products with well-known metallurgical and quality requirements. There have been extensive trials and modest successes with continuous cast can stock and automotive sheet. However, they have not been widely adopted commercially due to generally lower levels of surface quality and formability compared with sheet produced from scalped direct chill (DC) cast ingot. The metallurgical requirements for can and auto sheet are considered in more detail with emphasis on the microstructural features which limit their application, e.g., particle distribution, grain size, and texture. Looking forward, slab casting offers the most viable opportunity for producing strong (i.e., higher alloy content), formable structural auto sheet with acceptable surface quality.

  5. 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.

    2016-09-01

    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.

  6. Investment casting design of experiment. Final report

    SciTech Connect

    Owens, R.

    1997-10-01

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

  7. Strong and light plaster casts?

    PubMed

    Stewart, Todd; Cheong, Wen; Barr, Victoria; Tang, Daniel

    2009-08-01

    Three geometries of volar slab plaster cast for the stabilisation of wrist fractures were investigated. It was found that by moulding reinforcement ridges on the inferior surface of the slab the strength and stiffness could be doubled with only a 20% increase in weight. It was discovered that to provide the same increase in strength with a traditional cast the entire thickness of the cast would have to be doubled, with a 100% increase in weight that would be cumbersome to most users. Bending theory is presented in a simple manner to allow clinicians to understand how reinforcement mouldings can improve the strength and stiffness of plaster casts without adversely influencing weight, or cost.

  8. Casting Using A Polystyrene Pattern

    NASA Technical Reports Server (NTRS)

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

    1993-01-01

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

  9. Two Piece Compaction Die Design

    SciTech Connect

    Coffey, Ethan N

    2010-03-01

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

  10. Interface Formation During Fusion™ Casting of AA3003/AA4045 Aluminum Alloy Ingots

    NASA Astrophysics Data System (ADS)

    Di Ciano, Massimo; Caron, E. J. F. R.; Weckman, D. C.; Wells, M. A.

    2015-12-01

    Fusion™ casting is a unique Direct Chill continuous casting process whereby two different alloys can be cast simultaneously, producing a laminated ingot for rolling into clad sheet metal such as AA3003/AA4045 brazing sheet. Better understanding of the wetting and interface formation process during Fusion™ casting is required to further improve process yields and also explore use of other alloy systems for new applications. In this research, AA3003-core/AA4045-clad ingots were cast using a well-instrumented lab-scale Fusion™ casting system. As-cast Fusion™ interfaces were examined metallurgically and by mechanical testing. Computational fluid dynamic analyses of the FusionTM casts were also performed. It was shown that the liquid AA4045-clad alloy was able to successfully wet and create an oxide-free, metallurgical, and mechanically sound interface with the lightly oxidized AA3003-core shell material. Based on the results of this study, it is proposed that the bond formation process at the alloys interface during casting is a result of discrete penetration of AA4045 liquid at defects in the preexisting AA3003 oxide, dissolution of underlying AA3003 by liquid AA4045, and subsequent bridging between penetration sites. Spot exudation on the AA3003 chill cast surface due to remelting and inverse segregation may also improve the wetting and bonding process.

  11. Dying and multiplying life.

    PubMed

    Rodríguez-Arias, David

    2014-09-01

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

  12. The Dying Day

    NASA Astrophysics Data System (ADS)

    Heiles, Carl

    1993-05-01

    The 85-foot telescope's dying day was part of a week of memorably unusual weather---which, in turn, was part of a memorable winter in California (and elsewhere!). On this day, it spent several hours finishing a months-long, apparently successful observation of Zeeman splitting of the 18-cm OH lines in absorption against the Galactic center continuum source Sgr A. Later, it continued a survey of weak diffuse radio recombination lines near the Galactic plane---observations that were interrupted by strong winds, which made the telescope move to the stow position. We know the rest. Had the telescope not been destroyed, it would have been reconfigured the following day to observe the 21-cm line. It would have continued an ongoing survey of interstellar magnetic fields using Zeeman splitting of the 21-cm line. It would have begun a search for broad, weak line wings, which had been previously discovered in association with supernova remnants. It would have been involved in a number of H I mapping projects. And it would have continued its measurements of diffuse radio recombination lines. Had it not been for the inclement weather, the weekend would have seen it being used in laboratory exercises for undergraduates at UC Berkeley.

  13. Oscillator for continuous casting mold

    SciTech Connect

    Behrends, G.

    1993-06-15

    In a continuous casting machine comprising a chilled mold disposed to receive molten metal which is discharged from the mold as a curved casting having a predetermined casting radius, and an oscillating drive for oscillating the mold relative to the casting, wherein the improvement described comprises mold guidance means having a first tensile element having an inner end and an outer end, the outer end being anchored to a fixed external frame and the inner end being secured to move with the mold, the first tensile element lying on a first radius extending from the center of curvature of said pre-determined casting radius; and a second tensile element having an inner and an outer end both anchored to a fixed external frame and secured to move with the mold intermediate the inner and outer ends, at least one end having variable tensioning means adapted to apply a tensile force to the second tensile element, the second tensile element lying on a second radius extending from the center of curvature of said predetermined casting radius.

  14. Casting evaluation of U-Zr alloy system fuel slug for SFR prepared by injection casting method

    SciTech Connect

    Song, Hoon; Kim, Jong-Hwan; Kim, Ki-Hwan; Lee, Chan-Bock

    2013-07-01

    Metal fuel slugs of U-Pu-Zr alloys for Sodium-cooled Fast Reactor (SFR) have conventionally been fabricated by a vacuum injection casting method. Recently, management of minor actinides (MA) became an important issue because direct disposal of the long-lived MA can be a long-term burden for a tentative repository up to several hundreds of thousand years. In order to recycle transuranic elements (TRU) retained in spent nuclear fuel, remote fabrication capability in a shielded hot cell should be prepared. Moreover, generation of long-lived radioactive wastes and loss of volatile species should be minimized during the recycled fuel fabrication step. In order to prevent the evaporation of volatile elements such as Am, alternative fabrication methods of metal fuel slugs have been studied applying gravity casting, and improved injection casting in KAERI, including melting under inert atmosphere. And then, metal fuel slugs were examined with casting soundness, density, chemical analysis, particle size distribution and microstructural characteristics. Based on these results there is a high level of confidence that Am losses will also be effectively controlled by application of a modest amount of overpressure. A surrogate fuel slug was generally soundly cast by improved injection casting method, melted fuel material under inert atmosphere.

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

    NASA Astrophysics Data System (ADS)

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

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

  16. Energy Saving Melting and Revert Reduction Technology (Energy-SMARRT): Light Metals Permanent Mold Casting

    SciTech Connect

    Fasoyinu, Yemi

    2014-03-31

    Current vehicles use mostly ferrous components for structural applications. It is possible to reduce the weight of the vehicle by substituting these parts with those made from light metals such as aluminum and magnesium. Many alloys and manufacturing processes can be used to produce these light metal components and casting is known to be most economical. One of the high integrity casting processes is permanent mold casting which is the focus of this research report. Many aluminum alloy castings used in automotive applications are produced by the sand casting process. Also, aluminum-silicon (Al-Si) alloys are the most widely used alloy systems for automotive applications. It is possible that by using high strength aluminum alloys based on an aluminum-copper (Al-Cu) system and permanent mold casting, the performance of these components can be enhanced significantly. This will also help to further reduce the weight. However, many technological obstacles need to be overcome before using these alloys in automotive applications in an economical way. There is very limited information in the open literature on gravity and low-pressure permanent mold casting of high strength aluminum alloys. This report summarizes the results and issues encountered during the casting trials of high strength aluminum alloy 206.0 (Al-Cu alloy) and moderate strength alloy 535.0 (Al-Mg alloy). Five engineering components were cast by gravity tilt-pour or low pressure permanent mold casting processes at CanmetMATERIALS (CMAT) and two production foundries. The results of the casting trials show that high integrity engineering components can be produced successfully from both alloys if specific processing parameters are used. It was shown that a combination of melt processing and mold temperature is necessary for the elimination of hot tears in both alloys.

  17. Clean ferrous casting technology research. Annual report, September 29, 1994--September 28, 1995

    SciTech Connect

    Griffin, J.; Bates, C.E.; Piwonka, T.S.

    1995-10-31

    This annual report covers work performed in the second year of research on Clean Ferrous Casting Technology Research. Significant progress was made in establishing pouring practices which avoid re-oxidation of steel during pouring; application of revised pouring practices have led to reduced inclusion levels in commercially poured steel castings.

  18. 76 FR 5840 - The Basic Aluminum Castings Co., Cleveland, OH; Notice of Revised Determination on Reconsideration

    Federal Register 2010, 2011, 2012, 2013, 2014

    2011-02-02

    ... was published in the Federal Register on November 3, 2010 (75 FR 67773). Workers at the subject firm... Employment and Training Administration The Basic Aluminum Castings Co., Cleveland, OH; Notice of Revised... Assistance (TAA) applicable to workers and former workers of The Basic Aluminum Castings Co., Cleveland,...

  19. CAST STONE TECHNOLOGY FOR THE TREATMENT AND IMMOBILIZATION OF LOW-ACTIVITY WASTE

    SciTech Connect

    MINWALL HJ

    2011-04-08

    Cast stone technology is being evaluated for potential application in the treatment and immobilization of Hanford low-activity waste. The purpose of this document is to provide background information on cast stone technology. The information provided in the report is mainly based on a pre-conceptual design completed in 2003.

  20. Titan Casts Revealing Shadow

    NASA Astrophysics Data System (ADS)

    2004-05-01

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

  1. Informatics approach using metabolic reactivity classifiers to link in vitro to in vivo data in application to the ToxCast Phase I dataset

    EPA Science Inventory

    Strategic combinations and tiered application of alternative testing methods to replace or minimize the use of animal models is attracting much attention. With the advancement of high throughput screening (HTS) assays and legacy databases providing in vivo testing results, suffic...

  2. Effect of Varying Layers of Two Die Spacers on Precementation Space of Full Coverage Restorations.

    PubMed

    Mule, Shivkumar A; Dange, Shankar P; Khalikar, Arun N; Vaidya, Smita P

    2014-12-01

    The purpose of this study was to evaluate and compare the effect of varying layers of two commercially available die spacers on pre-cementation space of full coverage restorations in vitro and in vivo. Seven dies were prepared for each of 15 subjects. On three dies 1, 2, 3 layers of Pico-fit and on other three dies 1, 2, 3 layers of Yeti die spacers applied, wax pattern fabricated, invested and cast. Metal copings seated in vitro on die without die spacer and on prepared tooth of respective subject with fit-checker. Thickness of fit checker was measured using micrometer at mid-axial, mid-occlusal and near finish line locations that provided pre-cementation space. Result of ANOVA tests suggested significant difference among groups with varying layers. There was no significant difference between pre-cementation space achieved with Pico-fit and Yeti die spacers. The r values suggested positive correlation between the respective pair of in vivo and in vitro groups. (1) There was significant difference between pre-cementation space at mid-axial and mid-occlusal sites achieved with 1, 2 and 3 layers of die spacers except between 1 and 2 layers and 1 and 3 layers at mid-occlusal site. (2) Pre-cementation space achieved with Pico-fit and Yeti die spacers did not differ significantly for same location, layers and in vitro and in vivo. (3) Pre-cementation space achieved in vitro was analogous to pre-cementation space achieved in vivo for respective location, layers and die spacer.

  3. Fillability of Thin-Wall Steel Castings

    SciTech Connect

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

    2002-07-30

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

  4. A discussion on the proposed assisted dying law.

    PubMed

    Griffith, Richard

    2014-08-01

    Having failed in their attempt to persuade the United Kingdom Supreme Court to allow health professionals to participate in assisting patients to end their lives, the hopes of campaigners now lie with Parliament passing Lord Falconer's private members' Assisted Dying Bill. This article reviews the Supreme Court's decision in R (on the application of Nicklinson) v Ministry of Justice [2014] and considers how likely it is that Parliament will enact an assisted dying law. PMID:25089754

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

    PubMed

    Dubowitz, Gerald; Miller, Deborah M

    2003-01-01

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

  6. Differences in microstructure and texture of Al-Mg sheets produced by twin-roll continuous casting and by direct-chill casting

    SciTech Connect

    Slamova, M.; Karlik, M.; Robaut, F.; Slama, P.; Veron, M

    2002-10-15

    Over the last two decades, the use of aluminum sheets in automotive applications has increased. Aluminum sheets are currently produced from direct-chill (DC) cast plates. The need for low-cost aluminum sheets is a challenge for the development of new materials produced by twin-roll continuous (TRC) casting and cold rolling. It is expected that the sheets produced from these different casting procedures can differ in their microstructure. Therefore, they can exhibit different formability behavior. The paper presents the results of the microstructural characterization and texture evaluation of aluminum sheets produced by both technologies. Sheets produced from twin-roll cast materials have much finer and more numerous second-phase particles, the grain structures of both types of materials are similar. Electron backscatter diffraction (EBSD) and X-ray diffraction techniques were used for texture evaluation and both confirmed the presence of stronger cube texture in the strips produced from DC-cast plates.

  7. Improving care of dying children.

    PubMed Central

    Martinson, I M

    1995-01-01

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

  8. REFRACTORY DIE FOR EXTRUDING URANIUM

    DOEpatents

    Creutz, E.C.

    1959-08-11

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

  9. Factors contributing to the temperature beneath plaster or fiberglass cast material

    PubMed Central

    Hutchinson, Michael J; Hutchinson, Mark R

    2008-01-01

    Background Most cast materials mature and harden via an exothermic reaction. Although rare, thermal injuries secondary to casting can occur. The purpose of this study was to evaluate factors that contribute to the elevated temperature beneath a cast and, more specifically, evaluate the differences of modern casting materials including fiberglass and prefabricated splints. Methods The temperature beneath various types (plaster, fiberglass, and fiberglass splints), brands, and thickness of cast material were measured after they were applied over thermometer which was on the surface of a single diameter and thickness PVC tube. A single layer of cotton stockinette with variable layers and types of cast padding were placed prior to application of the cast. Serial temperature measurements were made as the cast matured and reached peak temperature. Time to peak, duration of peak, and peak temperature were noted. Additional tests included varying the dip water temperature and assessing external insulating factors. Ambient temperature, ambient humidity and dip water freshness were controlled. Results Outcomes revealed that material type, cast thickness, and dip water temperature played key roles regarding the temperature beneath the cast. Faster setting plasters achieved peak temperature quicker and at a higher level than slower setting plasters. Thicker fiberglass and plaster casts led to greater peak temperature levels. Likewise increasing dip-water temperature led to elevated temperatures. The thickness and type of cast padding had less of an effect for all materials. With a definition of thermal injury risk of skin injury being greater than 49 degrees Celsius, we found that thick casts of extra fast setting plaster consistently approached dangerous levels (greater than 49 degrees for an extended period). Indeed a cast of extra-fast setting plaster, 20 layers thick, placed on a pillow during maturation maintained temperatures over 50 degrees of Celsius for over 20

  10. Dying at the best time.

    PubMed

    Seale, C; Addington-Hall, J

    1995-03-01

    These are the results of two surveys of relatives, and others who knew people who had died, describing events in the year before death and their views on the time of the person's death. Those surveyed were identified from death certificates in England. The main focus is on a sample of 3696 people dying in 1990 in 20 health authorities, with supporting analysis from an earlier national sample of 639 people dying in 1987. Variation in peoples' views about whether an earlier death would have been better is reported, in the context of debate about euthanasia. Spouses were less likely than others to feel that it would have been better if the person had died earlier, and this held true even when controlling for the deceaseds' levels of pain, distress, dependency and age. Spouses were more likely than others to say that a later death would have been better, though not in cases where the deceased was reported as having said they wanted to die sooner. Spouses were influenced by the loss which the death of the person represented for them, being more likely than others to say they missed the person who died a great deal, and feel loneliness was a big problem. Non spouses (children and other relatives of the deceased, friends, neighbours and a few officials) on the other hand were more likely than spouses to say an earlier death would have been better, even when levels of pain, distress, dependency and age were controlled for.(ABSTRACT TRUNCATED AT 250 WORDS)

  11. Yield improvement and defect reduction in steel casting

    SciTech Connect

    Kent Carlson

    2004-03-16

    This research project investigated yield improvement and defect reduction techniques in steel casting. Research and technology development was performed in the following three specific areas: (1) Feeding rules for high alloy steel castings; (2) Unconventional yield improvement and defect reduction techniques--(a) Riser pressurization; and (b) Filling with a tilting mold; and (3) Modeling of reoxidation inclusions during filling of steel castings. During the preparation of the proposal for this project, these areas were identified by the High Alloy Committee and Carbon and Low Alloy Committee of the Steel Founders' Society of America (SFSA) as having the highest research priority to the steel foundry industry. The research in each of the areas involved a combination of foundry experiments, modeling and simulation. Numerous SFSA member steel foundries participated in the project through casting trials and meetings. The technology resulting from this project will result in decreased scrap and rework, casting yield improvement, and higher quality steel castings produced with less iteration. This will result in considerable business benefits to steel foundries, primarily due to reduced energy and labor costs, increased capacity and productivity, reduced lead-time, and wider use and application of steel castings. As estimated using energy data provided by the DOE, the technology produced as a result of this project will result in an energy savings of 2.6 x 10{sup 12} BTU/year. This excludes the savings that were anticipated from the mold tilting research. In addition to the energy savings, and corresponding financial savings this implies, there are substantial environmental benefits as well. The results from each of the research areas listed above are summarized.

  12. Morphological castes in a vertebrate.

    PubMed

    O'Riain, M J; Jarvis, J U; Alexander, R; Buffenstein, R; Peeters, C

    2000-11-21

    Morphological specialization for a specific role has, until now, been assumed to be restricted to social invertebrates. Herein we show that complete physical dimorphism has evolved between reproductives and helpers in the eusocial naked mole-rat. Dimorphism is a consequence of the lumbar vertebrae lengthening after the onset of reproduction in females. This is the only known example of morphological castes in a vertebrate and is distinct from continuous size variation between breeders and helpers in other species of cooperatively breeding vertebrates. The evolution of castes in a mammal and insects represents a striking example of convergent evolution for enhanced fecundity in societies characterized by high reproductive skew. Similarities in the selective environment between naked mole-rats and eusocial insect species highlight the selective conditions under which queen/worker castes are predicted to evolve in animal societies.

  13. Three-dimensional assessment of dental casts' occlusal surfaces using two impression materials.

    PubMed

    Tarawneh, F M; Panos, P G; Athanasiou, A E

    2008-11-01

    The aim of this study was to assess by means of a three-dimensional computed tomography scanning system the occlusal surface characteristics of dental casts made using two different impression materials. Alginate and polyvinyl siloxane impressions were taken of 20 dental students resulting in 40 dental casts. The casts were paired for each student separately so that each pair consisted of an alginate poured cast and a polyvinyl siloxane poured out cast. The casts were scanned using FlashCT scanner and for each cast, a three-dimensional digital image was obtained. The digitized casts were processed using the three-dimensional imaging software Geomagic Studio 9. A total of 464 paired teeth were digitally separated and superimposed. For each tooth, two measurements were obtained corresponding to the two different impression materials used. The two sets of volumes for all digitally separated teeth were compared and analysed using the Wilcoxon signed test. Larger volume measurements were obtained for teeth separated from alginate poured out casts than from their corresponding ones from polyvinyl siloxane casts (P = 0.005). When the teeth were divided into the groups of incisors, canines and premolars/molars, only the last one exhibited significant difference (P = 0.00). The mean difference between the volumes measured for all 464 teeth separated was 0.041 mm(3) (+/-0.33). The occlusal surfaces of teeth appear differently in dental casts depending on the impression materials used. Impressions of dental casts should be utilized with caution in relation to their research application and in reference with dental wear studies.

  14. Tape-cast sensors and method of making

    DOEpatents

    Mukundan, Rangachary; Brosha, Eric L.; Garzon, Fernando H.

    2009-08-18

    A method of making electrochemical sensors in which an electrolyte material is cast into a tape. Prefabricated electrodes are then partially embedded between two wet layers of the electrolyte tape to form a green sensor, and the green sensor is then heated to sinter the electrolyte tape around the electrodes. The resulting sensors can be used in applications such as, but not limited to, combustion control, environmental monitoring, and explosive detection. A electrochemical sensor formed by the tape-casting method is also disclosed.

  15. Texturing polymer surfaces by transfer casting. [cardiovascular prosthesis

    NASA Technical Reports Server (NTRS)

    Banks, B. A.; Weigand, A. J.; Sovey, J. S. (Inventor)

    1982-01-01

    A technique for fabricating textured surfaces on polymers without altering their surface chemistries is described. A surface of a fluorocarbon polymer is exposed to a beam of ions to texture it. The polymer which is to be surface-roughened is then cast over the textured surface of the fluorocarbon polymer. After curing, the cast polymer is peeled off the textured fluorocarbon polymer, and the peeled off surface has negative replica of the textured surface. The microscopic surface texture provides large surface areas for adhesive bonding. In cardiovascular prosthesis applications the surfaces are relied on for the development of a thin adherent well nourished thrombus.

  16. Casting propellant in rocket engine

    NASA Technical Reports Server (NTRS)

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

    1976-01-01

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

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

    SciTech Connect

    Kevin M. McHugh; Enrique J. Lavernia

    2006-01-01

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

  18. Rapid prototyping: A paradigm shift in investment casting

    SciTech Connect

    Atwood, C.L.; Maguire, M.C.; Baldwin, M.D.; Pardo, B.T.

    1996-09-01

    The quest for fabricating complex metal parts rapidly and with minimal cost has brought rapid prototyping (RP) processes to the forefront of the investment casting industry. Relatively recent advances in DTM Corporation`s selective laser sintering (SLS) and 3D Systems stereolithography (SL) processes have had a significant impact on the overall quality of patterns produced using these rapid prototyping processes. Sandia National Laboratories uses patterns generated from rapid prototyping processes to reduce the cycle time and cost of fabricating prototype and small lot production parts in support of a program called FASTCAST. The SLS process is used to fabricate patterns from materials such as investment casting wax, polycarbonate, and a new material called TrueForm PM{trademark}. With the timely introduction of each of these materials, the quality of patterns fabricated has improved. The development and implementation of SL QuickCast{trademark} software has enabled this process to produce highly accurate patterns for use in investment casting. This paper focuses on the successes with these new pattern materials and the infrastructure required to cast rapid prototyping patterns successfully. In addition, a brief overview of other applications of rapid prototyping at Sandia will be discussed.

  19. Feasibility Study for Casting of High Temperature Refractory Superalloy Composites

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A.

    1998-01-01

    Abstract This study investigated the feasibility of using conventional casting technique to fabricate refractory wires reinforced superalloy composites. These composites were being developed for advanced rocket engine turbine blades and other high temperature applications operating up to 2000 F. Several types of refractory metal wires such as W- Th, W-Re, Mo-Hf-C and W-HF-C reinforced waspaloy were experimentally cast and heat treated at 2000 F up to 48 hrs. Scanning electron microscope analysis was conducted in regions adjacent to the wire-matrix interface to determine the reaction zone and chemical compatibility resulting from material interdiffusion. It was concluded that fabrication using conventional casting may be feasible because the wire-matrix reaction zone thickness was comparable to similar composites produced by arc-sprayed monotape with hot isostatic pressing technique, Moreover, it was also found that the chemical compatibility could be improved significantly through a slight modification of the superalloy matrix compositions.

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

    SciTech Connect

    Thangirala, Mani

    2015-09-30

    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 Haynes 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

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

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

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

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

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

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

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

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

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

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

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

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

  5. Live and let die

    PubMed Central

    Milsom, Michael D.; Williams, David A.

    2007-01-01

    Gene transfer into hematopoietic stem cells (HSC) provides a potential means of correcting monogenic defects and altering drug sensitivity of normal bone marrow to cytotoxic agents. These applications have significant therapeutic potential but the translation of successful murine studies into human therapies has been hindered by low gene transfer in large animals (including humans), and recent serious side effects in a human immunodeficiency trial related to insertional mutagenesis. The latter trial, along with other subsequent trials, while bringing into focus the potential risks of integrating vector systems, also clearly demonstrate the potential usefulness of in vivo selection as it relates to inefficient stem cell transduction. Developing from initial studies by our group and other investigators in which drug resistance was utilized to demonstrate the feasibility of using gene transfer to effect protection from myelotoxicity of chemotherapeutic agents, expression of mutant forms of O6-methyguanine-DNA-methytransferase (MGMT) coupled with the simultaneous use of pharmacologic inhibitors and chemotherapeutic agents has been shown to provide a powerful method to select HSC in vivo. While stem and progenitor cell protection and resulting selection in vivo has potential applications for the treatment of selected cancers (allowing dose escalation) andor correction of monogenic disease (allowing an iatrogenic survival advantage of transduced cells in vivo), such an in vivo selection may have untoward effects on stem cell behavior. These deleterious effects may include stem cell exhaustion; lineage skewing; accumulation of genotoxic lesions; and clonal dominance driven towards a pro-leukemic phenotype. Knowledge of the likelihood of such deleterious events occurring as well as their potential implications will be critical to future clinical applications and may also enhance our understanding of both normal stem cell behavior and the evolution of hematopoietic

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

    NASA Astrophysics Data System (ADS)

    Bae, Chang-Jun

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

  7. Advanced Lost Foam Casting Technology

    SciTech Connect

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

    2000-11-30

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

  8. Casting Freedom, 1860-1862

    ERIC Educational Resources Information Center

    Social Education, 2005

    2005-01-01

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

  9. Tape casting of magnesium oxide.

    SciTech Connect

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

    2008-02-01

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

  10. Molding A Cast Metals Program

    ERIC Educational Resources Information Center

    Trumble, Dale E.

    1975-01-01

    The cast metals program, a two-year associate degree program, at Muskegon Community College, Musegon, Michigan operates in close cooperation with the local foundry industry to provide a background for entry-level technical jobs and for continued studies toward a four-year degree. (EA)

  11. Graphite Formation in Cast Iron

    NASA Technical Reports Server (NTRS)

    Stefanescu, D. M.

    1985-01-01

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

  12. Math: Objectives Guide. Project CAST.

    ERIC Educational Resources Information Center

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

    The guide lists math objectives needed for independent living by secondary special education students. One of a series of Project CAST (Community and School Together) life skills manuals, the guide outlines basic competencies in terms of goal statements, behavioral objectives, and specialized vocabulary for the following areas: money, making…

  13. Prediction of Microporosity in Shrouded Impeller Castings

    SciTech Connect

    Viswanathan, S. Nelson, C.D.

    1998-09-01

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

  14. 14 CFR 27.621 - Casting factors.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... 14 Aeronautics and Space 1 2012-01-01 2012-01-01 false Casting factors. 27.621 Section 27.621... STANDARDS: NORMAL CATEGORY ROTORCRAFT Design and Construction General § 27.621 Casting factors. (a) General... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings...

  15. 14 CFR 27.621 - Casting factors.

    Code of Federal Regulations, 2014 CFR

    2014-01-01

    ... 14 Aeronautics and Space 1 2014-01-01 2014-01-01 false Casting factors. 27.621 Section 27.621... STANDARDS: NORMAL CATEGORY ROTORCRAFT Design and Construction General § 27.621 Casting factors. (a) General... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings...

  16. 14 CFR 29.621 - Casting factors.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... 14 Aeronautics and Space 1 2011-01-01 2011-01-01 false Casting factors. 29.621 Section 29.621... STANDARDS: TRANSPORT CATEGORY ROTORCRAFT Design and Construction General § 29.621 Casting factors. (a... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings...

  17. 14 CFR 27.621 - Casting factors.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... 14 Aeronautics and Space 1 2011-01-01 2011-01-01 false Casting factors. 27.621 Section 27.621... STANDARDS: NORMAL CATEGORY ROTORCRAFT Design and Construction General § 27.621 Casting factors. (a) General... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings...

  18. 14 CFR 29.621 - Casting factors.

    Code of Federal Regulations, 2014 CFR

    2014-01-01

    ... 14 Aeronautics and Space 1 2014-01-01 2014-01-01 false Casting factors. 29.621 Section 29.621... STANDARDS: TRANSPORT CATEGORY ROTORCRAFT Design and Construction General § 29.621 Casting factors. (a... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings...

  19. 14 CFR 29.621 - Casting factors.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... 14 Aeronautics and Space 1 2012-01-01 2012-01-01 false Casting factors. 29.621 Section 29.621... STANDARDS: TRANSPORT CATEGORY ROTORCRAFT Design and Construction General § 29.621 Casting factors. (a... approved specifications. Paragraphs (c) and (d) of this section apply to structural castings...

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

    PubMed

    Sabir, Sharjeel

    2003-12-01

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

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

    MedlinePlus

    ... Web version Diabetic Neuropathy | What is a Total Contact Cast? What is a total contact cast? A total contact cast is a cast used to treat ulcers ( ... foot--that's why it is called a total contact cast. The cast helps to protect the skin ...

  2. Clinical management of dying patients.

    PubMed Central

    Gavrin, J; Chapman, C R

    1995-01-01

    Dying is universal, and death should be a peaceful time. Myriad comfort measures are available in the last weeks before life ends. Discussions about end-of-life issues often suffer from lack of informed opinion. Palliative care experts have identified specific somatic and psychological sources of distress for dying patients and their loved ones. Pain, shortness of breath, nausea and vomiting, and fear of abandonment contribute substantially to both physical and psychological discomfort toward the end of life. Simple, effective methods exist for relieving those symptoms. Knowledge about the natural events associated with dying and an informed approach to medical and psychological interventions contribute to systematic and successful comfort care. We describe the origin of physical and psychological distress at the end of life and provide strategies for alleviating many of the discomforts. PMID:7571591

  3. Acting to let someone die.

    PubMed

    McGee, Andrew

    2015-02-01

    This paper examines the recent prominent view in medical ethics that withdrawing life-sustaining treatment (LST) is an act of killing. I trace this view to the rejection of the traditional claim that withdrawing LST is an omission rather than an act. Although that traditional claim is not as problematic as this recent prominent view suggests, my main claim is that even if we accepted that withdrawing LST should be classified as an act rather than as an omission, it could still be classified as letting die rather than killing. Even though omissions are contrasted with acts, letting die need not be, for one can let die by means of acts. The remainder of the paper is devoted to establishing this claim and addresses certain objections to it.

  4. On dying and human suffering.

    PubMed

    Kellehear, A

    2009-07-01

    This review compares and contrasts the major reoccurring themes in two sources of research literature - social studies of dying and human suffering. The purpose of such a comparison is to employ the major insights of each field as a useful method of critically evaluating the insights of the other. Critical exchanges and comparisons between the research area of dying studies and on human suffering have been modest to date. This article will explain that the experience of dying benefits from being situated and analysed in a broader context of cultural experience, as suggested by the theory and study of human suffering. Conversely, the theory and methods involved in studies of human suffering can gain from a mortal view of vulnerability, grief, social ambiguity and identity changes characteristic of experiences at the end of life.

  5. Clinical management of dying patients.

    PubMed

    Gavrin, J; Chapman, C R

    1995-09-01

    Dying is universal, and death should be a peaceful time. Myriad comfort measures are available in the last weeks before life ends. Discussions about end-of-life issues often suffer from lack of informed opinion. Palliative care experts have identified specific somatic and psychological sources of distress for dying patients and their loved ones. Pain, shortness of breath, nausea and vomiting, and fear of abandonment contribute substantially to both physical and psychological discomfort toward the end of life. Simple, effective methods exist for relieving those symptoms. Knowledge about the natural events associated with dying and an informed approach to medical and psychological interventions contribute to systematic and successful comfort care. We describe the origin of physical and psychological distress at the end of life and provide strategies for alleviating many of the discomforts.

  6. Prototype casting fabrication by stereolithography

    SciTech Connect

    Cromwell, W.E.

    1990-11-01

    A new product development technology is emerging which could have a major impact on the investment casting industry. It's identified by several names, the most common of which is STEREOLITHOGRAPHY.'' This technology involves a three-dimensional printing process which will yield plastic parts (polymer models) from solid, surface, or wireframe CAD files. The concept links a CAD database to a process which guides a laser beam to solidify liquid photo-curable polymer into a programmed shaped. The process can produce models in far less time and at far less cost than can be done by other known (conventional) model producing methods. Parts that would normally require weeks or months to prototype with conventional processes can be produced in a matter of hours by Stereolithography. The Allied-Signal Inc., Kansas City Division, is engaged in a development project (funded by the Department of Energy) which is aimed at establishing this process as a practical, expedient, and cost-effective method fabricating prototype investment castings. The early phases of the project include procurement of a special designed test unit for several companies (Service Centers) involved in fabrication of models. These models are produced in various materials and used in experimental casting programs being conducted with four casting suppliers (two ferrous and two non-ferrous). This presentation will cover the objectives of the project and the results obtained up to this time. We will also briefly review future plans for the continuation of the project, until this new technology has been proven as a viable process for rapid development of investment castings.

  7. Development of a New Membrane Casting Apparatus for Studying Macrovoid Defects in Low-G

    NASA Technical Reports Server (NTRS)

    Lee, Hanyong; Hwang, Sun-Tak; Krantz, William B.; Greenberg, Alan R.; Khare, Vivek; Zartman, Jeremiah; Todd, Paul W.

    2002-01-01

    A new membrane-casting apparatus is developed for studying macrovoid defects in polymeric membranes made by the wet- and dry-casting process in low-gravity. Macrovoids are large (10-50 micron), open cavities interspersed among the smaller pores in the substructure under the gelled skin surface layer of the cast membrane. Although their occurrence is considered endemic to the wet- and dry-casting process since they can lead to compaction or skin rupture in the membrane process, recent studies suggest several useful applications such as transdermal and osmotic drug delivery systems, miniature bioreactors, etc. However, lack of knowledge about the macrovoid formation mechanism is an obstacle to further development of applications using them. An on-going debate is the role of the surface-tension-driven solutocapillary convection during macrovoid formation. The rapid growth of macrovoids within 1-5 seconds and the high polymer concentration in and near macrovoids make it difficult to explain the mechanism of macrovoid growth by diffusion alone, which is the widely accepted hypothesis proposed by Reuvers et al. The hypothesis advanced by our research group can explain this rapid growth via a mechanism that involves diffusion from the casting solution in the meta-stable region to the macrovoid enhanced by solutocapillary convection induced by the steep nonsolvent concentration gradient in the vicinity of the macrovoid. Since macrovoid growth is hypothesized to be the interplay of a solutocapillary-induced driving force counteracted by viscous drag and buoyancy, eliminate the latter provides a means for testing this hypothesis. Moreover, free convection mass transfer in the nonsolvent immersion bath used to cause phase-separation in membrane casting complicates developing a model for both the wet-casting process and macrovoid growth. The low-g environment minimizes gravitationally induced free convection thereby permitting a tractable solution to the ternary diffusion

  8. Care of the Dying Adolescent

    PubMed Central

    MacDonald, Faye

    1979-01-01

    This is a description of the obstacles encountered in the management of one 17 year old patient dying with malignant melanoma. Various areas are seen to contribute to the difficulties including the “health care system” (specifically the hospital environment), the patient himself, his family, his disease and its treatment, and his physician(s). An increased awareness of the difficulties would be helpful to those of us not frequently encountering the responsibility of caring for a dying adolescent. The details have been left vague or slightly changed in this real case to respect the privacy of those involved. PMID:21297759

  9. [Dying with cancer: Hollywood lessons].

    PubMed

    Niemeyer, Fernanda; Kruse, Maria Henriqueta Luce

    2013-12-01

    The study attempts to understand how dying from cancer is portrayed by five movies produced in Hollywood between 1993 and 2006. Based on the cultural studies and their post-structuralism version and supported by the notions of discourse and subjectivity, as proposed by philosopher Michel Foucault, we suggest one of the possible readings of the movie picture corpus. We assess how the movie picture discourse acts as a cultural pedagogy that produces ways of seeing dying with cancer: immortalizing the healthy body image, silencing death, taking care of the dead body and, finally, accepting death. Our proposal is intended to stimulate reflections that may contribute to care and education in nursing.

  10. Portable punch and die jig

    DOEpatents

    Lewandowski, Edward F.; Anderson, Petrus A.

    1978-01-01

    A portable punch and die jig includes a U-shaped jig of predetermined width having a slot of predetermined width in the base thereof extending completely across the width of the jig adapted to fit over the walls of rectangular tubes and a punch and die assembly disposed in a hole extending through the base of the jig communicating with the slot in the base of the jig for punching a hole in the walls of the rectangular tubes at precisely determined locations.

  11. Die Herz-Lungen-Maschine

    NASA Astrophysics Data System (ADS)

    Krane, Markus; Bauernschmitt, Robert; Lange, Rüdiger

    Das Kapitel der modernen Herzchirurgie mit Einsatz der Herz-Lungen-Maschine am Menschen beginnt am 6. Mai 1953, als J. Gibbon bei einer 18-jährigen Patientin einen angeborenen Defekt in der Vorhofscheidewand verschließt [1]. Mit ersten experimentellen Versuchen zur extrakorporalen Zirkulation begann Gibbon bereits in den 30er Jahren des 20. Jahrhunderts. Die Grundlage für die heute gebräuchliche Rollerpumpe schufen Porter und Bradley mit ihrer "rotary pump“, welche sie 1855 zum Patent anmeldeten. Diese Pumpe wurde von DeBakey und Schmidt modifiziert und entspricht im Wesentlichen noch der heute sich im Routinebetrieb befindlichen Rollerpumpe [2].

  12. Die hard monodisperse microfoams

    NASA Astrophysics Data System (ADS)

    Ganan-Calvo, Alfonso M.; Marquez-Oliver, Antonio; Marquez, Manuel

    2003-11-01

    In this work we experimentally investigate the influence of microbubble size (some tens of microns) on the draining of a foam of microbubbles with a high gas-to-liquid volume ratio. We have studied the detailed time evolution of the local microbubble size for both monodisperse and polydisperse size distributions. As it was anticipated by the Ostwald ripening phenomenon, a polydisperse microfoam drains following a well known coarsening mechanism. In our investigation on polydisperse microfoams, we have measured a more or less constant velocity of average bubble size increase, while the normalized geometric standard deviation of the bubble size remains approximately constant along the process. In sharp contrast, monodisperse foams as those produced by capillary flow focusing show a "frozen" time period (which depends on the liquid properties and the presence of surfactants) from a few to tens of minutes, during which the microbubble size remains static and monodisperse. In addition, these microbubble monodispersions tend to self-assemble in remarkable "mesocrystal" aggregations which seem to present an extra resistance to draining. The importance of these results for industrial applications, from foods and pharmaceuticals to metal foams, is highlighted.

  13. Land-based turbine casting initiative

    SciTech Connect

    Mueller, B.A.; Spicer, R.A.

    1995-12-31

    To meet goals for the ATS program, technical advances developed for aircraft gas turbine engines need to be applied to land-based gas turbines. These advances include directionally solidified and single crystal castings, alloys tailored to exploit these microstructures, complex internal cooling schemes, and coatings. The proposed program to scale aircraft gas turbine casting technology up to land based gas turbine size components is based on low sulfur alloys, casting process development, post-cast process development, and establishing casting defect tolerance levels. The inspection side is also discussed.

  14. Vacuum investment cast PH13-8Mo corrosion resistant steel. (SAE standard)

    SciTech Connect

    1991-07-01

    An industry-wide interest has arisen with regards to the properties and capabilities of investment cast PH 13-8Mo corrosion resistant steel. Specifically of interest are the structural applications in the aerospace industry for this product heat treated to the H1000 condition. The objective of this AMEC cooperative test program was to generate and compile useful data for aerospace structural evaluation of investment cast PH 13-8Mo heat treated to H1000. The determination was made of overall mechanical properties, fatigue, fracture toughness, and crack growth data along with basic microstructural evaluation of the investment cast material. The evaluation of mechanical property variations between cast and machined tensile specimens and evaluation of microstructural constituents. PH 13-8Mo, H1000 investment castings for use in the aerospace industry is included.

  15. Process development of thin strip steel casting

    SciTech Connect

    Sussman, R.C.; Williams, R.S.

    1990-12-01

    An important new frontier is being opened in steel processing with the emergence of thin strip casting. Casting steel directly to thin strip has enormous benefits in energy savings by potentially eliminating the need for hot reduction in a hot strip mill. This has been the driving force for numerous current research efforts into the direct strip casting of steel. The US Department of Energy initiated a program to evaluate the development of thin strip casting in the steel industry. In earlier phases of this program, planar flow casting on an experimental caster was studied by a team of engineers from Westinghouse Electric corporation and Armco Inc. A subsequent research program was designed as a fundamental and developmental study of both planar and melt overflow casting processes. This study was arranged as several separate and distinct tasks which were often completed by different teams of researchers. An early task was to design and build a water model to study fluid flow through different designs of planar flow casting nozzles. Another important task was mathematically modeling of melt overflow casting process. A mathematical solidification model for the formation of the strip in the melt overflow process was written. A study of the material and conditioning of casting substrates was made on the small wheel caster using the melt overflow casting process. This report discusses work on the development of thin steel casting.

  16. Ultra Large Castings to Produce Low Cost Aluminum Vehicle Structures

    SciTech Connect

    T. N. Meyer; M. J. Kinosz; E. M. Bradac; M. Mbaye; J. T. Burg; M. A. Klingensmith

    1999-04-26

    Through a cooperative effort with the U.S. Department of Energy (DOE) Office of Heavy Vehicle Technologies (OHVT), Alcoa is developing a casting process to produce ultra large thin wall components. The casting process is a low pressure, metal mold, multiport injection vertical casting process. The specific system for demonstration of the process is located at Alcoa's Technology Center and will be capable of producing parts extending 3 M long, 1.7 M wide and 0.4 M high. For example, single castings of car floor pan frames or side wall aperture structures are candidates for this installation. This shall provide a major opportunity to reduce the cost of lightweight transportation vehicle structures by (a) reducing the components or part count and (b) reducing the cost of assembly. To develop and demonstrate the process, an inner panel of the Chrysler minivan liftgate will be first produced on this system. Through computer analyses, the cast inner panel design was developed to satisfy both structural performance and casting process requirements. Currently, this is an 11 part assembly of steel components. At the time of this abstract, the numerous system components are in various phases of fabrication and site preparation is fully underway, with system shakedown beginning in the second quarter of 1999. Successful demonstration of caster system operation is anticipated to occur during the third quarter and production of a high quality product during the fourth quarter. Although the process is targeted toward reducing the cost of lightweight trucks, buses and autos, consideration is being given to application in the aircraft industry.

  17. WTEC panel report on advanced casting technologies in Japan and Europe

    SciTech Connect

    Flemings, M.C.; Apelian, D.; Bertram, D.; Hayden, W.; Mikkola, P.H.; Piwonka, T.S.

    1997-03-01

    This report presents the results and conclusions from a study of the Japanese foundry industry conducted by a WTEC study team in January 1996. Results of that study were supplemented by additional visits later in the spring to foundries and foundry laboratories in Europe. During its week in Japan, subgroups of the team visited 22 facilities. Included in these were four metal mold foundries, five iron and steel (sand mold) foundries, four investment casting foundries, four industrial research laboratories, four universities, and one government office. In Chapter 2, Melting and Handling, Diran Apelian discusses what he considers the most critical components in the overall metal casting operation: the melting of the metal and the process of liquid metal handling. Chapter 3 written by H.W. Hayden, reports findings on active R and D efforts in the Japanese casting companies directed to the development of new cast alloys and materials, new ceramic and cermet materials for application by the foundry industry, and major new process/product developments such as amorphous metals and magnetohydrodynamic (MHD) effects on the continuous casting of steel rolling ingots. The next chapter, Metal Mold Casting by Diran Apelian, discusses casting technologies in which the mold cavity is made of a metallic material. The fifth chapter, Japanese and European New Cast Product Development by Paul H. Mikkola, reports findings on new cast products being developed in both Japan and Europe. In Chapter 6, Specialized Sand Casting Technologies, Thomas S. Piwonka assesses the current state of innovation in the field of sand casting in Japan and Europe. In Chapter 7, Current Investment Casting Technology, Thomas S. Piwonka looks at the US precision investment casting industry, which developed during the Second World War. Chapter 8 by Dennis Bertram, assesses the state of manufacturing in Japan: how the Japanese use foundry processes, specialized equipment, alloys, human resources, and the

  18. Final Report, Volume 1, Metallurgical Evaluation of Cast Duplex Stainless Steels and their Weldments

    SciTech Connect

    Wen, Songqing; Lundin, Carl, W.; Batten, Greg, W.

    2005-09-30

    pitting and intergranular corrosion resistance for both the wrought and cast duplex alloys; (3) Castings generally have better toughness than their wrought counterparts in the temperature range of 80°C to +20°C; (4) All shield metal arc (SMA) test welds in DSS castings, with recommended or over matching filler metal, indicate that welding is not a significant factor when considering DSS applications.

  19. Final Report, Volume 1, Metallurgical Evaluation of Cast Duplex Stainless Steels and their Weldments

    SciTech Connect

    Wen, Songqing; Lundin, Carl, W.; Batten, Greg, W.

    2005-09-30

    pitting and intergranular corrosion resistance for both the wrought and cast duplex alloys; (3) Castings generally have better toughness than their wrought counterparts in the temperature range of -80 C to +20 C; (4) All shield metal arc (SMA) test welds in DSS castings, with recommended or over matching filler metal, indicate that welding is not a significant factor when considering DSS applications.

  20. Die Face Engineering based Springback Compensation Strategy and Implementation

    NASA Astrophysics Data System (ADS)

    Tang, Arthur; Lee, Wing; He, Jeanne; Xu, Jinbo; Liu, Kesu; Chen, Chin Chun

    2005-08-01

    Springback or shape change has been one of the major challenges in sheet metal fabrication, particularly with increase application of high strength steel (HSS) and aluminum alloys in automotive stamping. Springback, an elastic material recovery after the unloading of stamping tools, causes variations and inconsistencies of final part dimensions. Minor or mild springback usually can be corrected in the re-strike process. Excessive springback must be corrected so the part will be produced within the given design tolerance and dimension. The commonly used Spring Forward approaches and shape compensations such as over-crown and over-bending are proven effective to alleviate excessive springback. To enhance these approaches, a new strategy of Die Face Engineering (DFE) based processing is proposed to quickly and easily to achieve the maximum allowable compensation using the under cut (or die lock) as the primary criteria. The implementation of the die face compensation through iterative FEA calculation, automatic surface mapping, projection and manual morphing are crucial to meet production environment requirements in terms of generating NC quality CAD surfaces of the compensated or morphed die face. In this paper, the strategy of the die face compensation with the consideration of the under cut criteria is presented. The implementation of various processes to enable user to perform the die face compensation task in a production environment is also discussed. Finally, two examples are shown to demonstrate the implementation of the proposed springback compensation scheme based on the combined CAE/CAD methodology.

  1. Die Face Engineering based Springback Compensation Strategy and Implementation

    SciTech Connect

    Tang, Arthur; Lee Wing; He, Jeanne; Xu Jinbo; Liu Kesu; Chen Chinchun

    2005-08-05

    Springback or shape change has been one of the major challenges in sheet metal fabrication, particularly with increase application of high strength steel (HSS) and aluminum alloys in automotive stamping. Springback, an elastic material recovery after the unloading of stamping tools, causes variations and inconsistencies of final part dimensions. Minor or mild springback usually can be corrected in the re-strike process. Excessive springback must be corrected so the part will be produced within the given design tolerance and dimension. The commonly used Spring Forward approaches and shape compensations such as over-crown and over-bending are proven effective to alleviate excessive springback. To enhance these approaches, a new strategy of Die Face Engineering (DFE) based processing is proposed to quickly and easily to achieve the maximum allowable compensation using the under cut (or die lock) as the primary criteria. The implementation of the die face compensation through iterative FEA calculation, automatic surface mapping, projection and manual morphing are crucial to meet production environment requirements in terms of generating NC quality CAD surfaces of the compensated or morphed die face. In this paper, the strategy of the die face compensation with the consideration of the under cut criteria is presented. The implementation of various processes to enable user to perform the die face compensation task in a production environment is also discussed. Finally, two examples are shown to demonstrate the implementation of the proposed springback compensation scheme based on the combined CAE/CAD methodology.

  2. A good way to die.

    PubMed

    Trueland, Jennifer

    2016-03-23

    An end of life care service is providing joined-up care for patients. Care co-ordinators arrange packages of care so patients can die in the place of their choice – often at home. The result is high satisfaction rates among patients, families and staff.

  3. Attitudes on Death and Dying.

    ERIC Educational Resources Information Center

    Andrus, Charles E.

    This paper explored attitudes toward death and dying revealed through interviews with members of the clergy, the medical profession, funeral directors, nursing home residents, and selected others. The sampling was small and results are not intended to be representative of the groups to which these people belong. Rather, the study may be used as a…

  4. Robert Merton Dies at 92

    ERIC Educational Resources Information Center

    Snell, Joel C.

    2006-01-01

    This article features Robert Merton, who died recently at age 92. Merton came into this world as a Jewish baby named Meyer Schkolnick. He lived in South Philly where his parents wrenched a living as blue-collar workers. Merton chose an Anglicized name to move into the Yankee dominated America of the 20's and 30's. At Harvard, he studied under…

  5. Energy Saving Melting and Revert Reduction (E-SMARRT): Precision Casting of Steel

    SciTech Connect

    Dr. Von L. Richards

    2011-09-30

    of the casting opposite the gate. (3) It is recommended that lost foam castings in steel be gated for a quiescent fill in an empty cavity mold to prevent foam occlusion defects from the collapse mode. The energy benefit is primarily in yield savings and lower casting weight per function due to elimination of draft and parting lines for the larger lost foam castings. For the smaller investment casting, scrap losses due to shell cracking will be reduced. Both of these effects will reduce the metal melted per good ton of castings. There will also be less machine stock required per casting which is a yield savings and a small additional energy savings in machining. Downstream savings will come from heavy truck and railroad applications. Application of these processes to heavy truck castings will lighten the heavy truck fleet by about ten pounds per truck. Using ten years to achieve full penetration of the truck fleet at linear rate this will result in a fuel savings of 131 trillion BTU over ten years.

  6. ToxCast Chemical Landscape: Paving the Road to 21st Century Toxicology.

    PubMed

    Richard, Ann M; Judson, Richard S; Houck, Keith A; Grulke, Christopher M; Volarath, Patra; Thillainadarajah, Inthirany; Yang, Chihae; Rathman, James; Martin, Matthew T; Wambaugh, John F; Knudsen, Thomas B; Kancherla, Jayaram; Mansouri, Kamel; Patlewicz, Grace; Williams, Antony J; Little, Stephen B; Crofton, Kevin M; Thomas, Russell S

    2016-08-15

    The U.S. Environmental Protection Agency's (EPA) ToxCast program is testing a large library of Agency-relevant chemicals using in vitro high-throughput screening (HTS) approaches to support the development of improved toxicity prediction models. Launched in 2007, Phase I of the program screened 310 chemicals, mostly pesticides, across hundreds of ToxCast assay end points. In Phase II, the ToxCast library was expanded to 1878 chemicals, culminating in the public release of screening data at the end of 2013. Subsequent expansion in Phase III has resulted in more than 3800 chemicals actively undergoing ToxCast screening, 96% of which are also being screened in the multi-Agency Tox21 project. The chemical library unpinning these efforts plays a central role in defining the scope and potential application of ToxCast HTS results. The history of the phased construction of EPA's ToxCast library is reviewed, followed by a survey of the library contents from several different vantage points. CAS Registry Numbers are used to assess ToxCast library coverage of important toxicity, regulatory, and exposure inventories. Structure-based representations of ToxCast chemicals are then used to compute physicochemical properties, substructural features, and structural alerts for toxicity and biotransformation. Cheminformatics approaches using these varied representations are applied to defining the boundaries of HTS testability, evaluating chemical diversity, and comparing the ToxCast library to potential target application inventories, such as used in EPA's Endocrine Disruption Screening Program (EDSP). Through several examples, the ToxCast chemical library is demonstrated to provide comprehensive coverage of the knowledge domains and target inventories of potential interest to EPA. Furthermore, the varied representations and approaches presented here define local chemistry domains potentially worthy of further investigation (e.g., not currently covered in the testing library or

  7. Permanent mold casting of titanium alloy Ti-6Al-4V

    SciTech Connect

    Sadayappan, M.; Sahoo, M.; Lavender, C.; paul.jablonski, P.D.

    2008-01-01

    A literature review indicated that data on the effect of various casting defects, such as inclusions and porosity, on the properties of titanium alloy castings were not readily available. This information is required to reduce the cost of fabricating titanium castings for potential automotive applications. To this end, a research project was initiated to develop data on the as-cast properties of titanium alloy Ti-6Al-4V (Ti64). Step plate castings with 3.2, 6.3, 13, and 25 mm thick steps were produced in a high-density graphite mold following melting in an induction furnace with water-cooled copper hearth. The mechanical properties were determined in the as-cast condition and were found to be close to the values reported in standards. Few casting defects such as inclusions and porosity were observed, and the loss of strength due to these defects is not significant. It is shown that titanium castings with good mechanical properties can be produced in high-density graphite molds.

  8. FEM stress analysis of the cooling hole of an HPDC die

    NASA Astrophysics Data System (ADS)

    Kimura, T.; Yamagata, H.; Tanikawa, S.

    2015-06-01

    Cracking at a cooling hole is a typical die failure mode in a high-pressure die-casting (HPDC) die. We simulated the thermal distortion of a die considering the HPDC machine deflection and revealed a stress concentration at the cooling hole. The stress concentration at the cooling hole changes after injection or after spraying and blowing air. The cooling hole top remains in a compression stress state 5, 10, and 20 mm deep from the die surface, but the stress amplitudes are higher when the depths are shallower. It was suggested that cracking takes place due to the high compressive stress and that the shear stress assists the propagation of the initiated crack. On the other hand, the stress condition at the R portion of the cooling hole is always a tensile state, but the mean stress and stress amplitude values were not found to be in the range that causes fatigue fracture. It was demonstrated that the developed analysis is valuable in designing the cooling hole of an HPDC die.

  9. Comparing the Accuracy of Three Different Impression Materials in Making Duplicate Dies

    PubMed Central

    Bajoghli, Farshad; Sabouhi, Mahmoud; Nosouhian, Saeid; Davoudi, Amin; Behnamnia, Zeynab

    2015-01-01

    Background: Marginal adaptation is very important in cast restorations. Maladaptation leads to plaque retention, reduction of mechanical and esthetic properties. The aim of this study was to evaluate the precision of three different impression materials (including: Additional silicone [AS] and condensational silicone [CS] and polyether [PE]) for duplicating master dies. Materials and Methods: Three master dies from an acrylic tooth model-with supragingival and shoulder finishing line was made by using PE: Impergum, CS: Speedex, and AS: Panasil separately. The Ni-Cr copings were prepared from master dies separately. They were placed on the acrylic model and the mean marginal difference was recorded by using a stereomicroscope. Then 30 duplicate test dies were made by using the same impression materials and the marginal gaps were recorded. The comparison was done by one-way ANOVA and SPSS software (Version 13) at a significant level of 0.05. Results: The mean marginal difference of four walls from Impergum (38.56 um) was the lowest than Speedex (38.92 um) and Panasil (38.24 um). The Impergum had the highest capability in making duplicate dies (P > 0.05). Conclusion: The Impergum impression material manifested the highest capability in making a better marginal adaptation of duplicate dies but further studies are needed to make a precise decision. PMID:26229364

  10. Pressure rig for repetitive casting

    SciTech Connect

    Vasquez, P.; Hutto, W.R.; Philips, A.R.

    1989-09-12

    This patent describes a pressure rig for repetitive casting. It comprises: a hollow ceramic inner shell: an outer steel housing disposed around the outside of the ceramic inner shell. The housing having a pressure end at the lower end thereof and a mold end at the upper end thereof; a rubber diaphragm attached to the pressure end of the outer steel housing; a slideable transit plate located above the rubber diaphragm; a layer of blanket insulating material lining the remaining portion of the hollow ceramic inner shell, thereby defining an inner cavity wherein a casing material is located; a pressure means located at the lower end of the pressure rig for applying pressure to the lower end of the rubber diaphragm; whereby the casting material in the inner cavity is forced out of the pressure rig into a mold when pressure is applied to the lower end of the rubber diaphragm.

  11. Search for chameleons with CAST

    NASA Astrophysics Data System (ADS)

    Anastassopoulos, V.; Arik, M.; Aune, S.; Barth, K.; Belov, A.; Bräuninger, H.; Cantatore, G.; Carmona, J. M.; Cetin, S. A.; Christensen, F.; Collar, J. I.; Dafni, T.; Davenport, M.; Desch, K.; Dermenev, A.; Eleftheriadis, C.; Fanourakis, G.; Ferrer-Ribas, E.; Friedrich, P.; Galán, J.; García, J. A.; Gardikiotis, A.; Garza, J. G.; Gazis, E. N.; Geralis, T.; Giomataris, I.; Hailey, C.; Haug, F.; Hasinoff, M. D.; Hoffmann, D. H. H.; Iguaz, F. J.; Irastorza, I. G.; Jacoby, J.; Jakobsen, A.; Jakovčić, K.; Kaminski, J.; Karuza, M.; Kavuk, M.; Krčmar, M.; Krieger, C.; Krüger, A.; Lakić, B.; Laurent, J. M.; Liolios, A.; Ljubičić, A.; Luzón, G.; Neff, S.; Ortega, I.; Papaevangelou, T.; Pivovaroff, M. J.; Raffelt, G.; Riege, H.; Rosu, M.; Ruz, J.; Savvidis, I.; Solanki, S. K.; Vafeiadis, T.; Villar, J. A.; Vogel, J. K.; Yildiz, S. C.; Zioutas, K.; Brax, P.; Lavrentyev, I.; Upadhye, A.

    2015-10-01

    In this work we present a search for (solar) chameleons with the CERN Axion Solar Telescope (CAST). This novel experimental technique, in the field of dark energy research, exploits both the chameleon coupling to matter (βm) and to photons (βγ) via the Primakoff effect. By reducing the X-ray detection energy threshold used for axions from 1 keV to 400 eV CAST became sensitive to the converted solar chameleon spectrum which peaks around 600 eV. Even though we have not observed any excess above background, we can provide a 95% C.L. limit for the coupling strength of chameleons to photons of βγ ≲1011 for 1 <βm <106.

  12. Pressure rig for repetitive casting

    NASA Technical Reports Server (NTRS)

    Vasquez, Peter (Inventor); Hutto, William R. (Inventor); Philips, Albert R. (Inventor)

    1989-01-01

    The invention is a pressure rig for repetitive casting of metal. The pressure rig performs like a piston for feeding molten metal into a mold. Pressure is applied to an expandable rubber diaphragm which expands like a balloon to force the metal into the mold. A ceramic cavity which holds molten metal is lined with blanket-type insulating material, necessitating only a relining for subsequent use and eliminating the lengthy cavity preparation inherent in previous rigs. In addition, the expandable rubber diaphragm is protected by the insulating material thereby decreasing its vulnerability to heat damage. As a result of the improved design the life expectancy of the pressure rig contemplated by the present invention is more than doubled. Moreover, the improved heat protection has allowed the casting of brass and other alloys with higher melting temperatures than possible in the conventional pressure rigs.

  13. Focused rigidity casts: an overview.

    PubMed

    Dagg, A R; Chockalingam, N; Branthwaite, H

    2013-02-01

    Focused rigidity casts (FRCs) are a novel treatment made from polymer semi-flexible cast material, used in the management of plantar foot ulceration to offload the site of ulceration. Current anecdotal evidence suggests that use of FRCs helps achieve quicker healing time. While FRCs were first used in the treatment of fractures, previous reports suggest that the FRC may be effective in the treatment of plantar foot ulceration. Although there is a paucity of evidence to support the use of FRCs in the treatment of foot ulceration, current evidence demonstrates a decrease in both wound healing time and plantar pressure. The aim of the paper is to examine the importance of offloading plantar ulcerations and introduce FRCs.

  14. Cast shadows in wide perspective.

    PubMed

    Pont, Sylvia C; Wijntjes, Maarten W A; Oomes, Augustinus H J; van Doom, Andrea; van Nierop, Onno; de Ridder, Huib; Koenderink, Jan J

    2011-01-01

    We investigated the apparent spatial layout of cast shadows up to very wide fields of view. We presented up to 130 degrees wide images in which two 'flat poles' were standing on a green lawn under a cloudless blue sky on a sunny day. The poles threw sharp cast shadows on the green, of which one was fixed. The observer's task was to adjust the azimuth of the shadow of the other pole such that it fitted the scene. The source elevation was kept constant. The two cast shadows are, of course, parallel in physical space, but generically not in the picture plane because of the wide perspective. We found that observers made huge systematic errors, indicating that, generically, they fail to account for these perspective effects. The systematic deviations could be well described by a weighted linear combination of the directions in the picture plane and in the physical space, with weights that depended on the positions of, and distance between, the poles.

  15. Fractal structures in casting films from chlorophyll

    NASA Astrophysics Data System (ADS)

    Pedro, G. C.; Gorza, F. D. S.; de Souza, N. C.; Silva, J. R.

    2014-04-01

    Chlorophyll (Chl) molecules are important because they can act as natural light-harvesting devices during the photosynthesis. In addition, they have potential for application as component of solar cell. In this work, we have prepared casting films from chlorophyll (Chl) and demonstrated the occurrence of fractal structures when the films were submitted to different concentrations. By using optical microscopy and the box-count method, we have found that the fractal dimension is Df = 1.55. This value is close to predicted by the diffusion-limited aggregation (DLA) model. This suggests that the major mechanism - which determines the growth of the fractal structures from Chl molecules - is the molecular diffusion. Since the efficiencies of solar cells depend on the morphology of their interfaces, these finds can be useful to improve this kind of device.

  16. Casting inorganic structures with DNA molds

    PubMed Central

    Sun, Wei; Boulais, Etienne; Hakobyan, Yera; Wang, Wei Li; Guan, Amy; Bathe, Mark; Yin, Peng

    2014-01-01

    We report a general strategy for designing and synthesizing inorganic nanostructures with arbitrarily prescribed three-dimensional shapes. Computationally designed DNA strands self-assemble into a stiff “nano-mold” that contains a user-specified three-dimensional cavity and encloses a nucleating gold “seed”. Under mild conditions, this seed grows into a larger cast structure that fills and thus replicates the cavity. We synthesized a variety of nanoparticles with three nanometer resolution: three distinct silver cuboids with three independently tunable dimensions, silver and gold nanoparticles with diverse cross sections, and composite structures with homo-/heterogeneous components. The designer equilateral silver triangular and spherical nanoparticles exhibited plasmonic properties consistent with electromagnetism-based simulations. Our framework is generalizable to more complex geometries and diverse inorganic materials, offering a range of applications in biosensing, photonics, and nanoelectronics. PMID:25301973

  17. Fabrication of silk fibroin film using centrifugal casting technique for corneal tissue engineering.

    PubMed

    Lee, Min Chae; Kim, Dong-Kyu; Lee, Ok Joo; Kim, Jung-Ho; Ju, Hyung Woo; Lee, Jung Min; Moon, Bo Mi; Park, Hyun Jung; Kim, Dong Wook; Kim, Su Hyeon; Park, Chan Hum

    2016-04-01

    Films prepared from silk fibroin have shown potential as biomaterials in tissue engineering applications for the eye. Here, we present a novel process for fabrication of silk fibroin films for corneal application. In this work, fabrication of silk fibroin films was simply achieved by centrifugal force. In contrast to the conventional dry casting method, we carried out the new process in a centrifuge with a rotating speed of 4000 rpm, where centrifugal force was imposed on an aluminum tube containing silk fibroin solution. In the present study, we also compared the surface roughness, mechanical properties, transparency, and cell proliferation between centrifugal and dry casting method. In terms of surface morphology, films fabricated by the centrifugal casting have less surface roughness than those by the dry casting. For elasticity and transparency, silk fibroin films obtained from the centrifugal casting had favorable results compared with those prepared by dry casting. Furthermore, primary human corneal keratocytes grew better in films prepared by the centrifugal casting. Therefore, our results suggest that this new fabrication process for silk fibroin films offers important potential benefits for corneal tissue regeneration.

  18. [Dying with cancer: Hollywood lessons].

    PubMed

    Niemeyer, Fernanda; Kruse, Maria Henriqueta Luce

    2013-12-01

    The study attempts to understand how dying from cancer is portrayed by five movies produced in Hollywood between 1993 and 2006. Based on the cultural studies and their post-structuralism version and supported by the notions of discourse and subjectivity, as proposed by philosopher Michel Foucault, we suggest one of the possible readings of the movie picture corpus. We assess how the movie picture discourse acts as a cultural pedagogy that produces ways of seeing dying with cancer: immortalizing the healthy body image, silencing death, taking care of the dead body and, finally, accepting death. Our proposal is intended to stimulate reflections that may contribute to care and education in nursing. PMID:25080714

  19. Guide for extrusion dies eliminates straightening operation

    NASA Technical Reports Server (NTRS)

    Gyorgak, C. A.; Hoover, R. J.

    1964-01-01

    To prevent distortion of extruded metal, a guidance assembly is aligned with the die. As the metal emerges from the extrusion dies, it passes directly into the receiver and straightening tube system, and the completed extrusion is withdrawn.

  20. Clean Ferrous Casting Technology Research. Annual report, September 29, 1993--September 28, 1994

    SciTech Connect

    Stefanescu, D.M.; Lane, A.M.; Giese, S.R.; Pattabhi, R.; El-Kaddah, N.H.; Griffin, J.; Bates, C.E.; Piwonka, T.S.

    1994-10-01

    This annual report covers work performed in the first year of research on Clean Ferrous Casting Technology Research. During this year the causes of penetration of cast iron in sand molds were defined and a program which predicts the occurrence of penetration was written and verified in commercial foundries. Calculations were made to size a reaction chamber to remove inclusions from liquid steel using electromagnetic force and the chamber was built. Finally, significant progress was made in establishing pouring practices which avoid re-oxidation of steel during pouring application of revised pouring practices have led to reduced inclusion levels in commercially poured steel castings.