40 CFR 467.02 - General definitions.

Code of Federal Regulations, 2011 CFR

2011-07-01

... subcategory, but when present is an integral part of the aluminum forming process. (c) Contact cooling water.... (d) Continuous casting is the production of sheet, rod, or other long shapes by solidifying the metal... pulling metal through a die or succession of dies to reduce the metal's diameter or alter its shape. There...

Development of Thixomolded{reg_sign} magnesium products

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

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

1995-10-01

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

[Cervical adaptation of complete cast crowns of various metal alloys, with and without die spacers].

PubMed

Stephano, C B; Roselino, R F; Roselino, R B; Campos, G M

1989-01-01

A metallic replica from a dental preparation for crown was used to make 8 class-IV stone dies. The wax patterns for the casting of the crowns were obtained in two conditions: a) from the stone die with no spacer; and b) from the stone die with an acrylic spacer. Thus, 64 metallic crowns were casted, using 4 different alloys: DURACAST (Cu-Al), NICROCAST (Ni-Cr) and DURABOND (Ni-Cr), and gold. The casted crowns were fitted in the metallic replica and measured as to the cervical discrepance of fitting. The results showed that the use of die spacers decreases the clinical discrepancies of fitting of the casted crowns (in a statistically significant level), no matter the metallic alloy employed.

The Effect of Alloying Elements on Thermal Conductivity and Casting Characteristic in High Pressure Die Casting of Aluminum Alloy

NASA Astrophysics Data System (ADS)

Kim, Cheol-Woo; Cho, Jae-Ik; Choi, Se-Weon; Kim, Young-Chan; Kang, Chang-Seog

Recently, demand of aluminum alloys for use in high thermal conductivity application is increases but the most aluminum die casting alloys exhibit very lower thermal properties because of their high concentrations of alloying elements. However, those alloying elements are essential to obtain sufficient fluidity and mechanical strength. Therefore, the purpose of this study is to analyze the effect of alloying elements in die casting alloys, Si, Cu, Mg, Fe and Mn, in thermal conductivity, die casting characteristics and mechanical properties and find out the appropriate amount of each alloying element for development of heat sink component. The results showed that Mn had the most deleterious effect in thermal conductivity and Si and Fe contents were important to improve strength and limit casting defects, such as hot tearing and die soldering. The alloy with 0.2 1.0wt%Cu, 0.3 0.6wt%Fe and 1.0 2.0wt%Si showed very good combination of high thermal conductivity and good casting characteristics.

Effects of heat treatment on mechanical properties of h13 steel

NASA Astrophysics Data System (ADS)

Guanghua, Yan; Xinmin, Huang; Yanqing, Wang; Xingguo, Qin; Ming, Yang; Zuoming, Chu; Kang, Jin

2010-12-01

Heat treatment on the mechanical properties of H13 hot working die steel for die casting is discussed. The H13 steel for die casting was treated by different temperatures of vacuum quenching, tempering, and secondary tempering to investigate its mechanical properties. Strength, plasticity, hardness, and impact toughness of the H13 hot working die steel for die casting were measured. Microstructure, grain size, and carbide particle size after heat treatment have a great impact on the mechanical properties of H13 hot working die steel for die casting. The microstructure of the H13 was analyzed by scanning electron microscopy (SEM) and by a metallographic microscope. It is found that H13 exhibits excellent mechanical properties after vacuum quenching at 1050°C and twice tempering at 600°C.

Shrinkage Prediction for the Investment Casting of Stainless Steels

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

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.

Titanium Aluminide Casting Technology Development

NASA Astrophysics Data System (ADS)

Bünck, Matthias; Stoyanov, Todor; Schievenbusch, Jan; Michels, Heiner; Gußfeld, Alexander

2017-12-01

Titanium aluminide alloys have been successfully introduced into civil aircraft engine technology in recent years, and a significant order volume increase is expected in the near future. Due to its beneficial buy-to-fly ratio, investment casting bears the highest potential for cost reduction of all competing production technologies for TiAl-LPTB. However, highest mechanical properties can be achieved by TiAl forging. In view of this, Access e.V. has developed technologies for the production of TiAl investment cast parts and TiAl die cast billets for forging purposes. While these parts meet the highest requirements, establishing series production and further optimizing resource and economic efficiency are present challenges. In order to meet these goals, Access has recently been certified according to aircraft standards, aiming at qualifying parts for production on technology readiness level 6. The present work gives an overview of the phases of development and certification.

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

NASA Astrophysics Data System (ADS)

Singh, Rupinder

2018-02-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-04-01

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

The erosion resistance of tool alloys in foundry melt the Zamak 4 - 1

NASA Astrophysics Data System (ADS)

Muhametzyanova, GF; Kolesnikov, M. S.; Muhametzyanov, I. R.

2016-06-01

The paper considers the resistance against erosion dissolution in the melt of foundry Zamak 4 - 1 die steels used for press machine parts manufacturing for injection molding, and hard alloys system WC - Co. It is established that the solubility in the melt Zamak - 4 - 1 steel of 4H5MFS and DI - 22 are promising for the parts fabrication of metal-wire casting machines of CLT and IDRA types. A significant reserve to increase the resistance of metal wires is the use of cast steel, as well as in electroslag and electro-beam remelting options. Metal-ceramic alloy doped with chromium VK25H may be recommended for reinforcement of heavily loaded parts of the press-nodes of hot casting machines under pressure.

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

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

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

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

Quality Assessment of A356 Ingots from Different Suppliers in Wheel Production

NASA Astrophysics Data System (ADS)

Koca, Emre; Yuksel, Caglar; Erzi, Eray; Dışpınar, Derya

In a typical foundry floor, several precautions are taken prior to the casting in order to achieve pore-free, high quality parts. In low pressure die castings, these operations involve runner design, pressure adjustment, die temperature selection, cooling locations etc. For the melt, it is important to determine the degassing duration and gas flow rate. In addition, the period of modification (Ti, Sr) addition also plays a significant role. Even after optimization of all these parameters, reject parts can still be found. What has always been disregarded is the quality assessment of the ingot suppliers. Therefore, in this work, four different A356 ingot provider's quality has been investigated in the wheel producer company. Reduced pressure test was used to quantify melt quality by means of bifilm index measurement. In addition, fluidity, feedability and tensile tests have been carried out. The rejection rates were compared according to provider's quality level.

Microstructures and properties of aluminum die casting alloys

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

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

1998-10-01

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

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

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

Weiss, David; Purgert, Robert; Rhudy, Richard

1999-04-21

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

The influence of flushing time on the bonding quality of liquid white cast iron on the solid surface of similar material

NASA Astrophysics Data System (ADS)

Bandanadjaja, Beny; Purwadi, Wiwik; Idamayanti, Dewi; Lilansa, Noval; Hanaldi, Kus; Nurzaenal, Friya Kurnia

2018-05-01

Hard metal castings are widely used in the coal mill pulverizer as construction material for coal crushers. During its operation crushers and mills experience degradation caused by abrasion load. This research dealed with the surface overlaying of similiar material on the surface of white cast iron by mean of gravity casting. The die blank casting was preheated prior to the casting process of outer layer made of Ni-Hard white cast iron to guarantee bonding processes and avoid any crack. The preheating temperature of die blankin ther range of 500C up to 850C was set up to reach the interface temperature in the range of 887°C -1198°C and the flushing time was varied between 10-20 seconds. Studies carried on the microstructure of sample material revealed a formation of metallurgical bonding at the preheating temperature above 625 °C by pouring temperature ranging from 1438 °C to 1468 °C. Metallographical and chemical composition by mean of EDS examination were performed to observed the resut. This research concludes that the casting of Ni-Hard 1 overlay by applying gravity casting method can be done by preheating the surface of casting to 625 °C, interface temperature of 1150 °C, flushing time of 7 seconds and pouring temperature of 1430 °C. Excellent metallurgical bonding at the contact area between dieblank and overlay material has been achieved in which there is no parting line at the interface area to be observed.

Evaluating the Tensile Properties of Aluminum Foundry Alloys through Reference Castings-A Review.

PubMed

Anilchandra, A R; Arnberg, Lars; Bonollo, Franco; Fiorese, Elena; Timelli, Giulio

2017-08-30

The tensile properties of an alloy can be exploited if detrimental defects and imperfections of the casting are minimized and the microstructural characteristics are optimized through several strategies that involve die design, process management and metal treatments. This paper presents an analysis and comparison of the salient characteristics of the reference dies proposed in the literature, both in the field of pressure and gravity die-casting. The specimens produced with these reference dies, called separately poured specimens, are effective tools for the evaluation and comparison of the tensile and physical behaviors of Al-Si casting alloys. Some of the findings of the present paper have been recently developed in the frame of the European StaCast project whose results are complemented here with some more recent outcomes and a comprehensive analysis and discussion.

Energy-Saving Melting and Revert Reduction Technology (E-SMARRT): Use of Laser Engineered Net Shaping for Rapid Manufacturing of Dies with Protective Coatings and Improved Thermal Management

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

Brevick, Jerald R.

2014-06-13

In the high pressure die casting process, molten metal is introduced into a die cavity at high pressure and velocity, enabling castings of thin wall section and complex geometry to be obtained. Traditional die materials have been hot work die steels, commonly H13. Manufacture of the dies involves machining the desired geometry from monolithic blocks of annealed tool steel, heat treating to desired hardness and toughness, and final machining, grinding and polishing. The die is fabricated with internal water cooling passages created by drilling. These materials and fabrication methods have been used for many years, however, there are limitations. Toolmore » steels have relatively low thermal conductivity, and as a result, it takes time to remove the heat from the tool steel via the drilled internal water cooling passages. Furthermore, the low thermal conductivity generates large thermal gradients at the die cavity surfaces, which ultimately leads to thermal fatigue cracking on the surfaces of the die steel. The high die surface temperatures also promote the metallurgical bonding of the aluminum casting alloy to the surface of the die steel (soldering). In terms of process efficiency, these tooling limitations reduce the number of die castings that can be made per unit time by increasing cycle time required for cooling, and increasing downtime and cost to replace tooling which has failed either by soldering or by thermal fatigue cracking (heat checking). The objective of this research was to evaluate the feasibility of designing, fabricating, and testing high pressure die casting tooling having properties equivalent to H13 on the surface in contact with molten casting alloy - for high temperature and high velocity molten metal erosion resistance – but with the ability to conduct heat rapidly to interior water cooling passages. A layered bimetallic tool design was selected, and the design evaluated for thermal and mechanical performance via finite element analysis. H13 was retained as the exterior layer of the tooling, while commercially pure copper was chosen for the interior structure of the tooling. The tooling was fabricated by traditional machining of the copper substrate, and H13 powder was deposited on the copper via the Laser Engineered Net Shape (LENSTM) process. The H13 deposition layer was then final machined by traditional methods. Two tooling components were designed and fabricated; a thermal fatigue test specimen, and a core for a commercial aluminum high pressure die casting tool. The bimetallic thermal fatigue specimen demonstrated promising performance during testing, and the test results were used to improve the design and LENS TM deposition methods for subsequent manufacture of the commercial core. Results of the thermal finite element analysis for the thermal fatigue test specimen indicate that it has the ability to lose heat to the internal water cooling passages, and to external spray cooling, significantly faster than a monolithic H13 thermal fatigue sample. The commercial core is currently in the final stages of fabrication, and will be evaluated in an actual production environment at Shiloh Die casting. In this research, the feasibility of designing and fabricating copper/H13 bimetallic die casting tooling via LENS TM processing, for the purpose of improving die casting process efficiency, is demonstrated.« less

Influence of polyurethane resin dies on the fit and adaptation of full veneer crowns.

PubMed

Lillywhite, Graeme R R; Vohra, Fahim

2015-01-01

Polyurethane resin is a possible alternative to type IV dental stone for fabrication of indirect restorations however its dimensional accuracy is questionable. The aim was to investigate the dimensional accuracy of silica filled polyurethane resin die material by evaluating the marginal fit and adaptation of indirect gold castings. Experimental, in vitro study. Totally 40 copper plated replicas of a nickel chrome master die analogous to a veneer gold crown preparation were made and impressions recorded using polyvinylsiloxane material. Twenty impressions were poured in type IV dental stone (control group (Vel-mix, Kerr, UK) and the remaining (n = 20) in silica filled polyurethane die material (test group) (Alpha Die MF, CA, USA). Gold castings were fabricated for each die using standardized techniques. The castings were seated on their respective copper plated dies, embedded in resin and sectioned. The specimens were analyzed by measuring marginal opening and the area beneath the casting at a ×63 magnification and using image analysis software. Data were analyzed using a Student's t-test. No significant difference was observed between the experimental groups (P > 0.05). The mean marginal opening for type IV, dental stone and polyurethane resin, was 57 ± 22.6 μm and 63.47 ± 27.1 μm, respectively. Stone displayed a smaller area beneath the casting (31581 ± 16297 μm 2 ) as compared to polyurethane resin (35003 ± 23039 μm 2 ). The fit and adaptation of indirect gold castings made on polyurethane and type IV dental stone dies were comparable.

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

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

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.

Precision technique for trimming dies using a magnification device.

PubMed

Beck, D B

1980-05-01

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

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

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

Weiss, David; Purgert, Robert; Rhudy, Richard

1999-10-15

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

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

NASA Astrophysics Data System (ADS)

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

2004-06-01

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

Casting Technology.

ERIC Educational Resources Information Center

Wright, Michael D.; And Others

1992-01-01

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

New Lubricant for Pressure Die Casting,

DTIC Science & Technology

synthetic acids, finely dispersed graphite preparations, etc. The new lubricants are not inferior in their properties to the well known foreign lubricants antilov, olea , and emtek used in pressure die casting.

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

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

Weiss, David; Purgert, Robert; Rhudy, Richard

2000-04-21

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

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

NASA Astrophysics Data System (ADS)

Jin, Chul Kyu; Kang, Chung Gil

2011-10-01

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

Microstructure and Properties of Cobalt-and Zinc-Containing Magnetic Magnesium Alloys Processed by High-Pressure Die Casting

NASA Astrophysics Data System (ADS)

Klose, Christian; Demminger, Christian; Maier, Hans Jürgen

The inherent magnetic properties of lightweight alloys based on magnesium and cobalt offer a novel way in order to measure mechanical loads throughout the entire structural component using the magnetoelastic effect. Because the solubility of cobalt in the magnesium matrix is negligible, the magnetic properties mainly originate from Co-rich precipitates. Thus, the size and distribution of Co-containing phases within the alloy's microstructure wields a major influence on the amplitude of the load-sensitive properties which can be measured by employing the harmonic analysis of eddy-current signals. In this study, Mg-Co-based alloys are produced by several casting methods which allow the application of different cooling rates, e.g. gravity die casting and high-pressure die casting. The differences between the manufactured alloys' micro- and phase structures are compared depending on the applied cooling rate and the superior magnetic and mechanical properties of the high-pressure die cast material are demonstrated.

Evaluating the Tensile Properties of Aluminum Foundry Alloys through Reference Castings—A Review

PubMed Central

Anilchandra, A.R.; Arnberg, Lars; Bonollo, Franco; Fiorese, Elena

2017-01-01

The tensile properties of an alloy can be exploited if detrimental defects and imperfections of the casting are minimized and the microstructural characteristics are optimized through several strategies that involve die design, process management and metal treatments. This paper presents an analysis and comparison of the salient characteristics of the reference dies proposed in the literature, both in the field of pressure and gravity die-casting. The specimens produced with these reference dies, called separately poured specimens, are effective tools for the evaluation and comparison of the tensile and physical behaviors of Al-Si casting alloys. Some of the findings of the present paper have been recently developed in the frame of the European StaCast project whose results are complemented here with some more recent outcomes and a comprehensive analysis and discussion. PMID:28867796

Metallographic assessment of Al-12Si high-pressure die casting escalator steps.

PubMed

Vander Voort, George Frederic; Suárez-Peña, Beatriz; Asensio-Lozano, Juan

2014-10-01

A microstructural characterization study was performed on high-pressure die cast specimens extracted from escalator steps manufactured from an Al-12 wt.% Si alloy designed for structural applications. Black and white, color light optical imaging and scanning electron microscopy techniques were used to conduct the microstructural analysis. Most regions in the samples studied contained globular-rosette primary α-Al grains surrounded by an Al-Si eutectic aggregate, while primary dendritic α-Al grains were present in the surface layer. This dendritic microstructure was observed in the regions where the melt did not impinge directly on the die surface during cavity filling. Consequently, microstructures in the surface layer were nonuniform. Utilizing physical metallurgy principles, these results were analyzed in terms of the applied pressure and filling velocity during high-pressure die casting. The effects of these parameters on solidification at different locations of the casting are discussed.

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

PubMed

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

2011-02-01

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

E3 Success Story - Making an Investment in the Company: C.U.E.

EPA Pesticide Factsheets

C.U.E. in Mount Hope, West Virginia, makes molded and cast parts.An array of opportunities were found by WVMEP to implement lean production principles in areas such as mistake proofing, kanban systems, rapid exchange of dies, 5S, and value stream mapping.

Process research into metallic pipe wear of hot chamber die casting machines and methods ofincreasing wear resistance

NASA Astrophysics Data System (ADS)

Mukhametzyanova, G. F.; Kolesnikov, MS; Mukhametzyanov, I. R.; Astatshenko, V. I.

2017-09-01

The kinetics and reasons for metallic pipe wear of hot chamberzinc alloy die casting machines are established.Increasing metallic pipe wear components wear resistance is being achieved by means of die steelДИ - 22 with electroslag remelting modification and electron-beamremelting modification and after the processes of nitriding and boriding besides.

Die Soldering in Aluminium Die Casting

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

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

2000-03-15

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

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.

A process chain for integrating piezoelectric transducers into aluminum die castings to generate smart lightweight structures

NASA Astrophysics Data System (ADS)

Stein, Stefan; Wedler, Jonathan; Rhein, Sebastian; Schmidt, Michael; Körner, Carolin; Michaelis, Alexander; Gebhardt, Sylvia

The application of piezoelectric transducers to structural body parts of machines or vehicles enables the combination of passive mechanical components with sensor and actuator functions in one single structure. According to Herold et al. [1] and Staeves [2] this approach indicates significant potential regarding smart lightweight construction. To obtain the highest yield, the piezoelectric transducers need to be integrated into the flux of forces (load path) of load bearing structures. Application in a downstream process reduces yield and process efficiency during manufacturing and operation, due to the necessity of a subsequent process step of sensor/actuator application. The die casting process offers the possibility for integration of piezoelectric transducers into metal structures. Aluminum castings are particularly favorable due to their high quality and feasibility for high unit production at low cost (Brunhuber [3], Nogowizin [4]). Such molded aluminum parts with integrated piezoelectric transducers enable functions like active vibration damping, structural health monitoring or energy harvesting resulting in significant possibilities of weight reduction, which is an increasingly important driving force of automotive and aerospace industry (Klein [5], Siebenpfeiffer [6]) due to increasingly stringent environmental protection laws. In the scope of those developments, this paper focuses on the entire process chain enabling the generation of lightweight metal structures with sensor and actuator function, starting from the manufacturing of piezoelectric modules over electrical and mechanical bonding to the integration of such modules into aluminum (Al) matrices by die casting. To achieve this challenging goal, piezoceramic sensors/actuator modules, so-called LTCC/PZT modules (LPM) were developed, since ceramic based piezoelectric modules are more likely to withstand the thermal stress of about 700 °C introduced by the casting process (Flössel et al., [7]). The modules are made of low temperature cofired ceramic (LTCC) tapes with an embedded lead zirconate titanate (PZT) plate and are manufactured in multilayer technique. For joining conducting copper (Cu) wires with the electrode structure of the LPM, a novel laser drop on demand wire bonding method (LDB) is applied, which is based on the melting of a spherical CuSn12 braze preform with a liquidus temperature Tliquid of 989.9 °C (Deutsches Kupfer-Institut Düsseldorf, [8]) providing sufficient thermal stability for a subsequent casting process.

The Relationship between Dendrite Arm Spacing and Cooling Rate of Al-Si Casting Alloys in High Pressure Die Casting

NASA Astrophysics Data System (ADS)

Cho, Jae-Ik; Kim, Cheol-Woo; Kim, Young-Chan; Choi, Se-Weon; Kang, Chang-Seog

The effects of cooling rate on the solidification behavior of Al-8.5%Si-3%Cu and Al-11%Si-3%Cu alloys were studied during high pressure die casting (HPDC). The HPDC experiment was conducted by using the dies with 3 steps for 3 different cooling rates. Because of the high in both melt temperature and pressure, it was difficult to obtain the temperature profile directly from HPDC specimen. Therefore, in this study, cylindrical bar castings with different diameter were poured to acquire the cooling curves at the solidification range of 15°C/s up to 100°C/s and then the microstructures were compared to estimate the cooling rate in HPDC. The solidification characteristics including liquidus/solidus temperature and dendrite arm spacing of each alloy and each cooling rate was analyzed and the results showed strong proportional relationship between dendrite arm spacing and cooling rate in HPDC. The results were also compared with the actual die casting specimens and MAGMA simulation.

Application of superalloy powder metallurgy for aircraft engines

NASA Technical Reports Server (NTRS)

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

1980-01-01

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

Microstructure characterization and corrosion resistance properties of Pb-Sb alloys for lead acid battery spine produced by different casting methods.

PubMed

Seikh, Asiful H; Sherif, El-Sayed M; Khan Mohammed, Sohail M A; Baig, Muneer; Alam, Mohammad Asif; Alharthi, Nabeel

2018-01-01

The aim of this study is to find out the microstructure, hardness, and corrosion resistance of Pb-5%Sb spine alloy. The alloy has been produced by high pressure die casting (HPDC), medium pressure die casting (AS) and low pressure die casting (GS) methods, respectively. The microstructure was characterized by using optical microscopy and scanning electron microscopy (SEM). The hardness was also reported. The corrosion resistance of the spines in 0.5M H2SO4 solution has been analyzed by measuring the weight loss, impedance spectroscopy and the potentiodynamic polarization techniques. It has been found that the spine produced by HPDC has defect-free fine grain structure resulting improvement in hardness and excellent corrosion resistance.

Microstructure characterization and corrosion resistance properties of Pb-Sb alloys for lead acid battery spine produced by different casting methods

PubMed Central

Baig, Muneer; Alam, Mohammad Asif; Alharthi, Nabeel

2018-01-01

The aim of this study is to find out the microstructure, hardness, and corrosion resistance of Pb-5%Sb spine alloy. The alloy has been produced by high pressure die casting (HPDC), medium pressure die casting (AS) and low pressure die casting (GS) methods, respectively. The microstructure was characterized by using optical microscopy and scanning electron microscopy (SEM). The hardness was also reported. The corrosion resistance of the spines in 0.5M H2SO4 solution has been analyzed by measuring the weight loss, impedance spectroscopy and the potentiodynamic polarization techniques. It has been found that the spine produced by HPDC has defect-free fine grain structure resulting improvement in hardness and excellent corrosion resistance. PMID:29668709

Estimation of Heat Transfer Coefficient in Squeeze Casting of Magnesium Alloy AM60 by Experimental Polynomial Extrapolation Method

NASA Astrophysics Data System (ADS)

Sun, Zhizhong; Niu, Xiaoping; Hu, Henry

In this work, a different wall-thickness 5-step (with thicknesses as 3, 5, 8, 12, 20 mm) casting mold was designed, and squeeze casting of magnesium alloy AM60 was performed in a hydraulic press. The casting-die interfacial heat transfer coefficients (IHTC) in 5-step casting were determined based on experimental thermal histories data throughout the die and inside the casting which were recorded by fine type-K thermocouples. With measured temperatures, heat flux and IHTC were evaluated using the polynomial curve fitting method. The results show that the wall thickness affects IHTC peak values significantly. The IHTC value for the thick step is higher than that for the thin steps.

Precision forging technology for aluminum alloy

NASA Astrophysics Data System (ADS)

Deng, Lei; Wang, Xinyun; Jin, Junsong; Xia, Juchen

2018-03-01

Aluminum alloy is a preferred metal material for lightweight part manufacturing in aerospace, automobile, and weapon industries due to its good physical properties, such as low density, high specific strength, and good corrosion resistance. However, during forging processes, underfilling, folding, broken streamline, crack, coarse grain, and other macro- or microdefects are easily generated because of the deformation characteristics of aluminum alloys, including narrow forgeable temperature region, fast heat dissipation to dies, strong adhesion, high strain rate sensitivity, and large flow resistance. Thus, it is seriously restricted for the forged part to obtain precision shape and enhanced property. In this paper, progresses in precision forging technologies of aluminum alloy parts were reviewed. Several advanced precision forging technologies have been developed, including closed die forging, isothermal die forging, local loading forging, metal flow forging with relief cavity, auxiliary force or vibration loading, casting-forging hybrid forming, and stamping-forging hybrid forming. High-precision aluminum alloy parts can be realized by controlling the forging processes and parameters or combining precision forging technologies with other forming technologies. The development of these technologies is beneficial to promote the application of aluminum alloys in manufacturing of lightweight parts.

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

PubMed

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

2018-02-28

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

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

NASA Astrophysics Data System (ADS)

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

2015-08-01

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

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

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

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 maymore » 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.« less

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

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

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

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

The ultimate objective of this work was to eliminate approximately 30% of the machining performed in typical automotive engine and transmission plants by using thread forming fasteners in as-cast holes of aluminum and magnesium cast components. The primary issues at the source of engineers reluctance to implementing thread forming fasteners in lightweight castings are: * Little proof of consistency of clamp load vs. input torque in either aluminum or magnesium castings. * No known data to understand the effect on consistency of clamp load as casting dies wear. The clamp load consistency concern is founded in the fact that amore » portion of the input torque used to create clamp load is also used to create threads. The torque used for thread forming may not be consistent due to variations in casting material, hole size and shape due to tooling wear and process variation (thermal and mechanical). There is little data available to understand the magnitude of this concern or to form the basis of potential solutions if the range of clamp load variation is very high (> +/- 30%). The range of variation that can be expected in as-cast hole size and shape over the full life cycle of a high pressure die casting die was established in previous work completed by Pacific Northwest National Laboratory, (PNNL). This established range of variation was captured in a set of 12 cast bosses by designing core pins at the size and draft angles identified in the sited previous work. The cast bosses were cut into nuts that could be used in the Ford Fastener Laboratory test-cell to measure clamp load when a thread forming fastener was driven into a cast nut. There were two sets of experiments run. First, a series of cast aluminum nuts were made reflecting the range of shape and size variations to be expected over the life cycle of a die casting die. Taptite thread forming fasteners, (a widely used thread forming fastener suitable for aluminum applications), were driven into the various cored, as-cast nuts at a constant input torque and resulting clamp loads were recorded continuously. The clamp load data was used to determine the range of clamp loads to be expected. The bolts were driven to failure. The clamp load corresponding to the target input of 18.5 Nm was recorded for each fastener. In a like fashion, a second set of experiments were run with cast magnesium nuts and ALtracs thread forming fasteners, (a widely used thread forming fastener suitable for magnesium applications). Again all clamp loads were recorded and analyzed similarly to the Taptites in aluminum cast nuts. Results from previous work performed on the same test cell for a Battelle project using standard M8 bolts into standard M8 nuts were included as a comparator for a standard bolt and nut application. The results for the thread forming fasteners in aluminum cast holes were well within industry expectations of +/- 30% for out of the box and robustness range testing. The results for the dry and lubed extreme conditions were only slightly higher than industry expectations at +/- 35.6%. However, when compared to the actual Battelle results (+/- 40%) for a standard bolt and nut the tread forming fasteners performed slightly better. The results for the thread forming fasteners in magnesium cast holes were all well within industry expectations of +/- 30% for all three conditions. The robustness range (.05mm larger and smaller holes than the expected wear pattern of a die casting die at full life cycle) results also fell within the industry expectations for standard threaded fasteners. These results were very encouraging. It was concluded that this work showed that clamp load variation with thread forming fasteners is consistent with industry expectations for standard steel bolts and nuts at +/- 30%. There does not appear to be any significant increase in clamp load variation due to the application of thread forming fasteners in as-cast holes of aluminum or magnesium over the effective life of a die casting mold. The fully implemented potential benefit of thread forming fasteners in as-cast holes of aluminum and magnesium is estimated to be 6 trillion Btu per year for North America. Economic benefit is estimated to be nearly $800 million per year. Environmental benefits and quality improvements will also result from full implementation of this technology.« less

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

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

NASA Astrophysics Data System (ADS)

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

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

Experimental study on the use of spacer foils in two-step putty and wash impression procedures using silicone impression materials.

PubMed

Mann, Karsten; Davids, Andreas; Range, Ursula; Richter, Gert; Boening, Klaus; Reitemeier, Bernd

2015-04-01

The 2-step putty and wash impression technique is commonly used in fixed prosthodontics. However, cutting sluiceways to allow the light-body material to drain is time-consuming. A solution might be the use of a spacer foil. The purpose of this study was to evaluate the influence of spacer foil on the margin reproduction and dimensional accuracy of 2-step putty and wash impressions. Two methods of creating space for the wash material in a 2-step putty and wash impression were compared: the traditional cutout technique and a spacer foil. Eleven commercially available combinations of silicone impression materials were included in the study. The impressions and the cast production were carried out under standardized conditions. All casts were measured with a 3-dimensional (3D) coordinate measuring machine. Preparation margin reproduction and the diameters and spacing of the stone cast dies were measured (α=.05). The 2 methods showed significant differences (P<.05) in the reproduction of the preparation margins (complete reproduction cutout, 90% to 98%; foil, 74% to 91%). The use of a foil resulted in greater dimensional accuracy of the cast dies compared to the cutout technique. Cast dies from the cutout technique were significantly smaller than the metallic original cast (cutout median, 4.55 mm to 4.61 mm; foil median, 4.61 to 4.64). Spacing between the dies revealed only a few additional significant differences between the techniques. When spacer foils were used, dies were obtained that better corresponded to the original tooth. Copyright © 2015 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

A simplified simulation model for a HPDC die with conformal cooling channels

NASA Astrophysics Data System (ADS)

Frings, Markus; Behr, Marek; Elgeti, Stefanie

2017-10-01

In general, the cooling phase of the high-pressure die casting process is based on complex physical phenomena: so-lidification of molten material; heat exchange between cast part, die and cooling fluid; turbulent flow inside the cooling channels that needs to be considered when computing the heat flux; interdependency of properties and temperature of the cooling liquid. Intuitively understanding and analyzing all of these effects when designing HPDC dies is not feasible. A remedy that has become available is numerical design, based for example on shape optimization methods. However, current computing power is not sufficient to perform optimization while at the same time fully resolving all physical phenomena. But since in HPDC suitable objective functions very often lead to integral values, e.g., average die temperature, this paper identifies possible simplifications in the modeling of the cooling phase. As a consequence, the computational effort is reduced to an acceptable level. A further aspect that arises in the context of shape optimization is the evaluation of shape gradients. The challenge here is to allow for large shape deformations without remeshing. In our approach, the cooling channels are described by their center lines. The flow profile of the cooling fluid is then estimated based on experimental data found in literature for turbulent pipe flows. In combination, the heat flux throughout cavity, die, and cooling channel can be described by one single advection-diffusion equation on a fixed mesh. The parameters in the equation are adjusted based on the position of cavity and cooling channel. Both results contribute towards a computationally efficient, yet accurate method, which can be employed within the frame of shape optimization of cooling channels in HPDC dies.

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…

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

Federal Register 2010, 2011, 2012, 2013, 2014

2012-02-08

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

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

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

Liu, Y. F.; Yang, W.; Qin, Q. L.

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 CaCO 3 film was formed on the surface of the alloys and that the rate of CaCO 3 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.

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

PubMed Central

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

2018-01-01

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

Marginal adaptation of four inlay casting waxes on stone, titanium, and zirconia dies.

PubMed

Michalakis, Konstantinos X; Kapsampeli, Vassiliki; Kitsou, Aikaterini; Kirmanidou, Yvone; Fotiou, Anna; Pissiotis, Argirios L; Calvani, Pasquale Lino; Hirayama, Hiroshi; Kudara, Yukio

2014-07-01

Different inlay casting waxes do not produce copings with satisfactory marginal accuracy when used on different die materials. The purpose of this study was to evaluate the marginal accuracy of 4 inlay casting waxes on stone dies and titanium and zirconia abutments and to correlate the findings with the degree of wetting between the die specimens and the inlay casting waxes. The inlay casting waxes tested were Starwax (Dentaurum), Unterziehwachs (Bredent), SU Esthetic wax (Schuler), and Sculpturing wax (Renfert). The marginal opening of the waxes was measured with a stereomicroscope on high-strength stone dies and on titanium and zirconia abutments. Photographic images were obtained, and the mean marginal opening for each specimen was calculated. A total of 1440 measurements were made. Wetting between die materials and waxes was determined after fabricating stone, titanium, and zirconia rectangular specimens. A calibrated pipette was used to place a drop of molten wax onto each specimen. The contact angle was calculated with software after an image of each specimen had been made with a digital camera. Collected data were subjected to a 2-way analysis of variance (α=.05). Any association between marginal accuracy and wetting of different materials was found by using the Pearson correlation. The wax factor had a statistically significant effect both on the marginal discrepancy (F=158.31, P<.001) and contact angle values (F=68.09, P<.001). A statistically significant effect of the die material factor both on the marginal adaptation (F=503.47, P<.001) and contact angle values (F=585.02, P<.001) was detected. A significant correlation between the marginal accuracy and the contact angle values (Pearson=0.881, P=.01) was also found. Stone dies provided wax copings with the best marginal integrity, followed by titanium and zirconia abutments. Unterziehwachs (Bredent), wax produced the best marginal adaptation on different die materials. A significant correlation was found between the marginal accuracy and the contact angle values. As the contact angle value became smaller, the marginal accuracy improved. All combinations of waxes and stone and titanium dies presented a high wettability. Copyright © 2014 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

Improved design and durability of aluminum die casting horizontal shot sleeves

NASA Astrophysics Data System (ADS)

Birceanu, Sebastian

The design and performance of shot sleeves is critical in meeting the engineering requirements of aluminum die cast parts. Improvement in shot sleeve materials have a major impact on dimensional stability, reproducibility and quality of the product. This investigation was undertaken in order to improve the life of aluminum die casting horizontal shot sleeves. Preliminary pin tests were run to evaluate the soldering, wash-out and thermal fatigue behavior of commercially available materials and coatings. An experimental rig was designed and constructed for shot sleeve configuration evaluation. Fabrication and testing of experimental shot sleeves was based upon preliminary results and manufacturing costs. Three shot sleeve designs and materials were compared to a reference nitrided H13 sleeve. Nitrided H13 is the preferred material for aluminum die casting shot sleeves because of wear resistance, strength and relative good soldering and wash-out resistance. The study was directed towards damage evaluation on the area under the pouring hole. This area is the most susceptible to damage because of high temperatures and impingement of molten aluminum. The results of this study showed that tungsten and molybdenum had the least amount of soldering and wash-out damage, and the best thermal fatigue resistance. Low solubility in molten aluminum and stability of intermetallic layers are main factors that determine the soldering and wash-out behavior. Thermal conductivity and thermal expansion coefficient directly influence thermal fatigue behavior. TiAlN nanolayered coating was chosen as the material with the best damage resistance among several commercial PVD coatings, because of relatively large thickness and simple deposition conditions. The results show that molybdenum thermal sprayed coating provided the best protection against damage under the pouring hole. Improved bonding is however required for life extension of the coating. TiAlN PVD coating applied on H13 nitrided substrate performed very well as long as the coating was maintained. Nitrided H13 sleeve showed extensive damage that occurred as early as 200 cycles. The nitrided layer only slowed down the diffusion process and dissolution took place at a higher rate as soon as the layer wore off. Stellite 6 sleeve also showed considerable wear under the action of molten aluminum.

Effects of preparation relief and flow channels on seating full coverage castings during cementation.

PubMed

Webb, E L; Murray, H V; Holland, G A; Taylor, D F

1983-06-01

Machined steel dies were used to study the effects of three die modifications on seating full coverage castings during cementation. The die modifications consisted of occlusal channels, occlusal surface relief, and axial channels. Fourteen specimens having one or more forms of die modification were compared with two control specimens having no die modifications. Statistical analysis of the data revealed that the addition of four axial channels to the simulated preparation on the steel die produced a significant reduction in the mean marginal discrepancy during cementation. Occlusal modifications alone failed to produce significant reductions in marginal discrepancies when compared with the control specimens. Occlusal modifications in conjunction with axial channels failed to produce further significant reductions in marginal discrepancies when compared with those reductions observed in specimens having only axial channels.

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

NASA Astrophysics Data System (ADS)

Sakhuja, Amit; Brevick, Jerald R.

2004-06-01

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

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.

Fatigue properties of die cast zinc alloys for automotive lock applications

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

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

2004-06-01

During the 1970’s many automotive lock systems were converted from zinc die casting alloys to engineering plastics for reasons of weight and cost. Recent increases in requirements for precision and security have caused automotive and other lock designers to reconsider zinc alloy die-castings for these applications. To enable this, there is a need for mechanical property data comparable to that of the plastics materials used in these applications. In this work, rotary bending fatigue tests were performed on Alloys 3, 5, ZA-8 and AcuZinc 5 using an R.R. Moore fatigue machine. Testing was performed at 30 Hz and was stoppedmore » at 1x107 cycles. The fatigue limit results were compared to data reported in the literature for higher number of cycles and faster rotations.« less

Formation Mechanism of Discoloration on Die-Cast AZ91D Components Surface After Chemical Conversion

NASA Astrophysics Data System (ADS)

Liu, Bao-sheng; Wei, Ying-hui; Hou, Li-feng

2013-01-01

A notebook (NB) computer component was manufactured from AZ91D Mg alloy by a die-casting process. After chemical conversion treatment, a discoloration was noted on the component surface. The source of this discoloration has been studied in detail by scanning electron microscopy, energy dispersive spectroscopy, and spark atomic absorption spectroscopy. The corrosion resistance was also measured by potentiodynamic polarization, hydrogen evolution and salt spray testing. The formation mechanism for the discoloration which was caused by the residue left behind by excess mold release agent sprayed during the die-casting was discussed in detail. After chemical conversion treatment, the residual-baked mold release agent was apparent on the component surface as "white ash." Consequently, it degraded seriously both the appearance and the corrosion resistance of the manufactured component.

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.

Mechanical and physical properties of AlSi10Mg processed through selective laser melting

NASA Astrophysics Data System (ADS)

Raus, A. A.; Wahab, M. S.; Ibrahim, M.; Kamarudin, K.; Ahmed, Aqeel; Shamsudin, S.

2017-04-01

In the past few decade, Additive Manufacturing (AM) has become popular and substantial to manufacture direct functional parts in varieties industrial applications even in very challenging like aerospace, medical and manufacturing sectors. Selective Laser Melting (SLM) is one of the most efficient technique in the additive Manufacturing (AM) which able to manufacture metal component directly from Computer Aided Design (CAD) file data. Accuracy, mechanical and physical properties are essentials requirement in order to meet the demand of those engineering components. In this paper, the mechanical properties of SLM manufactured AlSi10Mg samples such as hardness, tensile strength, and impact toughness are investigated and compared to conventionally high pressure die cast A360 alloy. The results exposed that the hardness and the yield strength of AlSi10Mg samples by SLM were increased by 42% and 31% respectively to those of conventionally high pressure die cast A360 alloy even though without comprehensive post processing methods. It is also discovered that AlSi10Mg parts fabricated by SLM achieved the highest density of 99.13% at the best setting parameters from a previous study of 350 watts laser power, 1650 mm/s scanning speed and hatching distance 0.13 mm.

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

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

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

1998-06-05

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

A comparative evaluation of the marginal adaptation of a thermoplastic resin, a light cured wax and an inlay casting wax on stone dies: An in vitro study.

PubMed

Gopalan, Reji P; Nair, Vivek V; Harshakumar, K; Ravichandran, R; Lylajam, S; Viswambaran, Prasanth

2018-01-01

Different pattern materials do not produce copings with satisfactory, marginal accuracy when used on stone dies at varying time intervals. The purpose of this study was to evaluate and compare the vertical marginal accuracy of patterns formed from three materials, namely, thermoplastic resin, light cured wax and inlay casting wax at three-time intervals of 1, 12, and 24 h. A master die (zirconia abutment mimicking a prepared permanent maxillary central incisor) and metal sleeve (direct metal laser sintering crown #11) were fabricated. A total of 30 stone dies were obtained from the master die. Ten patterns were made each from the three materials and stored off the die at room temperature. The vertical marginal gaps were measured using digital microscope at 1, 12, and 24 h after reseating with gentle finger pressure. The results revealed a significant statistical difference in the marginal adaptation of three materials at all the three-time intervals. Light cured wax was found to be most accurate at all time intervals, followed by thermoplastic resin and inlay casting wax. Furthermore, there was a significant difference between all pairs of materials. The change in vertical marginal gap from 1 to 24 h between thermoplastic resin and light cured wax was not statistically significant. The marginal adaptation of all the three materials used, was well within the acceptable range of 25-70 μm. The resin pattern materials studied revealed significantly less dimensional change than inlay casting wax on storage at 1, 12, and 24 h time intervals. They may be employed in situations where high precision and delayed investing is expected.

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.

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.

Limitation of Shrinkage Porosity in Aluminum Rotor Die Casting

NASA Astrophysics Data System (ADS)

Kim, Young-Chan; Choi, Se-Weon; Kim, Cheol-Woo; Cho, Jae-Ik; Lee, Sung-Ho; Kang, Chang-Seog

Aluminum rotor prone to have many casting defects especially large amount of air and shrinkage porosity, which caused eccentricity, loss and noise during motor operation. Many attempts have been made to develop methods of shrinkage porosity control, but still there are some problems to solve. In this research, the process of vacuum squeeze die casting is proposed for limitation of defects. The 6 pin point gated dies which were in capable of local squeeze at the end ring were used. Influences of filling patterns on HPDC were evaluated and the important process control parameters were high injection speed, squeeze length, venting and process conditions. By using local squeeze and vacuum during filling and solidification, air and shrinkage porosity were significantly reduced and the feeding efficiency at the upper end ring was improved 10%. As a result of controlling the defects, the dynamometer test showed improved motor efficiency by more than 4%.

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

NASA Astrophysics Data System (ADS)

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

2017-01-01

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

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.

Quantitative Experimental Study of Defects Induced by Process Parameters in the High-Pressure Die Cast Process

NASA Astrophysics Data System (ADS)

Sharifi, P.; Jamali, J.; Sadayappan, K.; Wood, J. T.

2018-05-01

A quantitative experimental study of the effects of process parameters on the formation of defects during solidification of high-pressure die cast magnesium alloy components is presented. The parameters studied are slow-stage velocity, fast-stage velocity, intensification pressure, and die temperature. The amount of various defects are quantitatively characterized. Multiple runs of the commercial casting simulation package, ProCAST™, are used to model the mold-filling and solidification events. Several locations in the component including knit lines, last-to-fill region, and last-to-solidify region are identified as the critical regions that have a high concentration of defects. The area fractions of total porosity, shrinkage porosity, gas porosity, and externally solidified grains are separately measured. This study shows that the process parameters, fluid flow and local solidification conditions, play major roles in the formation of defects during HPDC process.

Marginal Accuracy of Castings Fabricated with Ringless Casting Investment System and Metal Ring Casting Investment System: A Comparative Study.

PubMed

Kalavathi, M; Sachin, Bhuvana; Prasanna, B G; Shreeharsha, T V; Praveen, B; Ragher, Mallikarjuna

2016-02-01

The thermal expansion of the investment can be restricted by the metal casting ring because the thermal expansion of the ring is less than that of the investment. The ringless casting procedure is in use in clinical dentistry, though there is little scientific data to support its use in fixed partial dentures. In this study, marginal discrepancy of castings produced with the ringless casting technique and the conventional technique using the metal rings were compared. A total of 30 wax patterns were fabricated directly on a metal die. Optical stereomicroscope was used to measure the marginal discrepancy between the metal die and wax patterns. A total of 15 castings were invested using Bellavest T phosphate-bonded investment with the ringless technique and 15 were invested with the same investment with a metal ring; 30 castings were produced using a nickel-chromium ceramo-metal alloy. The internal surface of the castings was not modified and seated with finger pressure. The vertical marginal discrepancy was measured using an optical stereomicroscope at a magnification of 100x. The data obtained were statistically analyzed using students t-test (paired t-test and unpaired t-test). The castings of the ringless technique provided less vertical marginal discrepancy (240.56 ± 45.81 μ) than the castings produced with the conventional metal ring technique (281.98± 53.05 μ). The difference was statistically significant. The ringless casting technique had produced better marginal accuracy compared with conventional casting technique. Ringless casting system can be used routinely for clinical purpose.

Characterization of the interfacial heat transfer coefficient for hot stamping processes

NASA Astrophysics Data System (ADS)

Luan, Xi; Liu, Xiaochuan; Fang, Haomiao; Ji, Kang; El Fakir, Omer; Wang, LiLiang

2016-08-01

In hot stamping processes, the interfacial heat transfer coefficient (IHTC) between the forming tools and hot blank is an essential parameter which determines the quenching rate of the process and hence the resulting material microstructure. The present work focuses on the characterization of the IHTC between an aluminium alloy 7075-T6 blank and two different die materials, cast iron (G3500) and H13 die steel, at various contact pressures. It was found that the IHTC between AA7075 and cast iron had values 78.6% higher than that obtained between AA7075 and H13 die steel. Die materials and contact pressures had pronounced effects on the IHTC, suggesting that the IHTC can be used to guide the selection of stamping tool materials and the precise control of processing parameters.

Experimental Damage Criterion for Static and Fatigue Life Assessment of Commercial Aluminum Alloy Die Castings

NASA Astrophysics Data System (ADS)

Battaglia, Eleonora; Bonollo, Franco; Ferro, Paolo

2017-05-01

Defects, particularly porosity and oxides, in high-pressure die casting can seriously compromise the in-service behavior and durability of products subjected to static or cyclic loadings. In this study, the influence of dimension, orientation, and position of casting defects on the mechanical properties of an AlSi12(b) (EN-AC 44100) aluminum alloy commercial component has been studied. A finite element model has been carried out in order to calculate the stress distribution induced by service loads and identify the crack initiation zones. Castings were qualitatively classified on the basis of porosities distribution detected by X-ray technique and oxides observed on fracture surfaces of specimens coming from fatigue and tensile tests. A damage criterion has been formulated which considers the influence of defects position and orientation on the mechanical strength of the components. Using the proposed damage criterion, it was possible to describe the mechanical behavior of the castings with good accuracy.

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.

Heated Hydro-Mechanical Deep Drawing of Magnesium Sheet Metal

NASA Astrophysics Data System (ADS)

Kurz, Gerrit

In order to reduce fuel consumption efforts have been made to decrease the weight of automobile constructions by increasing the use of lightweight materials. In this field of application magnesium alloys are important because of their low density. A promising alternative to large surfaced and thin die casting parts has been found in construction parts that are manufactured by sheet metal forming of magnesium. Magnesium alloys show a limited formability at room temperature. A considerable improvement of formability can be achieved by heating the material. Formability increases above a temperature of approximately T = 225 °C.

Alloy Shrinkage factors for the investment casting of 17-4PH stainless steel parts

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

Sabau, Adrian S; Porter, Wallace D

2008-01-01

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. For all the properties, the experimental data available in the literature did not cover the entire temperature range necessary for process simulation. A comparison between the predicted material property data measured property data is made. It was found that most material properties weremore » accurately predicted over the most of the temperature range of the process. Several assumptions were made in order to obtain a complete set of mechanical property data at high temperatures. Thermal expansion measurements for the 17-4PH alloy were conducted at heating and cooling. As a function of temperature, the thermal expansion for both the alloy and shell mold materials showed different evolution at heating and cooling. Thus, one generic simulation were performed with thermal expansion obtained at heating and another one with thermal expansion obtained at cooling. The alloy dimensions were obtained from numerical simulation results of solidification, heat transfer, and deformation phenomena. As compared with experimental results, the numerical simulation results for the shrinkage factors were slightly over-predicted.« less

Alloy Shrinkage Factors for the Investment Casting of 17-4PH Stainless Steel Parts

NASA Astrophysics Data System (ADS)

Sabau, Adrian S.; Porter, Wallace D.

2008-04-01

In this study, 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. The dimensions of the die tooling, wax pattern, and casting were measured using a coordinate measurement machine (CMM). For all the properties, the experimental data available in the literature did not cover the entire temperature range necessary for process simulation. A comparison between the predicted material property data and measured property data is made. It was found that most material properties were accurately predicted over most of the temperature range of the process. Several assumptions were made, in order to obtain a complete set of mechanical property data at high temperatures. Thermal expansion measurements for the 17-4PH alloy were conducted during heating and cooling. As a function of temperature, the thermal expansion for both the alloy and shell mold materials showed a different evolution on heating and cooling. Thus, one generic simulation was performed with thermal expansion obtained on heating, and another one was performed with thermal expansion obtained on cooling. The alloy dimensions were obtained from the numerical simulation results of the solidification, heat transfer, and deformation phenomena. As compared with experimental results, the numerical simulation results for the shrinkage factors were slightly overpredicted.

High pressure die casting of Fe-based metallic glass.

PubMed

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

2016-10-11

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.

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.

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

Thermal Stress Analysis for Ceramics Stalk in the Low Pressure Die Casting Machine

NASA Astrophysics Data System (ADS)

Noda, Nao-Aki; Hendra, Nao-Aki; Takase, Yasushi; Li, Wenbin

Low pressure die casting (LPDC) is defined as a net shape casting technology in which the molten metal is injected at high speeds and pressure into a metallic die. The LPDC process is playing an increasingly important role in the foundry industry as a low-cost and high-efficiency precision forming technique. The LPDC process is that the permanent die and filling systems are placed over the furnace containing the molten alloy. The filling of the cavity is obtained by forcing the molten metal by means of a pressurized gas in order to rise into a ceramic tube, which connects the die to the furnace. The ceramics tube called stalk has high temperature resistance and high corrosion resistance. However, attention should be paid to the thermal stress when the stalk is dipped into the molten aluminum. It is important to develop the design of the stalk to reduce the risk of fracture because of low fracture toughness of ceramics. In this paper, therefore, the finite element method is applied to calculate the thermal stresses when the stalk is dipped into the crucible by varying the dipping speeds and dipping directions. It is found that the thermal stress can be reduced by dipping slowly if the stalk is dipped into the crucible vertically, while the thermal stress can be reduced by dipping fast if it is dipped horizontally.

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.

Deducing material quality in cast and hot-forged steels by new bending test

NASA Astrophysics Data System (ADS)

Valberg, Henry; Langøy, Morten; Nedreberg, Mette; Helvig, Torgeir

2017-10-01

A special bend test has been developed and applied for the purpose of characterization and comparison of the material ductility in crankpin steel discs manufactured by casting, or casting subsequently followed by hot open-die forging (ODF) or closed-die forging (CDF). The bending test specimen consists of a small rectangular plate of material with a round hole cut out in the middle. The "eye-shape" specimens were cut out from various positions either near to the surface of, or from the interior of the discs. The test method revealed differences in ductility for the investigated materials, and for different depth positions inside the discs. The roughening of the specimen surface on the top-side of the specimen bend also varied dependent on the processing method for the material. Current results show that this test method is useful for evaluation of material quality in differently processed material. Experimental bend test results are presented for differently processed variants of the same material, i.e., crankpin discs either made by solely casting or casting subsequently followed by hot working either by ODF or CDF.

Comparison of marginal accuracy of castings fabricated by conventional casting technique and accelerated casting technique: an in vitro study.

PubMed

Reddy, S Srikanth; Revathi, Kakkirala; Reddy, S Kranthikumar

2013-01-01

Conventional casting technique is time consuming when compared to accelerated casting technique. In this study, marginal accuracy of castings fabricated using accelerated and conventional casting technique was compared. 20 wax patterns were fabricated and the marginal discrepancy between the die and patterns were measured using Optical stereomicroscope. Ten wax patterns were used for Conventional casting and the rest for Accelerated casting. A Nickel-Chromium alloy was used for the casting. The castings were measured for marginal discrepancies and compared. Castings fabricated using Conventional casting technique showed less vertical marginal discrepancy than the castings fabricated by Accelerated casting technique. The values were statistically highly significant. Conventional casting technique produced better marginal accuracy when compared to Accelerated casting. The vertical marginal discrepancy produced by the Accelerated casting technique was well within the maximum clinical tolerance limits. Accelerated casting technique can be used to save lab time to fabricate clinical crowns with acceptable vertical marginal discrepancy.

Evaluation of interlocking bond strength between structured 1.0338 steel sheets and high pressure die cast AlMg5Si2

NASA Astrophysics Data System (ADS)

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

2018-05-01

Multi-material components open up new possibilities for functional design. Such components combine beneficial physical properties of different materials in a single component as for instance chemical resistance, high strength or low density. The challenge is a reliable bond between both materials to enable a long term usage. This paper deals with a form closure connection to ensure a solid connection between steel strips and high pressure die cast aluminium. Two different sizes of channel structures with width ratios of 1.0 and 1.35 are produced on a steel sheet. An ensuing flat rolling pass is performed to create undercuts with a width of up to 50 µm, enabling an interlocking of the molten aluminium in the concluding casting process. For both rolling processes the resulting geometry is analysed depending on the thickness reduction. In a subsequent high pressure die casting process, aluminium is applied resulting in a complete form filling for the coarser structure. Comparing structures with and without undercuts, only structures suited with undercuts remain gap-free after solidification contraction. The finer structure could not be filled completely; nevertheless these structures result in shear strength of up to 45 MPa transversal to the channel-direction.

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.

R-HPDC Process with Forced Convection Mixing Device for Automotive Part of A380 Aluminum Alloy

PubMed Central

Zhou, Bing; Kang, Yonglin; Qi, Mingfan; Zhang, Huanhuan; Zhu, Guoming

2014-01-01

The continuing quest for cost-effective and complex shaped aluminum castings with fewer defects for applications in the automotive industries has aroused the interest in rheological high pressure die casting (R-HPDC). A new machine, forced convection mixing (FCM) device, based on the mechanical stirring and convection mixing theory for the preparation of semisolid slurry in convenience and functionality was proposed to produce the automotive shock absorber part by R-HPDC process. The effect of barrel temperature and rotational speed of the device on the grain size and morphology of semi-solid slurry were extensively studied. In addition, flow behavior and temperature field of the melt in the FCM process was investigated combining computational fluid dynamics simulation. The results indicate that the microstructure and pore defects at different locations of R-HPDC casting have been greatly improved. The vigorous fluid convection in FCM process has changed the temperature field and composition distribution of conventional solidification. Appropriately increasing the rotational speed can lead to a uniform temperature filed sooner. The lower barrel temperature leads to a larger uniform degree of supercooling of the melt that benefits the promotion of nucleation rate. Both of them contribute to the decrease of the grain size and the roundness of grain morphology. PMID:28788608

ELF-MF Occupational Exposure in Die-casting and Electroplating Workers in Korea.

PubMed

Rajitha Kawshalya, Mailan Arachchige Don; Jung, Joon-Sig; Lee, Yun-Jin; Hong, Seung-Cheol

2018-04-26

A 24-h exposure assessment was performed in two groups of blue-collar workers from a die-casting and an electroplating plant to investigate levels of exposure to extremely low-frequency magnetic fields (ELF-MF), using EMDEX Lite. ELF-MF exposure of workers from the die-casting plant AM±SD (AM=arithmetic mean, SD=standard deviation) (0.649±1.343µT)] is higher than in electroplating workers (0.138±0.045µT). Higher ELF-MF exposure was found among workers living in same building as their workplace compared to that among other workers. This study suggests that ELF-MF exposure levels should be taken into consideration when providing dormitories for workers to minimize the levels of residential ELF-MF exposure due to emission from plants. The study recommends that blue-collar workers should be made aware of measures to minimize their exposure to environmental agents such as ELF-MF and electromagnetic field (EMF) during work, such as maintaining a safe distance between machines and avoiding undesirable behavior with equipment.

Numerical simulation on semi-solid die-casting of magnesium matrix composite based on orthogonal experiment

NASA Astrophysics Data System (ADS)

Liu, Huihui; He, Xiongwei; Guo, Peng

2017-04-01

Three factors (pouring temperature, injection speed and mold temperature) were selected to do three levels L9 (33)orthogonal experiment, then simulate processing of semi-solid die-casting of magnesium matrix composite by Flow-3D software. The stress distribution, temperature field and defect distribution of filling process were analyzed to find the optimized processing parameter with the help of orthogonal experiment. The results showed that semi-solid has some advantages of well-proportioned stress and temperature field, less defect concentrated in the surface. The results of simulation were the same as the experimental results.

Notched bar Izod impact properties of zinc die castings

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

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

2007-03-01

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

Development of Thin Section Zinc Die Casting Technology

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

Goodwin, Frank

2013-10-31

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

Implementation of 3D Optical Scanning Technology for Automotive Applications

PubMed Central

Kuş, Abdil

2009-01-01

Reverse engineering (RE) is a powerful tool for generating a CAD model from the 3D scan data of a physical part that lacks documentation or has changed from the original CAD design of the part. The process of digitizing a part and creating a CAD model from 3D scan data is less time consuming and provides greater accuracy than manually measuring the part and designing the part from scratch in CAD. 3D optical scanning technology is one of the measurement methods which have evolved over the last few years and it is used in a wide range of areas from industrial applications to art and cultural heritage. It is also used extensively in the automotive industry for applications such as part inspections, scanning of tools without CAD definition, scanning the casting for definition of the stock (i.e. the amount of material to be removed from the surface of the castings) model for CAM programs and reverse engineering. In this study two scanning experiments of automotive applications are illustrated. The first one examines the processes from scanning to re-manufacturing the damaged sheet metal cutting die, using a 3D scanning technique and the second study compares the scanned point clouds data to 3D CAD data for inspection purposes. Furthermore, the deviations of the part holes are determined by using different lenses and scanning parameters. PMID:22573995

40 CFR Table 8 to Subpart Wwww of... - Initial Compliance With Organic HAP Emissions Limits

Code of Federal Regulations, 2011 CFR

2011-07-01

... organic HAP emissions limit . . . You have demonstrated initial complianceif . . . 1. open molding and... contents. 2. open molding centrifugal casting, continuous lamination/casting, SMC and BMC manufacturing... die injection, and/or wet-area enclosures that meet the criteria of § 63.5830. 6. pultrusion...

2D and 3D characterization of pore defects in die cast AM60

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

Yang, Zhuofei; CanmetMATERIALS, 183 Longwood Road South, Hamilton L8P 0A5, Ontario Canada; Maurey, Alexandre

2016-04-15

The widespread application of die castings can be hampered due to the potential of large scale porosity to act as nucleation sites for fracture and fatigue. It is therefore important to develop robust approaches to the characterization of porosity providing parameters that can be linked to the material's mechanical properties. We have tackled this problem in a study of the AM60 die cast Mg alloy, using samples extracted from a prototype shock tower. A quantitative characterization of porosity has been undertaken, analyzing porosity in both 2D (using classical metallographic methods) and in 3D (using X-ray computed tomography (XCT)). Metallographic characterizationmore » results show that shrinkage pores and small gas pores can be distinguished based on their distinct geometrical features. Shrinkage pores are irregular with multiple arms, resulting in a form factor less than 0.4. In contrast, gas pores are generally more circular in shape yielding form factors larger than 0.6. XCT provides deeper insight into the shape of pores, although this understanding is limited by the resolution obtainable by laboratory based XCT. It also shows how 2D sectioning can produce artefacts as single complex pores are sectioned into multiple small pores. - Highlights: • Mg (e.g. AM60) die castings may contain large scale porosity that act as nucleation sites for fracture and fatigue • Quantitative characterization of porosity metallography (2D) and X-ray tomography (3D) is used • Shrinkage pores and small gas pores can be distinguished based on their distinct geometrical features. • Shrinkage pores are irregular giving a form factor < 0.4; gas pores are rounder with form factors > 0.6 • XCT enables pore visualization, although limited by the resolution obtainable by laboratory based XCT.« less

Treatment of Aluminum Die Casting Operations for the Purposes of NSR Applicability

EPA Pesticide Factsheets

This document may be of assistance in applying the New Source Review (NSR) air permitting regulations including the Prevention of Significant Deterioration (PSD) requirements. This document is part of the NSR Policy and Guidance Database. Some documents in the database are a scanned or retyped version of a paper photocopy of the original. Although we have taken considerable effort to quality assure the documents, some may contain typographical errors. Contact the office that issued the document if you need a copy of the original.

Low-Cycle Fatigue Behavior of Die-Cast Mg Alloy AZ91

NASA Astrophysics Data System (ADS)

Rettberg, Luke; Anderson, Warwick; Jones, J. Wayne

An investigation has been conducted on the influence of microstructure and artificial aging response (T6) on the low-cycle fatigue behavior of super vacuum die-cast (SVDC) AZ91. Fatigue lifetimes were determined from total strain-controlled fatigue tests for strain amplitudes of 0.2%, 0.4% and 0.6%, under fully reversed loading at a frequency of 5 Hz. Cyclic stress-strain behavior was determined using incremental step test (IST) methods. Two locations in a prototype casting with different thicknesses and, therefore, solidification rates, microstructure and porosity, were examined. In general., at all total strain amplitudes fatigue life was unaffected by microstructure refinement and was attributed to significant levels of porosity. Cyclic softening and a subsequent increased cyclic hardening rate, compared to monotonic tests, were observed, independent of microstructure. These results, fractography and damage accumulation processes, determined from metallographic sectioning, are discussed.

40 CFR Table 8 to Subpart Wwww of... - Initial Compliance With Organic HAP Emissions Limits

Code of Federal Regulations, 2014 CFR

2014-07-01

.... open molding and centrifugal casting operations a. an organic HAP emissions limit shown in Tables 3 or... method meet the appropriate organic HAP contents. 2. open molding centrifugal casting, continuous... reduction is being claimed, are using direct die injection, and/or wet-area enclosures that meet the...

40 CFR Table 8 to Subpart Wwww of... - Initial Compliance With Organic HAP Emissions Limits

Code of Federal Regulations, 2013 CFR

2013-07-01

.... open molding and centrifugal casting operations a. an organic HAP emissions limit shown in Tables 3 or... method meet the appropriate organic HAP contents. 2. open molding centrifugal casting, continuous... reduction is being claimed, are using direct die injection, and/or wet-area enclosures that meet the...

40 CFR Table 8 to Subpart Wwww of... - Initial Compliance With Organic HAP Emissions Limits

Code of Federal Regulations, 2012 CFR

2012-07-01

.... open molding and centrifugal casting operations a. an organic HAP emissions limit shown in Tables 3 or... method meet the appropriate organic HAP contents. 2. open molding centrifugal casting, continuous... reduction is being claimed, are using direct die injection, and/or wet-area enclosures that meet the...

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…

A comparison of the accuracy of patterns processed from an inlay casting wax, an auto-polymerized resin and a light-cured resin pattern material.

PubMed

Rajagopal, Praveen; Chitre, Vidya; Aras, Meena A

2012-01-01

Traditionally, inlay casting waxes have been used to fabricate patterns for castings. Newer resin pattern materials offer greater rigidity and strength, allowing easier laboratory and intraoral adjustment without the fear of pattern damage. They also claim to possess a greater dimensional stability when compared to inlay wax. This study attempted to determine and compare the marginal accuracy of patterns fabricated from an inlay casting wax, an autopolymerized pattern resin and a light polymerized pattern resin on storage off the die for varying time intervals. Ten patterns each were fabricated from an inlay casting wax (GC Corp., Tokyo, Japan), an autopolymerized resin pattern material (Pattern resin, GC Corp, Tokyo, Japan) and a light-cured resin pattern material (Palavit GLC, Hereaus Kulzer GmbH, Germany). The completed patterns were stored off the die at room temperature. Marginal gaps were evaluated by reseating the patterns on their respective dies and observing it under a stereomicroscope at 1, 12, and 24 h intervals after pattern fabrication. The results revealed that the inlay wax showed a significantly greater marginal discrepancy at the 12 and 24 h intervals. The autopolymerized resin showed an initial (at 1 h) marginal discrepancy slightly greater than inlay wax, but showed a significantly less marginal gap (as compared to inlay wax) at the other two time intervals. The light-cured resin proved to be significantly more dimensionally stable, and showed minimal change during the storage period. The resin pattern materials studied, undergo a significantly less dimensional change than the inlay waxes on prolonged storage. They would possibly be a better alternative to inlay wax in situations requiring high precision or when delayed investment (more than 1 h) of patterns can be expected.

Cheatgrass Dead Zones in Northern Nevada

USDA-ARS?s Scientific Manuscript database

Reports of areas of cheatgrass die-off are becoming more frequent. In 2009, we investigated cheatgrass die-off in north-central Nevada. Dead zones ranged from several to hundreds of acres in size and were largely unvegetated and covered by cheatgrass litter with a distinct gray cast. We collected re...

Evaluation and comparison of dimensional accuracy of newly introduced elastomeric impression material using 3D laser scanners: an in vitro study.

PubMed

Pandita, Amrita; Jain, Teerthesh; Yadav, Naveen S; Feroz, S M A; Pradeep; Diwedi, Akankasha

2013-03-01

Aim of the present study was to comparatively evaluate dimensional accuracy of newely introduced elastomeric impression material after repeated pours at different time intervals. In the present study a total of 20 (10 + 10) impressions of master model were made from vinyl polyether silicone and vinyl polysiloxane impression material. Each impression was repeatedly poured at 1, 24 hours and 14 days. Therefore, a total of 60 casts were obtained. Casts obtained were scanned with three-dimensional (3D) laser scanner and measurements were done. Vinyl polyether silicone produced overall undersized dies, with greatest change being 0.14% only after 14 days. Vinyl polysiloxane produced smaller dies after 1 and 24 hours and larger dies after 14 days, differing from master model by only 0.07% for the smallest die and to 0.02% for the largest die. All the deviations measured from the master model with both the impression materials were within a clinically acceptable range. In a typical fixed prosthodontic treatment accuracy of prosthesis is critical as it determines the success, failure and the prognosis of treatment including abutments. This is mainly dependent upon fit of prosthesis which in turn is dependent on dimensional accuracy of dies, poured from elastomeric impressions.

Accuracy of Multiple Pour Cast from Various Elastomer Impression Methods

PubMed Central

Saad Toman, Majed; Ali Al-Shahrani, Abdullah; Ali Al-Qarni, Abdullah

2016-01-01

The accurate duplicate cast obtained from a single impression reduces the profession clinical time, patient inconvenience, and extra material cost. The stainless steel working cast model assembly consisting of two abutments and one pontic area was fabricated. Two sets of six each custom aluminum trays were fabricated, with five mm spacer and two mm spacer. The impression methods evaluated during the study were additional silicone putty reline (two steps), heavy-light body (one step), monophase (one step), and polyether (one step). Type IV gypsum casts were poured at the interval of one hour, 12 hours, 24 hours, and 48 hours. The resultant cast was measured with traveling microscope for the comparative dimensional accuracy. The data obtained were subjected to Analysis of Variance test at significance level <0.05. The die obtained from two-step putty reline impression techniques had the percentage of variation for the height −0.36 to −0.97%, while diameter was increased by 0.40–0.90%. The values for one-step heavy-light body impression dies, additional silicone monophase impressions, and polyether were −0.73 to −1.21%, −1.34%, and −1.46% for the height and 0.50–0.80%, 1.20%, and −1.30% for the width, respectively. PMID:28096815

Predicting Stress vs. Strain Behaviors of Thin-Walled High Pressure Die Cast Magnesium Alloy with Actual Pore Distribution

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

Choi, Kyoo Sil; Barker, Erin; Cheng, Guang

2016-01-06

In this paper, a three-dimensional (3D) microstructure-based finite element modeling method (i.e., extrinsic modeling method) is developed, which can be used in examining the effects of porosity on the ductility/fracture of Mg castings. For this purpose, AM60 Mg tensile samples were generated under high-pressure die-casting in a specially-designed mold. Before the tensile test, the samples were CT-scanned to obtain the pore distributions within the samples. 3D microstructure-based finite element models were then developed based on the obtained actual pore distributions of the gauge area. The input properties for the matrix material were determined by fitting the simulation result to themore » experimental result of a selected sample, and then used for all the other samples’ simulation. The results show that the ductility and fracture locations predicted from simulations agree well with the experimental results. This indicates that the developed 3D extrinsic modeling method may be used to examine the influence of various aspects of pore sizes/distributions as well as intrinsic properties (i.e., matrix properties) on the ductility/fracture of Mg castings.« less

Functionally graded alumina-based thin film systems

DOEpatents

Moore, John J.; Zhong, Dalong

2006-08-29

The present invention provides coating systems that minimize thermal and residual stresses to create a fatigue- and soldering-resistant coating for aluminum die casting dies. The coating systems include at least three layers. The outer layer is an alumina- or boro-carbide-based outer layer that has superior non-wettability characteristics with molten aluminum coupled with oxidation and wear resistance. A functionally-graded intermediate layer or "interlayer" enhances the erosive wear, toughness, and corrosion resistance of the die. A thin adhesion layer of reactive metal is used between the die substrate and the interlayer to increase adhesion of the coating system to the die surface.

Elastomeric impression materials: a comparison of accuracy of multiple pours.

PubMed

Kumar, Dheeraj; Madihalli, Anand U; Reddy, K Rajeev Kumar; Rastogi, Namrataa; Pradeep, N T

2011-07-01

The aim of the present study is to compare the various elastomeric impression materials in terms of accuracy and dimensional stability, with respect to obtaining multiple casts from a single elastomeric impression at various times of pours. Three master dies were prepared for the impression making, two of these were made of brass containing a central hole with undercuts. The third die simulated a conventionally prepared typodont maxillary central incisor. Three elastomeric impression materials were chosen for the study. Each impression was poured at various time periods. Casts thus obtained were evaluated under a traveling microscope to evaluate various dimensional changes. Addition silicones provided dies which were shorter in height and bigger in diameter. Polyethers provided dies which were shorter in both height and diameter. Condensation silicones showed insignificant changes from the master die at the immediate pour but deteriorated rapidly after that in subsequent pours. None of the impression material showed a consistent behavior up to the fourth pour. They occasionally showed deviation from the pattern, but all these values were statistically insignificant. Polyethers showed lesser ability than both the addition silicones as well as the condensation silicones to recover from induced deformation. Addition silicones as well as the condensation silicones have better ability to recover from induced deformation when compared to polyether.

[Variables effecting casting accuracy of quick heating casting investments].

PubMed

Takahashi, H; Nakamura, H; Iwasaki, N; Morita, N; Habu, N; Nishimura, F

1994-06-01

Recently, several new products of investments for "quick heating" have been put on the Japanese market. The total casting procedure time for this quick heating method involves only one hour; 30-minutes waiting after the start of mixing before placing the mold directly into the 700 degrees C furnace and 30-minutes heating in the furnace. The purpose of this study was to evaluate two variables effecting casting accuracy using these new investments. The effect of thickness of the casting liner inside the casting ring and the effect of waiting time before placing the mold into the 700 degrees C furnace were evaluated. A stainless-steel die with a convergence angle of 8 degrees was employed. Marginal discrepancies of the crown between the wax patterns and castings were measured. The size of the cast crown became larger when the thickness of the ring liner was thick and when the waiting time before placing the mold into the furnace was long. These results suggest that these new investments have the advantage of providing sound castings using short-time casting procedures. However, it is necessary to pay careful attention to the casting conditions for obtaining reproducible castings.

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.

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.

Hot forging of roll-cast high aluminum content magnesium alloys

NASA Astrophysics Data System (ADS)

Kishi, Tomohiro; Watari, Hisaki; Suzuki, Mayumi; Haga, Toshio

2017-10-01

This paper reports on hot forging of high aluminum content magnesium alloy sheets manufactured using horizontal twin-roll casting. AZ111 and AZ131 were applied for twin-roll casting, and a hot-forging test was performed to manufacture high-strength magnesium alloy components economically. For twin-roll casting, the casting conditions of a thick sheet for hot forging were investigated. It was found that twin-roll casting of a 10mm-thick magnesium alloy sheet was possible at a roll speed of 2.5m/min. The grain size of the cast strip was 50 to 70µm. In the hot-forging test, blank material was obtained from as-cast strip. A servo press machine with a servo die cushion was used to investigate appropriate forging conditions (e.g., temperature, forging load, and back pressure) for twin-roll casts (TRCs) AZ111 and AZ131. It was determined that high aluminum content magnesium alloy sheets manufactured using twin-roll casting could be forged with a forging load of 150t and a back pressure of 3t at 420 to 430°C. Applying back pressure during hot forging effectively forged a pin-shaped product.

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.

Oil spill model coupled to an ultra-high-resolution circulation model: implementation for the Adriatic Sea

NASA Astrophysics Data System (ADS)

Korotenko, K.

2003-04-01

An ultra-high-resolution version of DieCAST was adjusted for the Adriatic Sea and coupled with an oil spill model. Hydrodynamic module was developed on base of th low dissipative, four-order-accuracy version DieCAST with the resolution of ~2km. The oil spill model was developed on base of particle tracking technique The effect of evaporation is modeled with an original method developed on the base of the pseudo-component approach. A special dialog interface of this hybrid system allowing direct coupling to meteorlogical data collection systems or/and meteorological models. Experiments with hypothetic oil spill are analyzed for the Northern Adriatic Sea. Results (animations) of mesoscale circulation and oil slick modeling are presented at wabsite http://thayer.dartmouth.edu/~cushman/adriatic/movies/

Solid Lubricants for Space Structures

DTIC Science & Technology

1993-04-17

will utilize mechanically interlocked hardware (caged bearings or bearings for ultra precision gimbals pointing mechanisms) controlled through precision...structure unless the lubricant were of low vapor pressure and/or suitably sealed to I prevent molecular effusion . While temperatures within spacecraft or...incorporation in the continuous cast system. The die made of graphite, consists of a plurality of openings or holes located in the die and positioned (unlined

Rapid Tooling for Functional Prototype of Metal Mold Processes Final Report CRADA No. TC-1032-98

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

Heestand, G.; Jaskolski, T.

Production inserts for die-casting were generally fabricated from materials with sufficient strength and· good wear properties at casting temperatures for long life. Frequently tool steels were used and machining was done with a combination of. conventional and Electric Discharge Machining (EDM) with some handwork, an expensive and time consuming process, partilly for prototype work. We proposed electron beam physical vapor deposition (EBPVD) as a process for rapid fabrication of dies. Metals, ranging from low melting point to refractory metals (Ta, Mo, etc.), would be evaporated and deposited at high rates (-2mm/hr.). Alloys could be easily evaporated and deposited if theirmore » constituent vapor pressures were similar and with more difficulty if they were not. Of course, layering of different materials was possible if required for a specific application. For example, a hard surface layer followed by a tough steel and backed by a high thermal conductivity (possibly cooled) copper layer could be fabricated. Electron-beam deposits exhibited 100% density and lull strength when deposited at a substrate (mandrel) temperature that was a substantial fraction of the deposited material's melting point. There were several materials that could have the required high temperature properties and ease of fabrication required for such a mandrel. We had successfully used graphite, machined from free formed objects with a replicator, to produce aluminum-bronze test molds. There were several parting layer materials of interest, but the ideal material depended upon the specific application.« less

Accuracy of a new ring-opening metathesis elastomeric dental impression material with spray and immersion disinfection.

PubMed

Kronström, Mats H; Johnson, Glen H; Hompesch, Richard W

2010-01-01

A new elastomeric impression material has been formulated with a ring-opening metathesis chemistry. In addition to other properties of clinical significance, the impression accuracy must be confirmed. The purpose of this study was to compare the accuracy of the new elastomeric impression material with vinyl polysiloxane and polyether following both spray and immersion disinfection. Impressions of a modified dentoform with a stainless steel crown preparation in the lower right quadrant were made, and type IV gypsum working casts and dies were formed. Anteroposterior (AP), cross-arch (CA), buccolingual (BL), mesiodistal (MD), occlusogingivobuccal (OGB), and occlusogingivolingual (OGL) dimensions were measured using a microscope. Working cast and die dimensions were compared to those of the master model. The impression materials were a newly formulated, ring-opening metathesis-polymerization impression material (ROMP Cartridge Tray and ROMP Volume Wash), vinyl polysiloxane (VPS, Aquasil Ultra Monophase/LV), and a polyether (PE, Impregum Penta Soft/Permadyne Garant L). Fifteen impressions with each material were made, of which 5 were disinfected by spray for 10 minutes (CaviCide), 5 were disinfected by immersion for 90 minutes (ProCide D), and 5 were not disinfected. There were significant cross-product interactions with a 2-way ANOVA, so a 1-way ANOVA and Dunnett's T3 multiple comparison test were used to compare the dimensional changes of the 3 impression materials, by disinfection status and for each location (alpha=.05). For ROMP, there were no significant differences from the master, for any dimension, when comparing the control and 2 disinfectant conditions. No significant differences were detected among the 3 impression materials for CA, BL, and MD. The working die dimensions of OGB and OGL for VPS with immersion disinfection were significantly shorter than with PE and ROMP (P<.05). Overall, the AP dimension was more accurate than CA, and the BL of working dies was 0.040 mm greater in diameter than MD. The accuracy of gypsum working casts and working dies from the new and 2 existing types of impression material were similar, for both spray and immersion disinfection. Judicious application of a die spacer can compensate for the small differences observed. VPS may require additional laboratory accommodation to compensate for a shorter working die. Copyright 2010 The Editorial Council of the Journal of Prosthetic Dentistry. Published by Mosby, Inc. All rights reserved.

A System Approach to Navy Medical Education and Training. Appendix 45. Competency Curricula for Dental Prosthetic Assistant and Dental Prosthetic Technician.

DTIC Science & Technology

1974-08-31

Removable Partial Dentures ..................... 34 XI. Fixed Partial Denture Construction .. ........ 35 l. Construct Master Cast with Removable...Dies . . . 36 2. Construct Patterns for Fixed Partial Dentures .. . ..... 37 3. Spruing and Investing oeu . . . 38 4. Wax Elimination and Casting...42 S. Re3in Jacket Crowns . . ............ 43 9. Temporary Crowns and Fixed Partial Dentures . . 44 10. Post and Core Techniques . . o

Cast erosion from the cleaning of debris after the use of a cast trimmer.

PubMed

Hansen, Paul A; Beatty, Mark W

2017-02-01

Whether using tap water to rinse off debris will make a clinical difference to the surface detail of a gypsum cast is unknown. In addition, how best to remove debris from the cast is unknown. The purpose of this in vitro study was to evaluate the efficiency of different methods of cleaning a gypsum cast after trimming and the effect of short-term exposure to tap water on the surface quality of the cast. A die fitting American National Standards Institute/American Dental Association specification 25 (International Standards Organization specification 6873) for dental gypsum products was embedded in a Dentoform with the machined lines positioned at the same level as the occlusal surface of the posterior teeth. A flat plate was used to ensure that the plane of occlusion for the die was at the same position as the posterior teeth. Forty polyvinyl siloxane impressions of the Dentoform were made and poured with vacuum-mixed improved Type IV dental stone. Each cast was inspected for the accurate reproduction of the lines. The base of the 2-stage pour was trimmed with a cast trimmer with water, and surface debris was removed by rinsing by hand under tap water for 10 seconds, by brushing the cast with a soft toothbrush for 10 seconds, or by resoaking the cast and using a soft camel hair brush in slurry water for 10 seconds. The amount of debris was evaluated on a scale of 1 to 4, and the quality of the 20-μm line was evaluated on a scale of 1 to 4 under ×15 magnification. The nonparametric Kruskal-Wallis ranks test was used to identify significant differences among the different cleaning methods (α=.05). Results of the Kruskal-Wallis and Kruskal-Wallis Z-value tests demonstrated that all cleaning methods produced cleaner casts than were observed for uncleansed controls (P<.001), but no differences in debris removal were found among the different cleaning methods (.065≤P≤.901). The ability to see the quality of a 20-μm line (P=.974) was not statistically different among the groups. Rinsing the cast under flowing tap water and brushing, or hand washing under flowing tap water, or using a soft camel hair brush in slurry water for 10 seconds had no noticeable effects on the quality of a 20-μm line, and all 3 methods resulted in a clean cast. Copyright © 2016 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

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.

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.

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.

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

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

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 ofmore » 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.« less

Corrosion fatigue behaviors of two biomedical Mg alloys - AZ91D and WE43 - In simulated body fluid.

PubMed

Gu, X N; Zhou, W R; Zheng, Y F; Cheng, Y; Wei, S C; Zhong, S P; Xi, T F; Chen, L J

2010-12-01

Magnesium alloys have been recently developed as biodegradable implant materials, yet there has been no study concerning their corrosion fatigue properties under cyclic loading. In this study the die-cast AZ91D (A for aluminum 9%, Z for zinc 1% and D for a fourth phase) and extruded WE43 (W for yttrium 4%, E for rare earth mischmetal 3%) alloys were chosen to evaluate their fatigue and corrosion fatigue behaviors in simulated body fluid (SBF). The die-cast AZ91D alloy indicated a fatigue limit of 50MPa at 10⁷ cycles in air compared to 20MPa at 10⁶ cycles tested in SBF at 37°C. A fatigue limit of 110MPa at 10⁷ cycles in air was observed for extruded WE43 alloy compared to 40MPa at 10⁷ cycles tested in SBF at 37°C. The fatigue cracks initiated from the micropores when tested in air and from corrosion pits when tested in SBF, respectively. The overload zone of the extruded WE43 alloy exhibited a ductile fracture mode with deep dimples, in comparison to a brittle fracture mode for the die-cast AZ91D. The corrosion rate of the two experimental alloys increased under cyclic loading compared to that in the static immersion test. Copyright © 2010 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

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

NASA Astrophysics Data System (ADS)

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

2015-08-01

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

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

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

Diran Apelian

2012-08-15

Semi-solid metal (SSM) processing has emerged as an attractive method for near-net-shape manufacturing due to the distinct advantages it holds over conventional near-net-shape forming technologies. These advantages include lower cycle time, increased die life, reduced porosity, reduced solidification shrinkage, improved mechanical properties, etc. SSM processing techniques can not only produce the complex dimensional details (e.g. thin-walled sections) associated with conventional high-pressure die castings, but also can produce high integrity castings currently attainable only with squeeze and low-pressure permanent mold casting processes. There are two primary semi-solid processing routes, (a) thixocasting and (b) rheocasting. In the thixocasting route, one starts frommore » a non-dendritic solid precursor material that is specially prepared by a primary aluminum manufacturer, using continuous casting methods. Upon reheating this material into the mushy (a.k.a. "two-phase") zone, a thixotropic slurry is formed, which becomes the feed for the casting operation. In the rheocasting route (a.k.a. "slurry-on-demand" or "SoD"), one starts from the liquid state, and the thixotropic slurry is formed directly from the melt via careful thermal management of the system; the slurry is subsequently fed into the die cavity. Of these two routes, rheocasting is favored in that there is no premium added to the billet cost, and the scrap recycling issues are alleviated. The CRP (Trade Marked) is a process where the molten metal flows through a reactor prior to casting. The role of the reactor is to ensure that copious nucleation takes place and that the nuclei are well distributed throughout the system prior to entering the casting cavity. The CRP (Trade Marked) has been successfully applied in hyper-eutectic Al-Si alloys (i.e., 390 alloy) where two liquids of equal or different compositions and temperatures are mixed in the reactor and creating a SSM slurry. The process has been mostly used for hypo-eutectic Al-Si alloys (i.e., 356, 357, etc.) where a single melt passes through the reactor. In addition, the CRP (Trade Marked) was designed to be flexible for thixocasting or rheocasting applications as well as batch or continuous casting. Variable heat extraction rates can be obtained by controlling either the superheat of the melt, the temperature of the channel system, or the temperature of the reactor. This program had four main objectives all of which were focused on a mechanistic understanding of the process in order to be able to scale it up, to develop it into a robust process,and for SSM processing to be commercially used.« less

Comparative Evaluation of Conventional and Accelerated Castings on Marginal Fit and Surface Roughness.

PubMed

Jadhav, Vivek Dattatray; Motwani, Bhagwan K; Shinde, Jitendra; Adhapure, Prasad

2017-01-01

The aim of this study was to evaluate the marginal fit and surface roughness of complete cast crowns made by a conventional and an accelerated casting technique. This study was divided into three parts. In Part I, the marginal fit of full metal crowns made by both casting techniques in the vertical direction was checked, in Part II, the fit of sectional metal crowns in the horizontal direction made by both casting techniques was checked, and in Part III, the surface roughness of disc-shaped metal plate specimens made by both casting techniques was checked. A conventional technique was compared with an accelerated technique. In Part I of the study, the marginal fit of the full metal crowns as well as in Part II, the horizontal fit of sectional metal crowns made by both casting techniques was determined, and in Part III, the surface roughness of castings made with the same techniques was compared. The results of the t -test and independent sample test do not indicate statistically significant differences in the marginal discrepancy detected between the two casting techniques. For the marginal discrepancy and surface roughness, crowns fabricated with the accelerated technique were significantly different from those fabricated with the conventional technique. Accelerated casting technique showed quite satisfactory results, but the conventional technique was superior in terms of marginal fit and surface roughness.

Unique case of fatal carbon monoxide poisoning in the absence of a combustible fossil fuel.

PubMed

Morgan, D R; Poon, P; Titley, J; Jagger, S F; Rutty, G N

2001-09-01

A 37-year-old man died as a result of exposure to carbon monoxide within an apartment. An investigation of the apartment showed no gas appliances or gas supply to the apartment and no evidence of any combustion event to any part of the apartment or roof space. Inhalation of dichloromethane was excluded. Heating to the apartment was found to be via an electrical storage heater, the examination of which revealed that the cast-iron core and insulating material showed evidence of heat damage with significant areas devoid of carbon. This electric storage heater is hypothesized to be the source of carbon for the fatal production of carbon monoxide within the apartment.

ELID grinding characteristics of large stamping die for Wolter mirror.

PubMed

Yin, Shaohui; Ohmori, Hitoshi; Liu, Qing; Morita, Shinnya; Chen, Fengjun; Asami, Muneaki; Fan, Yufeng

2009-01-01

An ultra-precision ELID grinding of large stamping dies of Wolter mirror for X-ray telescope was presented in this paper. The large stamping dies (S55C) with confocal paraboloid and hyperboloid was ground by ELID arc-enveloped grinding. In this ELID grinding system, cast iron fiber bonded (CIFB) diamond wheels were controlled by 3-dimentional ways to scan the work-piece and generate required surfaces. Its grinding characteristics such as attainable form accuracy, surface roughness were investigated. Furthermore, some measures to improve form accuracy were discussed and verified such as truing, compensating, and on-machine measuring.

40 CFR 464.11 - Specialized definitions.

Code of Federal Regulations, 2010 CFR

2010-07-01

.... tetrachloroethylene 87. trichloroethylene (2) Die Casting (§ 464.15(c) and § 464.16(c)): 1. acenaphthene 4. benzene 7... (2-ethylhexyl) phthalate 84. pyrene 85. tetrachloroethylene 87. trichloroethylene (5) Melting Furnace.... pyrene 85. tetrachloroethylene 87. trichloroethylene ...

Comparative Evaluation of Conventional and Accelerated Castings on Marginal Fit and Surface Roughness

PubMed Central

Jadhav, Vivek Dattatray; Motwani, Bhagwan K.; Shinde, Jitendra; Adhapure, Prasad

2017-01-01

Aims: The aim of this study was to evaluate the marginal fit and surface roughness of complete cast crowns made by a conventional and an accelerated casting technique. Settings and Design: This study was divided into three parts. In Part I, the marginal fit of full metal crowns made by both casting techniques in the vertical direction was checked, in Part II, the fit of sectional metal crowns in the horizontal direction made by both casting techniques was checked, and in Part III, the surface roughness of disc-shaped metal plate specimens made by both casting techniques was checked. Materials and Methods: A conventional technique was compared with an accelerated technique. In Part I of the study, the marginal fit of the full metal crowns as well as in Part II, the horizontal fit of sectional metal crowns made by both casting techniques was determined, and in Part III, the surface roughness of castings made with the same techniques was compared. Statistical Analysis Used: The results of the t-test and independent sample test do not indicate statistically significant differences in the marginal discrepancy detected between the two casting techniques. Results: For the marginal discrepancy and surface roughness, crowns fabricated with the accelerated technique were significantly different from those fabricated with the conventional technique. Conclusions: Accelerated casting technique showed quite satisfactory results, but the conventional technique was superior in terms of marginal fit and surface roughness. PMID:29042726

Comparison of optimization algorithms for the slow shot phase in HPDC

NASA Astrophysics Data System (ADS)

Frings, Markus; Berkels, Benjamin; Behr, Marek; Elgeti, Stefanie

2018-05-01

High-pressure die casting (HPDC) is a popular manufacturing process for aluminum processing. The slow shot phase in HPDC is the first phase of this process. During this phase, the molten metal is pushed towards the cavity under moderate plunger movement. The so-called shot curve describes this plunger movement. A good design of the shot curve is important to produce high-quality cast parts. Three partially competing process goals characterize the slow shot phase: (1) reducing air entrapment, (2) avoiding temperature loss, and (3) minimizing oxide caused by the air-aluminum contact. Due to the rough process conditions with high pressure and temperature, it is hard to design the shot curve experimentally. There exist a few design rules that are based on theoretical considerations. Nevertheless, the quality of the shot curve design still depends on the experience of the machine operator. To improve the shot curve it seems to be natural to use numerical optimization. This work compares different optimization strategies for the slow shot phase optimization. The aim is to find the best optimization approach on a simple test problem.

Gas turbine bucket wall thickness control

DOEpatents

Stathopoulos, Dimitrios; Xu, Liming; Lewis, Doyle C.

2002-01-01

A core for use in casting a turbine bucket including serpentine cooling passages is divided into two pieces including a leading edge core section and a trailing edge core section. Wall thicknesses at the leading edge and the trailing edge of the turbine bucket can be controlled independent of each other by separately positioning the leading edge core section and the trailing edge core section in the casting die. The controlled leading and trailing edge thicknesses can thus be optimized for efficient cooling, resulting in more efficient turbine operation.

Casting Characteristics of High Cerium Content Aluminum Alloys

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

Weiss, D; Rios, O R; Sims, Z C

This paper compares the castability of the near eutectic aluminum-cerium alloy system to the aluminum-silicon and aluminum-copper systems. The alloys are compared based on die filling capability, feeding characteristics and tendency to hot tear in both sand cast and permanent mold applications. The castability ranking of the binary Al–Ce systems is as good as the aluminum-silicon system with some deterioration as additional alloying elements are added. In alloy systems that use cerium in combination with common aluminum alloying elements such as silicon, magnesium and/or copper, the casting characteristics are generally better than the aluminum-copper system. In general, production systems formore » melting, de-gassing and other processing of aluminum-silicon or aluminum-copper alloys can be used without modification for conventional casting of aluminum-cerium alloys.« less

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

Effect of Heat Treatment on Commercial AlSi12Cu1(Fe) and AlSi12(b) Aluminum Alloy Die Castings

NASA Astrophysics Data System (ADS)

Battaglia, E.; Bonollo, F.; Ferro, P.; Fabrizi, A.

2018-03-01

High-pressure die castings (HPDCs) cannot normally be heat-treated at a high temperature because of the presence of inner air/gas- or shrinkage-porosity that may lead to the formation of undesired surface blisters. In this paper, an unconventional heat treatment is proposed. Two secondary Al-Si alloys, AlSi12(b) and AlSi12Cu1(Fe), were stabilization heat-treated at 624 K (350 °C) with soaking times ranging from 1 to 8 hours. Enhancement of both static and dynamic mechanical properties was found to be related to the fragmentation of interconnected eutectic Si particles and the smoothing of coarser crystals. Increased ductility after heat treatment was correlated with a decrease in hardness and Si particle roundness. The formation of Si precipitates within the α-Al matrix was also observed.

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.

Comparative Evaluation of Tensile Strength in Die Stone Incorporated with Sodium and Calcium Hypochlorite as Disinfectants: An in vitro Study.

PubMed

Pramodh, N R; Kumar, C N Vijay; Pradeep, M R; Naik, Ravi; Mahesh, C S; Kumari, Manju R

2017-12-01

The aim of this study was to evaluate the tensile strength of die stone incorporated with sodium and calcium hypochlorite as disinfectants. Two commercially available type IV die stone (Kalrock: Kalabhai Karson Pvt., Ltd and Pearlstone: Asian Chemicals) and two commercially available disinfectant solutions (sodium hypochlorite and calcium hypochlorite: Beachem Laboratory Chemical Private Limited, Chennai and Leo Chem Private Limited, Bengaluru) were used in this study, and the tensile strength was measured using Lloyd's Universal Testing Machine. The results show that incorporating the disinfecting solutions decreases the tensile strength of both products. The effect of decreasing tensile strength on type IV gypsum product is seen more in calcium hypochlorite when compared with sodium hypochlorite disinfecting solution, and the tensile strength of Kalrock specimens is higher than Pearlstone specimens after disinfecting with sodium hypochlorite and calcium hypochlorite solution. The statistical results also show significant results in all the groups when compared with the control group. The incorporation of sodium and calcium hypochlorite disinfecting solutions is not an encouraging method for both die materials as it reduces the tensile strength of type IV gypsum product. Tensile strength of Kalstone® die material is superior than Pearlstone® die material after mixing with sodium hypochlorite and calcium hypochlorite. According to the recommendations of Americans with Disability Act (ADA) and the Centers for Disease Control and Prevention, disinfecting the whole cast without or minimal changes in physical and mechanical properties was the motto of the study. The tensile strength in type IV gypsum product plays a most important role in retrieval of cast from impression, especially in narrow tooth preparation. This study reveals that incorporating method of disinfecting solutions is not recommended as it reduces the tensile strength.

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.

Innovative Vacuum Distillation for Magnesium Recycling

NASA Astrophysics Data System (ADS)

Zhu, Tianbai; Li, Naiyi; Mei, Xiaoming; Yu, Alfred; Shang, Shixiang

Magnesium recycling now becomes a very important subject as magnesium consumption increases fast around the world. All commonly used magnesium die-casting alloys can be recycled and recovered to the primary metal quality. The recycled materials may be comprised of biscuits, sprues, runners, flash, overflows, dross, sludge, scrap parts, and old parts that are returned from service, An innovative magnesium recycle method, vacuum distillation, is developed and proved out to be able to recycle magnesium scraps, especially machining chips, oily magnesium, smelting sludge, dross or the mixture. With this process at a specific temperature and environment condition, magnesium in scraps can be gasified and then solidified to become crystal magnesium crown. This `recycled' magnesium crown is collected and used as the raw material of magnesium alloys. The experimental results show the vacuum distillation is a feasible and plausible method to recycle magnesium. Further, the cost analysis will be addressed in this paper.

[Comparative adaptation of crowns of selective laser melting and wax-lost-casting method].

PubMed

Li, Guo-qiang; Shen, Qing-yi; Gao, Jian-hua; Wu, Xue-ying; Chen, Li; Dai, Wen-an

2012-07-01

To investigate the marginal adaptation of crowns fabricated by selective laser melting (SLM) and wax-lost-casting method, so as to provide an experimental basis for clinic. Co-Cr alloy full crown were fabricated by SLM and wax-lost-casting for 24 samples in each group. All crowns were cemented with zinc phosphate cement and cut along longitudinal axis by line cutting machine. The gap between crown tissue surface and die was measured by 6-point measuring method with scanning electron microscope (SEM). The marginal adaptation of crowns fabricated by SLM and wax-lost-casting were compared statistically. The gap between SLM crowns were (36.51 ± 2.94), (49.36 ± 3.31), (56.48 ± 3.35), (42.20 ± 3.60) µm, and wax-lost-casting crowns were (68.86 ± 5.41), (58.86 ± 6.10), (70.62 ± 5.79), (69.90 ± 6.00) µm. There were significant difference between two groups (P < 0.05). Co-Cr alloy full crown fabricated by wax-lost-casting method and SLM method provide acceptable marginal adaptation in clinic, and the marginal adaptation of SLM is better than that of wax-lost-casting method.

Microstructure, Mechanical and Surface Morphological Properties of Al5Ti5Cr Master Alloy as Friction Material Prepared by Stir Die Casting

NASA Astrophysics Data System (ADS)

Ahmed, Syed Faisal; Srivastava, Sanjay; Agarwal, Alka Bani

2018-04-01

Metal matrix composite offers outstanding properties for better performance of disc brakes. In the present study, the composite of AlTiCr master alloy was prepared by stir die casting method. The developed material was reinforced with (0-10 wt%) silicon carbide (SiC) and boron carbide (B4C). The effects of SiC reinforcement from 0 to 10 wt% on mechanical, microstructure and surface morphological properties of Al MMC was investigated and compared with B4C reinforcement. Physical properties like density and micro Vickers hardness number show an increasing trend with an increase in the percentage of SiC and B4C reinforcement. Mechanical properties viz. UTS, yield strength and percentage of elongation are improved with increasing the fraction of reinforcement. The surface morphology and phase were identified from scanning electron microscopy (SEM) and X-ray diffraction analysis and the oxidized product formed during the casting was investigated by Fourier transformation infrared spectroscopy. This confirms the presence of crystallization of corundum (α-Al2O3) in small traces as one of the alumina phases, within casting sample. Micro-structural characterization by SEM depicted that the particles tend to be more agglomerated more and more with the percentage of the reinforcement. The AFM results reveal that the surface roughness value shows a decreasing trend with SiC reinforcement while roughness increases with increase the percentage of B4C.

Marginal accuracy of nickel chromium copings fabricated by conventional and accelerated casting procedures, produced with ringless and metal ring investment procedures: A comparative in vitro study.

PubMed

Alex, Deepa; Shetty, Y Bharath; Miranda, Glynis Anita; Prabhu, M Bharath; Karkera, Reshma

2015-01-01

Conventional investing and casting techniques are time-consuming and usually requires 2-4 h for completion. Accelerated nonstandard, casting techniques have been reported to achieve similar quality results in significantly less time, namely, in 30-40 min. During casting, it is essential to achieve compensation for the shrinkage of solidifying alloy by investment expansion. The metal casting ring restricts the thermal expansion of investment because the thermal expansion of the ring is lesser than that of the investment. The use of casting ring was challenged with the introduction of the ringless technique. A total of 40 test samples of nickel chromium (Ni-Cr) cast copings were obtained from the patterns fabricated using inlay casting wax. The 20 wax patterns were invested using metal ring and 20 wax patterns were invested using the ringless investment system. Of both the groups, 10 samples underwent conventional casting, and the other 10 underwent accelerated casting. The patterns were casted using the induction casting technique. All the test samples of cast copings were evaluated for vertical marginal gaps at four points on the die employing a stereo optical microscope. The vertical marginal discrepancy data obtained were tabulated. Mean and standard deviations were obtained. Vertical discrepancies were analyzed using analysis of variance and Tukey honestly significantly different. The data obtained were found to be very highly significant (P < 0.001). Mean vertical gap was the maximum for Group II (53.64 μm) followed by Group IV (47.62 μm), Group I (44.83 μm) and Group III (35.35 μm). The Ni-Cr cast copings fabricated with the conventional casting using ringless investment system showed significantly better marginal fit than that of cast copings fabricated from conventional and accelerated casting with metal ring investment and accelerated casting using ringless investment since those copings had shown the least vertical marginal discrepancies among the four methods evaluated in this study.

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

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

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

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 tomore » 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.« less

Adhesive Bonding and Corrosion Protection of a Die Cast Magnesium Automotive Door

NASA Astrophysics Data System (ADS)

Bretz, G. T.; Lazarz, K. A.; Hill, D. J.; Blanchard, P. J.

It is well known that magnesium alloys, in close proximity to other alloys, are susceptible to galvanic corrosion. Combined with this fact, in automotive applications, it is rare that magnesium will be present in the absence of other alloys such as steel or aluminum. Therefore, in wet applications, where the galvanic cell is completed, it is necessary to isolate the magnesium in order to prevent accelerated corrosion. There are numerous commercial pre-treatments available for magnesium, however this paper focuses on conversion coatings in conjunction with a spray powder coat. By means of example, results for a hem flange joint on an AM50 die cast magnesium door structure will be presented. The outer door skin is an aluminum alloy hemmed around a cast magnesium flange. An adhesive is used between the inner and outer to help with stiffness and NVH (Noise, Vibration and Harshness). Results from bonded lap-shear coupon tests that have been exposed to accelerated corrosion cycles are presented. A second phase of this work considered a surrogate hem flange coupon, which was similarly exposed to the same accelerated corrosion cycle. Results from both of these tests are presented within this paper along with a discussion as to their suitability for use within automotive applications.

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 prevent segregation, and sintering and cristobalite transformation in fused silica compacts.

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.

Evolution of the mandibular mesh implant.

PubMed

Salyer, K E; Johns, D F; Holmes, R E; Layton, J G

1977-07-01

Between 1960 and 1972, the Dallas Veterans Administration Hospital Maxillofacial Research Laboratory developed and made over 150 cast-mesh implants. Successive designs were ovoid, circular, and double-lumened in cross section to improve implant strength, surface area for bioattachment, and adjustability. Sleeves, collars, and bows were employed in the assembly of these implants, with an acrylic condylar head attached when indicated. In 1972, our laboratory developed a mandibular mesh tray, cast in one piece on a single sprue, with preservation of the vertically adjustable ramus. Stainless steel replaced Vitallium because of its greater malleability. Essentially, a lost-wax technique is used to cast the mesh tray. The model of a mandibular segment is duplicated as a refractory model. Mesh wax, made in our own custom-made die, is adapted to the refractory model. The unit is then sprued and invested. The wax is fired our of the mold in a gas furnace. Casting is done by the transferral of molten stainless steel from the crucible to the mold by centrifugal force in an electro-induction casting machine. Other mesh implants that have been developed are made from wire mesh, Dacron mesh, cast Ticonium, and hydroformed titanium.

Grain Refinement of Magnesium Alloys: A Review of Recent Research, Theoretical Developments, and Their Application

NASA Astrophysics Data System (ADS)

StJohn, D. H.; Easton, M. A.; Qian, M.; Taylor, J. A.

2013-07-01

This paper builds on the "Grain Refinement of Mg Alloys" published in 2005 and reviews the grain refinement research on Mg alloys that has been undertaken since then with an emphasis on the theoretical and analytical methods that have been developed. Consideration of recent research results and current theoretical knowledge has highlighted two important factors that affect an alloy's as-cast grain size. The first factor applies to commercial Mg-Al alloys where it is concluded that impurity and minor elements such as Fe and Mn have a substantially negative impact on grain size because, in combination with Al, intermetallic phases can be formed that tend to poison the more potent native or deliberately added nucleant particles present in the melt. This factor appears to explain the contradictory experimental outcomes reported in the literature and suggests that the search for a more potent and reliable grain refining technology may need to take a different approach. The second factor applies to all alloys and is related to the role of constitutional supercooling which, on the one hand, promotes grain nucleation and, on the other hand, forms a nucleation-free zone preventing further nucleation within this zone, consequently limiting the grain refinement achievable, particularly in low solute-containing alloys. Strategies to reduce the negative impact of these two factors are discussed. Further, the Interdependence model has been shown to apply to a broad range of casting methods from slow cooling gravity die casting to fast cooling high pressure die casting and dynamic methods such as ultrasonic treatment.

40 CFR 464.11 - Specialized definitions.

Code of Federal Regulations, 2014 CFR

2014-07-01

.... fluoranthene 44. methylene chloride (dichloromethane) 65. phenol 66. bis(2-ethylhexyl) phthalate 67. butyl benzyl phthalate 84. pyrene 85. tetrachloroethylene 87. trichloroethylene (2) Die Casting (§ 464.15(c...) phthalate 67. butyl benzyl phthalate 68. di-n-butyl phthalate 70. diethyl phthalate 72. benzo (a)anthracene...

40 CFR 464.11 - Specialized definitions.

Code of Federal Regulations, 2012 CFR

2012-07-01

.... fluoranthene 44. methylene chloride (dichloromethane) 65. phenol 66. bis(2-ethylhexyl) phthalate 67. butyl benzyl phthalate 84. pyrene 85. tetrachloroethylene 87. trichloroethylene (2) Die Casting (§ 464.15(c...) phthalate 67. butyl benzyl phthalate 68. di-n-butyl phthalate 70. diethyl phthalate 72. benzo (a)anthracene...

Microstructure, Tensile Properties, and Corrosion Behavior of Die-Cast Mg-7Al-1Ca- xSn Alloys

NASA Astrophysics Data System (ADS)

Wang, Feng; Dong, Haikuo; Sun, Shijie; Wang, Zhi; Mao, Pingli; Liu, Zheng

2018-02-01

The microstructure, tensile properties, and corrosion behavior of die-cast Mg-7Al-1Ca- xSn ( x = 0, 0.5, 1.0, and 2.0 wt.%) alloys were studied using OM, SEM/EDS, tensile test, weight loss test, and electrochemical test. The experimental results showed that Sn addition effectively refined grains and intermetallic phases and increased the amount of intermetallic phases. Meanwhile, Sn addition to the alloys suppressed the formation of the (Mg,Al)2Ca phase and resulted in the formation of the ternary CaMgSn phase and the binary Mg2Sn phase. The Mg-7Al-1Ca-0.5Sn alloy exhibited best tensile properties at room temperature, while Mg-7Al-1Ca-1.0Sn alloy exhibited best tensile properties at elevated temperature. The corrosion resistance of studied alloys was improved by the Sn addition, and the Mg-7Al-1Ca-0.5Sn alloy presented the best corrosion resistance.

AMCC casting development. Volume 1: Executive Summary

NASA Technical Reports Server (NTRS)

1995-01-01

The Advanced Combustion Chamber Casting (AMCC) has been a technically challenging part due to its size, configuration, and alloy type. The height and weight of the wax pattern assembly necessitated the development of a hollow gating system to ensure structural integrity of the shell throughout the investment process. The complexity in the jacket area of the casting required the development of an innovative casting technology that PCC has termed 'TGC' or Thermal Gradient Control. This method, of setting up thermal gradients in the casting during solidification, represents a significant process improvement for PCC and has been successfully implemented on other programs. Metallurgical integrity of the final four castings was very good. Only the areas of the parts that utilized 'TGC Shape & Location System #2' showed any significant areas of microshrinkage when evaluated by non-destructive tests. Alumina oxides detected by FPI on the 'float' surfaces (top sid surfaces of the casting during solidification) of the part were almost entirely less than the acceptance criteria of .032 inches in diameter. Destructive chem mill of the castings was required to determine the effect of the process variables used during the processing of these last four parts (with the exception of the 'Shape & Location of TGC' variable).

Accuracy of ringless casting and accelerated wax-elimination technique: a comparative in vitro study.

PubMed

Prasad, Rahul; Al-Keraif, Abdulaziz Abdullah; Kathuria, Nidhi; Gandhi, P V; Bhide, S V

2014-02-01

The purpose of this study was to determine whether the ringless casting and accelerated wax-elimination techniques can be combined to offer a cost-effective, clinically acceptable, and time-saving alternative for fabricating single unit castings in fixed prosthodontics. Sixty standardized wax copings were fabricated on a type IV stone replica of a stainless steel die. The wax patterns were divided into four groups. The first group was cast using the ringless investment technique and conventional wax-elimination method; the second group was cast using the ringless investment technique and accelerated wax-elimination method; the third group was cast using the conventional metal ring investment technique and conventional wax-elimination method; the fourth group was cast using the metal ring investment technique and accelerated wax-elimination method. The vertical marginal gap was measured at four sites per specimen, using a digital optical microscope at 100× magnification. The results were analyzed using two-way ANOVA to determine statistical significance. The vertical marginal gaps of castings fabricated using the ringless technique (76.98 ± 7.59 μm) were significantly less (p < 0.05) than those castings fabricated using the conventional metal ring technique (138.44 ± 28.59 μm); however, the vertical marginal gaps of the conventional (102.63 ± 36.12 μm) and accelerated wax-elimination (112.79 ± 38.34 μm) castings were not statistically significant (p > 0.05). The ringless investment technique can produce castings with higher accuracy and can be favorably combined with the accelerated wax-elimination method as a vital alternative to the time-consuming conventional technique of casting restorations in fixed prosthodontics. © 2013 by the American College of Prosthodontists.

The effect of preparation taper on the retention of cemented cast crowns under lateral fatigue loading.

PubMed

Cameron, Stephen M; Morris, W Jack; Keesee, Stephen M; Barsky, Todd B; Parker, M Harry

2006-06-01

Clinicians have used resistance form as a basis for determining guidelines for preparation design to ensure clinical success of cemented cast restorations. Disagreement on whether clinical success follows the on-off or linear nature of resistance form continues. The purpose of this study was to evaluate the number of cycles required to dislodge a cemented complete crown casting under a cyclic lateral load as a function of taper and to compare this relationship for the resistive and nonresistive ranges of taper. Three dies were milled from stainless steel at each of the following tapers: 4, 8, 12, 16, 20, 24, 28, and 32 degrees. A gold-palladium metal-ceramic alloy crown was fabricated for each die, cemented, and subjected to lateral cyclic loading until failure or 1,000,000 cycles. The limiting taper for the dies with their given height and base was 26.6 degrees. Dies with taper less than 26.6 degrees had resistance form, whereas dies with taper larger than 26.6 degrees did not. A linear regression (alpha=.05) was used to evaluate the relation of cycles at dislodgement to taper. The average number of cycles to crown dislodgement or completion for each taper (SD), in units of 10,000, was as follows: 4 degrees, 100 (0); 8 degrees, 100 (0); 12 degrees, 93.54 (16.56); 16 degrees, 61.33 (38.47); 20 degrees, 25.73 (34.67); 24 degrees, 4.33 (7.36); 28 degrees, 0.06 (0.08); and 32 degrees, 0.05 (0.09). The crowns in the resistive area less than 26.6 degrees that demonstrated failure showed a linear regression with a correlation coefficient of -0.995 between the average number of cycles to dislodge the crown and the taper. The slope was significantly different from zero (P=.0048), with a value of -7.58 and a standard error of 0.53. The number of cycles required to cause crown dislodgement was linear after 12 degrees in the resistive area and nearly zero for preparations in the nonresistive area. The limiting taper concept closely predicted the transition point where the slope of the graph of cycles to dislodgement as a function of taper abruptly changed.

Distortion of three-unit implant frameworks during casting, soldering, and simulated porcelain firings.

PubMed

Zervas, P J; Papazoglou, E; Beck, F M; Carr, A B

1999-09-01

The aim of this study was to assess distortion inherent in casting, soldering, and simulated porcelain firings of screw-retained, implant-supported three-unit fixed partial dentures (FPDs). Ten wax patterns were fabricated on a die-stone cast containing two implants, 20 mm apart from center to center. Five specimens were cast in a high-palladium alloy, exposed to simulated porcelain firings, sectioned, and then soldered with low-fusing solder. Five specimens were cast, sectioned, soldered with high-fusing solder, and then exposed to simulated porcelain firings. For each specimen, two horizontal and six vertical distances between appropriately scribed reference points were measured with a traveling microscope. Comparisons were made among the various measurements taken after wax-pattern fabrication, casting, high- and low-fusing soldering, and each porcelain firing. Data were analyzed using a repeated-measures factorial ANOVA (alpha = 0.05). Significant difference was detected in the amount of horizontal distortion during casting (53 +/- 24 microns) and high-fusing soldering (-49 +/- 50 microns), as well as in the amount of horizontal distortion during high-fusing soldering (-49 +/- 50 microns) and low-fusing soldering (17 +/- 26 microns). However, no clinically significant difference was found in the amount of horizontal distortion during casting, low-fusing, and high-fusing soldering. The greatest amount of distortion during the simulated porcelain firings took place during the oxidizing cycle. Soldering did not improve the casting misfit of a three-unit implant-retained FPD model. Metal-ceramic implant frameworks should be oxidized before intraoral fit evaluation.

Rapid Freeform Sheet Metal Forming: Technology Development and System Verification

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

Kiridena, Vijitha; Verma, Ravi; Gutowski, Timothy

The objective of this project is to develop a transformational RApid Freeform sheet metal Forming Technology (RAFFT) in an industrial environment, which has the potential to increase manufacturing energy efficiency up to ten times, at a fraction of the cost of conventional technologies. The RAFFT technology is a flexible and energy-efficient process that eliminates the need for having geometry-specific forming dies. The innovation lies in the idea of using the energy resource at the local deformation area which provides greater formability, process control, and process flexibility relative to traditional methods. Double-Sided Incremental Forming (DSIF), the core technology in RAFFT, ismore » a new concept for sheet metal forming. A blank sheet is clamped around its periphery and gradually deformed into a complex 3D freeform part by two strategically aligned stylus-type tools that follow a pre-described toolpath. The two tools, one on each side of the blank, can form a part with sharp features for both concave and convex shapes. Since deformation happens locally, the forming force at any instant is significantly decreased when compared to traditional methods. The key advantages of DSIF are its high process flexibility, high energy-efficiency, low capital investment, and the elimination of the need for massive amounts of die casting and machining. Additionally, the enhanced formability and process flexibility of DSIF can open up design spaces and result in greater weight savings.« less

The Effects of Die Relief Agent on the Retention of Full Coverage Castings,

DTIC Science & Technology

1981-02-19

autopolymerizing resin. A diamond rotary instrument and a high speed dental handpiece using air- water coolant were employed to prepare the crown of each tooth...777 109 502 ARMY INST OF DENTAL RESEARCH WASHINGTON DC F/6 6/5 THE EFFECTS OF DIE RELIEF AGENT ON THE RETENTION OF FULL COYERA--ETC(U) FES 81 S 6...Kuffler" 4W Eugene F.Huget, COL, (Ret.) .9. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT. PROJECT, TASK U.S. Army Institute of Dental

[Experimental processing of corrosion casts of large animal organs].

PubMed

Pálek, R; Liška, V; Eberlová, L; Mírka, H; Svoboda, M; Haviar, S; Emingr, M; Brzoň, O; Mik, P; Třeška, V

2018-01-01

Corrosion casts (CCs) are used for the visualization and assessment of hollow structures. CCs with filled capillaries enable (with the help of imaging methods) to obtain data for mathematical organ perfusion modelling. As the processing is more difficult in case of organs with greater volume of the vasculature, mainly organs from small animals have been cast up to now. The aim of this study was to optimize the protocol of corrosion casting of different organs of pig. Porcine organs are relatively easily accessible and frequently used in experimental medicine. Organs from 10 healthy Prestice Black-Pied pigs (6 females, body weight 35-45 kg), were used in this study (liver, spleen, kidneys and small intestine). The organs were dissected, heparin was administered into the systemic circulation and then the vascular bed of the organs was flushed with heparinized saline either in situ (liver) or after their removal (spleen, kidney, small intestine). All handling was done under the water surface to prevent air embolization. The next step was an intraarterial (in case of the liver also intraportal) administration of Biodur E20® (Heidelberg, Germany) resin. After hardening of the resin the organ tissue was dissolved by 15% KOH and the specimen was rinsed with tap water. Voluminous casts were stored in 70% denatured alcohol, the smaller ones were lyophilized. The casts were assessed with a stereomicroscope, computed and microcomputed tomography (CT and microCT), a scanning electron microscope (SEM) and high-resolution digital microscope (HRDM). High-quality CCs of the porcine liver, kidneys, spleen and small intestine were created owing to the sophisticated organ harvesting, the suitable resin and casting procedure. Macroscopic clarity was improved thanks to the possibility of resin dying. Scanning by CT was performed and showed to be a suitable method for the liver cast examination. MicroCT, SEM and HRDM produced images of the most detailed structures of vascular bed. Despite the fact that SEM seems to be an irreplaceable method for CCs quality control, it seems that this modality could be partly replaced by HRDM. MicroCT enabled to obtain data about three-dimensional layout of the vascular bed and data for mathematical modelling of organ perfusion. With regard to the quality of the CCs, they could also be used to teach human anatomy. The protocol of the corrosion casting of the porcine liver, kidneys, spleen and small intestine CCs was optimized. Thanks to different imaging methods, the CCs can be used as a source of data on three-dimensional architecture of the vascular bed. These data can be used for mathematical modeling of organ perfusion which can be helpful for example for optimization of organ resections.Key words: corrosion casts microvasculature Biodur E20® domestic pig animal model.

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.

A Comparison of Accuracy of Matrix Impression System with Putty Reline Technique and Multiple Mix Technique: An In Vitro Study.

PubMed

Kumar, M Praveen; Patil, Suneel G; Dheeraj, Bhandari; Reddy, Keshav; Goel, Dinker; Krishna, Gopi

2015-06-01

The difficulty in obtaining an acceptable impression increases exponentially as the number of abutments increases. Accuracy of the impression material and the use of a suitable impression technique are of utmost importance in the fabrication of a fixed partial denture. This study compared the accuracy of the matrix impression system with conventional putty reline and multiple mix technique for individual dies by comparing the inter-abutment distance in the casts obtained from the impressions. Three groups, 10 impressions each with three impression techniques (matrix impression system, putty reline technique and multiple mix technique) were made of a master die. Typodont teeth were embedded in a maxillary frasaco model base. The left first premolar was removed to create a three-unit fixed partial denture situation and the left canine and second premolar were prepared conservatively, and hatch marks were made on the abutment teeth. The final casts obtained from the impressions were examined under a profile projector and the inter-abutment distance was calculated for all the casts and compared. The results from this study showed that in the mesiodistal dimensions the percentage deviation from master model in Group I was 0.1 and 0.2, in Group II was 0.9 and 0.3, and Group III was 1.6 and 1.5, respectively. In the labio-palatal dimensions the percentage deviation from master model in Group I was 0.01 and 0.4, Group II was 1.9 and 1.3, and Group III was 2.2 and 2.0, respectively. In the cervico-incisal dimensions the percentage deviation from the master model in Group I was 1.1 and 0.2, Group II was 3.9 and 1.7, and Group III was 1.9 and 3.0, respectively. In the inter-abutment dimension of dies, percentage deviation from master model in Group I was 0.1, Group II was 0.6, and Group III was 1.0. The matrix impression system showed more accuracy of reproduction for individual dies when compared with putty reline technique and multiple mix technique in all the three directions, as well as the inter-abutment distance.

Cool Cast Facts

MedlinePlus

... Kinds of Casts? Most casts are made of fiberglass. Fiberglass is a kind of plastic that can be ... to the body part. It dries hard. Some fiberglass casts are waterproof. Doctors only use this type ...

Marginal accuracy of nickel chromium copings fabricated by conventional and accelerated casting procedures, produced with ringless and metal ring investment procedures: A comparative in vitro study

PubMed Central

Alex, Deepa; Shetty, Y. Bharath; Miranda, Glynis Anita; Prabhu, M. Bharath; Karkera, Reshma

2015-01-01

Background: Conventional investing and casting techniques are time-consuming and usually requires 2–4 h for completion. Accelerated nonstandard, casting techniques have been reported to achieve similar quality results in significantly less time, namely, in 30–40 min. During casting, it is essential to achieve compensation for the shrinkage of solidifying alloy by investment expansion. The metal casting ring restricts the thermal expansion of investment because the thermal expansion of the ring is lesser than that of the investment. The use of casting ring was challenged with the introduction of the ringless technique. Materials and Methods: A total of 40 test samples of nickel chromium (Ni-Cr) cast copings were obtained from the patterns fabricated using inlay casting wax. The 20 wax patterns were invested using metal ring and 20 wax patterns were invested using the ringless investment system. Of both the groups, 10 samples underwent conventional casting, and the other 10 underwent accelerated casting. The patterns were casted using the induction casting technique. All the test samples of cast copings were evaluated for vertical marginal gaps at four points on the die employing a stereo optical microscope. Results: The vertical marginal discrepancy data obtained were tabulated. Mean and standard deviations were obtained. Vertical discrepancies were analyzed using analysis of variance and Tukey honestly significantly different. The data obtained were found to be very highly significant (P < 0.001). Mean vertical gap was the maximum for Group II (53.64 μm) followed by Group IV (47.62 μm), Group I (44.83 μm) and Group III (35.35 μm). Conclusion: The Ni-Cr cast copings fabricated with the conventional casting using ringless investment system showed significantly better marginal fit than that of cast copings fabricated from conventional and accelerated casting with metal ring investment and accelerated casting using ringless investment since those copings had shown the least vertical marginal discrepancies among the four methods evaluated in this study. PMID:26929488

The die is cast - Arsenic exposure in early life and disease susceptibility

EPA Science Inventory

Abstract Early life exposure to arsenic in humans and mice produces similar patterns of disease in later life. Given the long interval between exposure and effect, epigenetic effects of early life exposure to arsenic may account for development and progression of disease in bo...

Phase Transformation and Creep of Mg-Al-Ca Based Die-Cast Alloys

NASA Astrophysics Data System (ADS)

Suzuki, Akane; Saddock, Nicholas D.; Jones, J. Wayne; Pollock, Tresa M.

The microstructure and microstructural stability of die-cast AC53 (Mg-5Al-3Ca) and AXJ530 (Mg-5Al-3Ca-0.15Sr) have been investigated in detail by transmission electron microscopy (TEM). Both alloys have an as-cast microstructure of α-Mg with (Mg, Al)2Ca (dihexagonal C36) eutectic at grain boundaries. During aging at 573 K, the C36 phase transforms to Al2Ca (cubic Cl5) phase. These two phases have a crystallographic orientation relationship of (0001)C36//{111}C15 and [2110]C36//[011]C15, and the transformation from C36 to C15 occurs by a shear-assisted process. Despite this change in the phase constitution, the network structure of the intermetallic compound(s) surrounding α-Mg grains is fairly stable, morphologically, even after prolonged exposure at elevated temperature. In the α-Mg matrix phase, precipitation of Al2Ca was observed after aging for 360 ks at 573 K. The precipitates are disc-shaped with a habit plane of {111}C15//(0001)α. AXJ530 shows higher creep resistance than AC53. The dislocation substructure that evolved during creep deformation was investigated in both alloys, and the basal and non-basal slip of a-dislocation and other slip modes of a+c- dislocations were observed. The relationship between creep properties and microstructure is discussed.

Effect of Holding Pressure on Microstructure and Mechanical Properties of A356 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Wu, Xiaoyan; Zhang, Huarui; Ma, Zhen; Jia, Lina; Zhang, Hu

2018-02-01

In this study, the effect of holding pressure on microstructure and mechanical properties of low-pressure die cast A356 aluminum alloy was investigated. The results showed that the application of high holding pressure (300 kPa) generated castings with denser structure and superior mechanical properties. By increasing the holding pressure up to 300 kPa, the size of secondary dendrite arm spacing greatly reduced by 22.7% at the cooling rate of 1°C/s and decreased by 12.8% at 10°C/s. The Feret's diameter and aspect ratio of eutectic silicon particles decreased by 8.4 and 5.1% at the cooling rate of 1°C/s and decreased by 9.3 and 6.4% at 10°C/s, respectively. Meanwhile, the density of A356 aluminum alloy increased to 2.678 g/cm3 and the area fraction of porosity decreased to 0.035%. Thus, tensile properties of A356 aluminum alloy obtained at high holding pressure were enhanced, especially the ductility. All these could be associated with the better filling capability and faster cooling rate caused by high holding pressure. In the analytical range of experimental conditions, the correlation of mechanical properties with process parameters was established by statistical models to predict the ultimate tensile strength and elongation of low-pressure die cast A356 aluminum alloy.

Clean Metal Casting

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

Makhlouf M. Makhlouf; Diran Apelian

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

Corrosion and protection of heterogeneous cast Al-Si (356) and Al-Si-Cu-Fe (380) alloys by chromate adn cerium inhibitors

NASA Astrophysics Data System (ADS)

Jain, Syadwad

In this study, the localized corrosion and conversion coating on cast alloys 356 (Al-7.0Si-0.3Mg) and 380 (Al-8.5Si-3.5Cu-1.6Fe) were characterized. The intermetallic phases presence in the permanent mold cast alloy 356 are primary-Si, Al5FeSi, Al8Si6Mg3Fe and Mg2Si. The die cast alloy 380 is rich in Cu and Fe elements. These alloying elements result in formation of the intermetallic phases Al 5FeSi, Al2Cu and Al(FeCuCr) along with primary-Si. The Cu- and Fe-rich IMPS are cathodic with respect to the matrix phase and strongly govern the corrosion behavior of the two cast alloys in an aggressive environment due to formation of local electrochemical cell in their vicinity. Results have shown that corrosion behavior of permanent mould cast alloy 356 is significantly better than the die cast aluminum alloy 380, primarily due to high content of Cu- and Fe-rich phases such as Al2Cu and Al 5FeSi in the latter. The IMPS also alter the protection mechanism of the cast alloys in the presence of inhibitors in an environment. The presence of chromate in the solution results in reduced cathodic activity on all the phases. Chromate provides some anodic inhibition by increasing pitting potentials and altering corrosion potentials for the phases. Results have shown that performance of CCC was much better on 356 than on 380, primarily due to inhomogeneous and incomplete coating deposition on Cu- and Fe- phases present in alloy 380. XPS and Raman were used to characterize coating deposition on intermetallics. Results show evidence of cyanide complex formation on the intermetallic phases. The presence of this complex is speculated to locally suppress CCC formation. Formation and breakdown of cerium conversion coatings on 356 and 380 was also analyzed. Results showed that deposition of cerium hydroxide started with heavy precipitation on intermetallic particles with the coatings growing outwards onto the matrix. Electrochemical analysis of synthesized intermetallics compounds in the presence of soluble cerium cations showed that of anodic and cathodic activity was not as strongly inhibited as was observed for chromate ions. Overall cerium conversion coating showed good performance on Al-Si (356) ally, but poor performance on Fe- and Cu-rich alloy (380).

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

PubMed

Consani, Rafael Leonardo Xediek; Domitti, Saide Sarckis; Consani, Simonides

2002-09-01

The pressure of final closure may be released when the flask is removed from the mechanical or pneumatic press and placed in the spring clamp. This release in pressure may result in dimensional changes that distort the denture base. The purpose of this study was to investigate differences between the dimensional stability of standardized simulated denture bases processed by traditional moist heat-polymerization and those processed by use of a new tension system. A metal master die was fabricated to simulate an edentulous maxillary arch without irregularities in the alveolar ridge walls. A silicone mold of this metallic die was prepared, and 40 stone casts were formed from the mold with type III dental stone. The casts were randomly assigned to 4 test groups (A-D) of 10 specimens each. A uniform denture base pattern was made on each stone cast with a 1.5-mm thickness of base-plate wax, measured with a caliper. The patterns were invested for traditional hot water processing. A polymethyl methacrylate dough was prepared and packed for processing. The flasks in groups A and B were closed with the traditional pressure technique and placed in spring clamps after final closure. The flasks in groups C and D were pressed between the metallic plates of the new tension system after the final closure. The group A and C flasks were immediately immersed in the water processing unit at room temperature (25 degrees +/- 2 degrees C). The unit was programmed to raise the temperature to 74 degrees C over 1 hour, and then maintained the temperature at 74 degrees C for 8 hours. The group B and D flasks were bench stored at room temperature (25 degrees +/- 2 degrees C) for 6 hours and were then subjected to the same moist heat polymerization conditions as groups A and C. All processed dentures were bench cooled for 3 hours. After recovery from the flasks, the base-cast sets were transversally sectioned into 3 parts (corresponding to 3 zones): (1) distal of the canines, (2) mesial of the first molars, and (3) mesial of the posterior palate). These areas had been previously established and standardized by use of a pattern denture in the sawing device to determine the sections in each base-cast set. Base-cast gaps were measured at 5 predetermined points on each section with an optical micrometer that had a tolerance of 0.001 mm. Collected data were analyzed with analysis of variance and Tukey's test. Denture bases processed with the new tension system exhibited significantly better base adaptation than those processed with traditional acrylic resin packing. Immediately after polymerization (Groups A and C), mean dimensional change values were 0.213 +/- 0.055 mm for the traditional packing technique and 0.173 +/- 0.050 mm for new tension system. After delayed polymerization (Groups B and D), the values were 0.216 +/- 0.074 mm for the traditional packing technique and 0.164 +/- 0.032 mm for new tension system. With both techniques, dimensional changes in the posterior palatal zone were greater (conventional = 0.286 +/- 0.038 mm; new system = 0.214 +/- 0.024 mm) than those elsewhere on the base-cast set. Within the limitations of this study, the new tension packing system was associated with decreased dimensional changes in the simulated maxillary denture bases processed with heat-polymerization.

Method of reducing the green density of a slip cast article

DOEpatents

Mangels, John A.; Dickie, Ray A.

1985-01-01

The method disclosed in this specification is one of reducing the green density of an article cast in a slip casting operation. The article is cast from a casting slip containing silicon metal particles, yttrium containing particles, and a small amount of a fluoride salt which is effective to suppress flocculation of the silicon metal particles by y.sup.+3 ions derived from the yttrium containing particles. The method is characterized by the following step. A small amount of compound which produces a cation which will partly flocculate the particles of silicon metal is added to the casting slip. The small amount of this compound is added so that when the casting slip is slip cast into a casting mold, the partly flocculated particles of silicon will interrupt an otherwise orderly packing of the particles of silicon and particles of yttrium. In this manner, the green density of the slip cast article is reduced and the article may be more easily nitrided.

Effect of dental technician disparities on the 3-dimensional accuracy of definitive casts.

PubMed

Emir, Faruk; Piskin, Bulent; Sipahi, Cumhur

2017-03-01

Studies that evaluated the effect of dental technician disparities on the accuracy of presectioned and postsectioned definitive casts are lacking. The purpose of this in vitro study was to evaluate the accuracy of presectioned and postsectioned definitive casts fabricated by different dental technicians by using a 3-dimensional computer-aided measurement method. An arch-shaped metal master model consisting of 5 abutments resembling prepared mandibular incisors, canines, and first molars and with a 6-degree total angle of convergence was designed and fabricated by computer-aided design and computer-aided manufacturing (CAD-CAM) technology. Complete arch impressions were made (N=110) from the master model, using polyvinyl siloxane (PVS) and delivered to 11 dental technicians. Each technician fabricated 10 definitive casts with dental stone, and the obtained casts were numbered. All casts were sectioned, and removable dies were obtained. The master model and the presectioned and postsectioned definitive casts were digitized with an extraoral scanner, and the virtual master model and virtual presectioned and postsectioned definitive casts were obtained. All definitive casts were compared with the master model by using computer-aided measurements, and the 3-dimensional accuracy of the definitive casts was determined with best fit alignment and represented in color-coded maps. Differences were analyzed using univariate analyses of variance, and the Tukey honest significant differences post hoc tests were used for multiple comparisons (α=.05). The accuracy of presectioned and postsectioned definitive casts was significantly affected by dental technician disparities (P<.001). The largest dimensional changes were detected in the anterior abutments of both of the definitive casts. The changes mostly occurred in the mesiodistal dimension (P<.001). Within the limitations of this in vitro study, the accuracy of presectioned and postsectioned definitive casts is susceptible to dental technician differences. Copyright © 2016 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

9 CFR 381.194 - Transportation and other transactions concerning dead, dying, disabled, or diseased poultry, and...

Code of Federal Regulations, 2010 CFR

2010-01-01

... concerning dead, dying, disabled, or diseased poultry, and parts of carcasses of poultry that died otherwise... transactions concerning dead, dying, disabled, or diseased poultry, and parts of carcasses of poultry that died... commerce, or importing any dead, dying, disabled, or diseased poultry or parts of the carcasses of any...

9 CFR 381.194 - Transportation and other transactions concerning dead, dying, disabled, or diseased poultry, and...

Code of Federal Regulations, 2012 CFR

2012-01-01

... concerning dead, dying, disabled, or diseased poultry, and parts of carcasses of poultry that died otherwise... transactions concerning dead, dying, disabled, or diseased poultry, and parts of carcasses of poultry that died... commerce, or importing any dead, dying, disabled, or diseased poultry or parts of the carcasses of any...

9 CFR 381.194 - Transportation and other transactions concerning dead, dying, disabled, or diseased poultry, and...

Code of Federal Regulations, 2014 CFR

2014-01-01

... concerning dead, dying, disabled, or diseased poultry, and parts of carcasses of poultry that died otherwise... transactions concerning dead, dying, disabled, or diseased poultry, and parts of carcasses of poultry that died... commerce, or importing any dead, dying, disabled, or diseased poultry or parts of the carcasses of any...

9 CFR 381.194 - Transportation and other transactions concerning dead, dying, disabled, or diseased poultry, and...

Code of Federal Regulations, 2013 CFR

2013-01-01

... concerning dead, dying, disabled, or diseased poultry, and parts of carcasses of poultry that died otherwise... transactions concerning dead, dying, disabled, or diseased poultry, and parts of carcasses of poultry that died... commerce, or importing any dead, dying, disabled, or diseased poultry or parts of the carcasses of any...

9 CFR 381.194 - Transportation and other transactions concerning dead, dying, disabled, or diseased poultry, and...

Code of Federal Regulations, 2011 CFR

2011-01-01

... concerning dead, dying, disabled, or diseased poultry, and parts of carcasses of poultry that died otherwise... transactions concerning dead, dying, disabled, or diseased poultry, and parts of carcasses of poultry that died... commerce, or importing any dead, dying, disabled, or diseased poultry or parts of the carcasses of any...

Development and Demonstration of Adanced Tooling Alloys for Molds and Dies

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

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,more » 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.« less

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

NASA Astrophysics Data System (ADS)

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

2017-05-01

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

Aluminum space frame technology

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

Birch, S.

This article examines the increased application of aluminum to the construction of automobile frames. The topics of the article include a joint venture between Audi and Alcoa, forms in which aluminum is used, new alloys and construction methods, meeting rigidity and safety levels, manufacturing techniques, the use of extrusions, die casting, joining techniques, and pollution control during manufacturing.

Morphology transition of the primary silicon particles in a hypereutectic A390 alloy in high pressure die casting.

PubMed

Wang, J; Guo, Z; Song, J L; Hu, W X; Li, J C; Xiong, S M

2017-11-03

The microstructure of a high-pressure die-cast hypereutectic A390 alloy, including PSPs, pores, α-Al grains and Cu-rich phases, was characterized using synchrotron X-ray tomography, together with SEM, TEM and EBSD. The Cu-rich phases exhibited a net morphology and distributed at the boundaries of the α-Al grains, which in turn surrounded the PSPs. Statistical analysis of the reconstructed 1000 PSPs showed that both equivalent diameter and shape factor of the PSPs exhibited a unimodal distribution with peaks corresponding to 25 μm and 0.78, respectively.) PSPs morphology with multiple twinning were observed and morphological or growth transition of the PSPs from regular octahedral shape (with a shape factor of 0.85 was mainly caused by the constraint of the Cu-rich phases. In particular, the presence of the Cu-rich phases restricted the growth of the α-Al grains, inducing stress on the internal silicon particles, which caused multiple twinning occurrence with higher growth potential and consequently led to growth transitions of the PSPs.

Method and mold for casting thin metal objects

DOEpatents

Pehrson, Brandon P; Moore, Alan F

2014-04-29

Provided herein are various embodiments of systems for casting thin metal plates and sheets. Typical embodiments include layers of mold cavities that are oriented vertically for casting the metal plates. In some embodiments, the mold cavities include a beveled edge such that the plates that are cast have a beveled edge. In some embodiments, the mold cavities are filled with a molten metal through an open horizontal edge of the cavity. In some embodiments, the mold cavities are filled through one or more vertical feed orifices. Further disclosed are methods for forming a thin cast metal plate or sheet where the thickness of the cast part is in a range from 0.005 inches to 0.2 inches, and the surface area of the cast part is in a range from 16 square inches to 144 square inches.

Method for casting thin metal objects

DOEpatents

Pehrson, Brandon P; Moore, Alan F

2015-04-14

Provided herein are various embodiments of systems for casting thin metal plates and sheets. Typical embodiments include layers of mold cavities that are oriented vertically for casting the metal plates. In some embodiments, the mold cavities include a beveled edge such that the plates that are cast have a beveled edge. In some embodiments, the mold cavities are filled with a molten metal through an open horizontal edge of the cavity. In some embodiments, the mold cavities are filled through one or more vertical feed orifices. Further disclosed are methods for forming a thin cast metal plate or sheet where the thickness of the cast part is in a range from 0.005 inches to 0.2 inches, and the surface area of the cast part is in a range from 16 square inches to 144 square inches.

Casting fine grained, fully dense, strong inorganic materials

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

Brown, Sam W.; Spencer, Larry S.; Phillips, Michael R.

2015-11-24

Methods and apparatuses for casting inorganic materials are provided. The inorganic materials include metals, metal alloys, metal hydrides and other materials. Thermal control zones may be established to control the propagation of a freeze front through the casting. Agitation from a mechanical blade or ultrasonic energy may be used to reduce porosity and shrinkage in the casting. After solidification of the casting, the casting apparatus may be used to anneal the cast part.

Additive Manufacturing and Casting Technology Comparison: Mechanical Properties, Productivity and Cost Benchmark

NASA Astrophysics Data System (ADS)

Vevers, A.; Kromanis, A.; Gerins, E.; Ozolins, J.

2018-04-01

The casting technology is one of the oldest production technologies in the world but in the recent years metal additive manufacturing also known as metal 3D printing has been evolving with huge steps. Both technologies have capabilities to produce parts with internal holes and at first glance surface roughness is similar for both technologies, which means that for precise dimensions parts have to be machined in places where precise fit is necessary. Benchmark tests have been made to find out if parts which are produced with metal additive manufacturing can be used to replace parts which are produced with casting technology. Most of the comparative tests have been made with GJS-400-15 grade which is one of the most popular cast iron grades. To compare mechanical properties samples have been produced using additive manufacturing and tested for tensile strength, hardness, surface roughness and microstructure and then the results have been compared with the samples produced with casting technology. In addition, both technologies have been compared in terms of the production time and production costs to see if additive manufacturing is competitive with the casting technology. The original paper has been written in the Latvian language as part of the Master Thesis within the framework of the production technology study programme at Riga Technical University.

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

Code of Federal Regulations, 2011 CFR

2011-07-01

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

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

Code of Federal Regulations, 2014 CFR

2014-07-01

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

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.

Food equipment manufacturer takes a slice out of its scrap rate

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

Bernard, D.; Hannahs, J.; Carter, M.

1996-09-01

The PMI Food Equipment Group began manufacturing circular slicer knives for its commercial Hobart line of slicers in the early 1930s. The company manufacturers the only cast knife in the food industry. The cast knives offer superior edge retention and overall corrosion resistance. The slicer knives are cast in PMI`s foundry. The casting process sometimes produces shrinkage voids or gas bubbles in the knife blank. Surface discontinuities often do not appear until rough cutting or final machining, i.e., after several hours of value-added manufacturing. Knife blanks with these discontinuities were scrapped and sent back to the foundry for remelting. Tomore » scrap the knives at that point meant the cost for casting plus the value-added machining added up to a considerable amount. Weld repair allows the recovery of casting and machining expenses equal to a significant percentage of the total manufacturing cost of slicer knives. Repair costs include welding, grinding, shipping, surface finishing and material handling. Other good applications for this GMAW-P process include repair of jet engine components, rotating process industry equipment, and hardfacing of cutting tools and dies. In addition, dissimilar metals and any material that is heat treated to develop its properties such as precision investment castings are excellent applications. The low resultant distortion, elimination of postweld heat treatment and non-line-of-site welding capability solves thin wall, limited access and precision machined component repair challenges.« less

9 CFR 325.20 - Transportation and other transactions concerning dead, dying, disabled, or diseased livestock...

Code of Federal Regulations, 2014 CFR

2014-01-01

... concerning dead, dying, disabled, or diseased livestock, and parts of carcasses of livestock that died... other transactions concerning dead, dying, disabled, or diseased livestock, and parts of carcasses of... transporting in commerce, or importing any dead, dying, disabled or diseased animals or parts of the carcasses...

9 CFR 325.20 - Transportation and other transactions concerning dead, dying, disabled, or diseased livestock...

Code of Federal Regulations, 2012 CFR

2012-01-01

... concerning dead, dying, disabled, or diseased livestock, and parts of carcasses of livestock that died... other transactions concerning dead, dying, disabled, or diseased livestock, and parts of carcasses of... transporting in commerce, or importing any dead, dying, disabled or diseased animals or parts of the carcasses...

9 CFR 325.20 - Transportation and other transactions concerning dead, dying, disabled, or diseased livestock...

Code of Federal Regulations, 2010 CFR

2010-01-01

... concerning dead, dying, disabled, or diseased livestock, and parts of carcasses of livestock that died... other transactions concerning dead, dying, disabled, or diseased livestock, and parts of carcasses of... transporting in commerce, or importing any dead, dying, disabled or diseased animals or parts of the carcasses...

9 CFR 325.20 - Transportation and other transactions concerning dead, dying, disabled, or diseased livestock...

Code of Federal Regulations, 2011 CFR

2011-01-01

... concerning dead, dying, disabled, or diseased livestock, and parts of carcasses of livestock that died... other transactions concerning dead, dying, disabled, or diseased livestock, and parts of carcasses of... transporting in commerce, or importing any dead, dying, disabled or diseased animals or parts of the carcasses...

9 CFR 325.20 - Transportation and other transactions concerning dead, dying, disabled, or diseased livestock...

Code of Federal Regulations, 2013 CFR

2013-01-01

... concerning dead, dying, disabled, or diseased livestock, and parts of carcasses of livestock that died... other transactions concerning dead, dying, disabled, or diseased livestock, and parts of carcasses of... transporting in commerce, or importing any dead, dying, disabled or diseased animals or parts of the carcasses...

Effect of Cold Forging on Microstructure and MechanicalProperties of Al/SiC Composites

NASA Astrophysics Data System (ADS)

Hanamantraygouda, M. B.; Shivakumar, B. P., Dr; Siddappa, P. N.; Sampathkumar, L.; Prashanth, L.

2018-02-01

The objective of this work was to investigate the effect of cold forging on mechanical properties and microstructural study of Al MMCs, at different wt% of SiC and forging cycle. The Al-SiC composite material was fabricated by stir casting method at different weight percentage of SiC such as 2.5, 5, 7.5 and 10%. Further, the deformation characteristics during open-die forging of Al-SiC composite at cold conditions was investigated. Cast and forged composite material was subjected to hardness test, tensile test and impact test. The grain size, microstructure behaviour was investigated using optical microscope. The results show that hardness and strength of Al-SiC composite increases and ductility decreases as compared to Al alloy in both as-cast and forged conditions. Optical microscope images showed that the distribution of SiC in Al matrix was more homogeneous in a forged composite as compared to cast one and reduction of porosity was found. Further, it showed that due to forging cycle the grain size was reduced by 30% to 35% from initial size.

High-Throughput Study of Diffusion and Phase Transformation Kinetics of Magnesium-Based Systems for Automotive Cast Magnesium Alloys

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

Luo, Alan A; Zhao, Ji-Cheng; Riggi, Adrienne

The objective of the proposed study is to establish a scientific foundation on kinetic modeling of diffusion, phase precipitation, and casting/solidification, in order to accelerate the design and optimization of cast magnesium (Mg) alloys for weight reduction of U.S. automotive fleet. The team has performed the following tasks: 1) study diffusion kinetics of various Mg-containing binary systems using high-throughput diffusion multiples to establish reliable diffusivity and mobility databases for the Mg-aluminum (Al)-zinc (Zn)-tin (Sn)-calcium (Ca)-strontium (Sr)-manganese (Mn) systems; 2) study the precipitation kinetics (nucleation, growth and coarsening) using both innovative dual-anneal diffusion multiples and cast model alloys to provide largemore » amounts of kinetic data (including interfacial energy) and microstructure atlases to enable implementation of the Kampmann-Wagner numerical model to simulate phase transformation kinetics of non-spherical/non-cuboidal precipitates in Mg alloys; 3) implement a micromodel to take into account back diffusion in the solid phase in order to predict microstructure and microsegregation in multicomponent Mg alloys during dendritic solidification especially under high pressure die-casting (HPDC) conditions; and, 4) widely disseminate the data, knowledge and information using the Materials Genome Initiative infrastructure (http://www.mgidata.org) as well as publications and digital data sharing to enable researchers to identify new pathways/routes to better cast Mg alloys.« less

Integrated System of Thermal/Dimensional Analysis for Quality Control of Metallic Melt and Ductile Iron Casting Solidification

NASA Astrophysics Data System (ADS)

Stan, Stelian; Chisamera, Mihai; Riposan, Iulian; Neacsu, Loredana; Cojocaru, Ana Maria; Stan, Iuliana

2018-03-01

The main objective of the present work is to introduce a specific experimental instrument and technique for simultaneously evaluating cooling curves and expansion or contraction of cast metals during solidification. Contraction/expansion analysis illustrates the solidification parameters progression, according to the molten cast iron characteristics, which are dependent on the melting procedure and applied metallurgical treatments, mold media rigidity and thermal behavior [heat transfer parameters]. The first part of the paper summarizes the performance of this two-mold device. Its function is illustrated by representative shrinkage tendency results in ductile cast iron as affected by mold rigidity (green sand and furan resin sand molds) and inoculant type (FeSi-based alloys), published in part previously. The second part of the paper illustrates an application of this equipment adapted for commercial foundry use. It conducts thermal analysis and volume change measurements in a single ceramic cup so that mold media as well as solidification conditions are constants, with cast iron quality as the variable. Experiments compared gray and ductile cast iron solidification patterns. Gray iron castings are characterized by higher undercooling at the beginning and at the end of solidification and lower graphitic expansion. Typically, ductile cast iron exhibits higher graphitic, initial expansion, conducive for shrinkage formation in soft molds.

Fatigue Analysis of Magnesium Alloys Components for Car Industry

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Embedding Optical Fibers In Cast Metal Parts

NASA Technical Reports Server (NTRS)

Gibler, William N.; Atkins, Robert A.; Lee, Chung E.; Taylor, Henry F.

1995-01-01

Use of metal strain reliefs eliminates breakage of fibers during casting process. Technique for embedding fused silica optical fibers in cast metal parts devised. Optical fiber embedded in flange, fitting, or wall of vacuum or pressure chamber, to provide hermetically sealed feedthrough for optical transmission of measurement or control signals. Another example, optical-fiber temperature sensor embedded in metal structural component to measure strain or temperature inside component.

49 CFR 192.373 - Service lines: Cast iron and ductile iron.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 49 Transportation 3 2010-10-01 2010-10-01 false Service lines: Cast iron and ductile iron. 192.373... Regulators, and Service Lines § 192.373 Service lines: Cast iron and ductile iron. (a) Cast or ductile iron... cast iron pipe or ductile iron pipe is installed for use as a service line, the part of the service...

A Comparison of Accuracy of Matrix Impression System with Putty Reline Technique and Multiple Mix Technique: An In Vitro Study

PubMed Central

Kumar, M Praveen; Patil, Suneel G; Dheeraj, Bhandari; Reddy, Keshav; Goel, Dinker; Krishna, Gopi

2015-01-01

Background: The difficulty in obtaining an acceptable impression increases exponentially as the number of abutments increases. Accuracy of the impression material and the use of a suitable impression technique are of utmost importance in the fabrication of a fixed partial denture. This study compared the accuracy of the matrix impression system with conventional putty reline and multiple mix technique for individual dies by comparing the inter-abutment distance in the casts obtained from the impressions. Materials and Methods: Three groups, 10 impressions each with three impression techniques (matrix impression system, putty reline technique and multiple mix technique) were made of a master die. Typodont teeth were embedded in a maxillary frasaco model base. The left first premolar was removed to create a three-unit fixed partial denture situation and the left canine and second premolar were prepared conservatively, and hatch marks were made on the abutment teeth. The final casts obtained from the impressions were examined under a profile projector and the inter-abutment distance was calculated for all the casts and compared. Results: The results from this study showed that in the mesiodistal dimensions the percentage deviation from master model in Group I was 0.1 and 0.2, in Group II was 0.9 and 0.3, and Group III was 1.6 and 1.5, respectively. In the labio-palatal dimensions the percentage deviation from master model in Group I was 0.01 and 0.4, Group II was 1.9 and 1.3, and Group III was 2.2 and 2.0, respectively. In the cervico-incisal dimensions the percentage deviation from the master model in Group I was 1.1 and 0.2, Group II was 3.9 and 1.7, and Group III was 1.9 and 3.0, respectively. In the inter-abutment dimension of dies, percentage deviation from master model in Group I was 0.1, Group II was 0.6, and Group III was 1.0. Conclusion: The matrix impression system showed more accuracy of reproduction for individual dies when compared with putty reline technique and multiple mix technique in all the three directions, as well as the inter-abutment distance. PMID:26124599

An Accelerated Method for Testing Soldering Tendency of Core Pins

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

Han, Qingyou; Xu, Hanbing; Ried, Paul

2010-01-01

An accelerated method for testing die soldering has been developed. High intensity ultrasonic vibrations has been used to simulate the die casting conditions such as high pressure and high impingement speed of molten metal on the pin. Soldering tendency of steels and coated pins has been examined. The results indicate that in the low carbon steel/Al system, the onset of soldering is 60 times faster with ultrasonic vibration than that without ultrasonic vibration. In the H13/A380 system, the onset of soldering reaction is accelerated to 30-60 times. Coating significantly reduces the soldering tendency of the core pins.

40 CFR 464.16 - Pretreatment standards for new sources.

Code of Federal Regulations, 2010 CFR

2010-07-01

... GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Aluminum Casting Subcategory § 464... CFR part 403 and achieve the following pretreatment standards for new sources. (a) Casting Cleaning...) 0.114 0.0431 (b) Casting Quench Operations. PSNS Pollutant or pollutant property Maximum for any 1...

Fractography of cast gypsum.

PubMed

Mori, T; Yamane, M

1982-02-01

A fractographical study of dental cast gypsum was made in order to correlate the mechanical properties with the microstructure. Wet specimens fractured under tensile stress showed intercrystalline fracture and the tensile strength depended on the porosity present. Thus, it was assumed that tensile strength was dependent on the contact area between individual gypsum crystals and changes in porosity approximated to changes in contact area. Strength differences among specimens of a given W/P ratio, therefore, can be related to differences in intercrystalline contact areas. These theoretical considerations suggest that the classification of dental die stone and dental stone into high and low strength types based on strength properties only would be more practical and less confusing than at present.

Resistivity Changes Due to Precipitation Effects in Fibre Reinforced Mg-Al-Zn-Mn Alloy

NASA Astrophysics Data System (ADS)

Kiehn, J.; Kainer, K. U.; Vostrý, P.; Stulíková, I.

1997-05-01

The change of electrical properties of alumina short fibre reinforced Mg-Al-Zn-Mn alloy AZ91D during isochronal annealing up to 300 °C is discussed. The Saffil® fibres were incorporated into the magnesium alloy by direct squeeze casting. The fibre distribution is random planar parallel to the flat faces of the dc four-point resistivity specimens machined from the solution treated castings. A sharp drop of resistivity between 140 and 260 °C is explained by the formation of incoherent -phase particles. Some practical recommendations concerning the use of alumina short fibre reinforced AZ91 alloy are made on the basis of the results obtained. Es werden die Änderungen der elektrischen Eigenschaften der aluminiumoxid-kurzfaserverstärkten Mg-Al-Zn-Mn Legierung AZ91D während isochroner Wärmebehandlungen bis 300 °C diskutiert. Das direkte Preßgießverfahren diente zur Herstellung der Saffil®-Faser Magnesium Verbundwerkstoffe. Die Proben zur Widerstandsmessung nach der Vier-Punkt Methode wurden durch spanende Bearbeitung aus den lösungsgeglühten Preßgußstücken herausgearbeitet, so daß sie regellose Faserverteilung in den Ebenen parallel zu den flachen Probenseiten aufwiesen. Ein starker Abfall des elektrischen Widerstands im Temperaturbereich zwischen 140 und 260 °C wird durch die Bildung inkohärenter β-Phase erklärt. Auf Grundlage der Ergebnisse werden einige Empfehlungen zur Anwendung der kurzfaserverstärkten Legierung AZ91 gegeben.

High Integrity Castings: Proceedings of the Conference on Advances in High Integrity Castings Held in Conjunction with the 1988 World Materials Congress, Chicago, Illinois, USA, 24-30 September 1988

DTIC Science & Technology

1988-01-01

above design requirements. The The first cast parts used in this higher strength standard chemistry parts application were of the Extra Low...present work was to study the use of beta THE HIGH COST OF TITANIUM alloys can limit their titanium alloys in the cast form. Beta or use to applications ...refractory as was is intended to achieve a pouring stream su- used with the nozzles for steel applications . perior to conventional nozzle designs , and this

Summary of "Magnesium Vision 2020: A North American Automotive Strategic Vision for Magnesium"

NASA Astrophysics Data System (ADS)

Cole, Gerald S.

This paper summarizes the monograph, "Magnesium Vision 2020. A North American Automotive Strategic Vision for Magnesium"1 prepared under the auspices of the United States Automotive Materials Partnership The objective was to understand the infrastructural and technical challenge that can increase the use of magnesium in the automotive industry. One hundred sixty three (163) Research and Technology Development Themes (RTDTs), or RTD projects were developed that addressed issues of corrosion, fastening, and processing-other-than-high pressure die casting to produce automotive magnesium parts. A major problem identified in the study is the limited ability of the current magnesium industrial infrastructure to supply RTD and implementation-ready automotive magnesium components. One solution is to create a magnesium cyber center wrhere globally networked experts would be able to innovate in process and product development, model metalworking and non-HPDC foundry processes, and integrate theoretical predictions/models of metallurgical structure with component function.

Impact properties of zinc die cast alloys

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

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

2005-01-01

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

Failure Mechanisms of the Protective Coatings for the Hot Stamping Applications

NASA Astrophysics Data System (ADS)

Zhao, Chen

In the present study, four different nitriding techniques were carried on the ductile irons NAAMS-D6510 and cast steels NAAMS-S0050A, which are widely used stamping die materials; duplex treatments (PVD CrN coating+nitriding) were carried on H13 steels, which are common inserts for the hot stamping dies. Inclined impact-sliding wear tests were performed on the nitriding cases under simulated stamping conditions. Surface profilometer, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and X-ray photoelectron spectroscopy (XPS) were used to investigate the wear and failure mechanisms of the protective coatings. It was found that the nitrided ductile iron samples performed better than the nitrided cast steel specimens. High temperature inclined impact-sliding wear tests were carried out on the CrN coatings. It was found that the coating performed better at elevated temperature. XPS analysis indicated the top surface layer (about 3-4nm) of the coating was oxidized at 400 °C and formed a Cr2O3 protective film. The in-situ formation of the thin Cr2O3 protective layer likely led to the change of wear mechanisms from severe adhesive failure to mild abrasive wear.

40 CFR 63.5790 - What parts of my plant does this subpart cover?

Code of Federal Regulations, 2014 CFR

2014-07-01

... 40 Protection of Environment 13 2014-07-01 2014-07-01 false What parts of my plant does this... Composites Production What This Subpart Covers § 63.5790 What parts of my plant does this subpart cover? (a... casting, polymer casting, pultrusion, sheet molding compound (SMC) manufacturing, bulk molding compound...

40 CFR 63.5790 - What parts of my plant does this subpart cover?

Code of Federal Regulations, 2012 CFR

2012-07-01

... 40 Protection of Environment 13 2012-07-01 2012-07-01 false What parts of my plant does this... Composites Production What This Subpart Covers § 63.5790 What parts of my plant does this subpart cover? (a... casting, polymer casting, pultrusion, sheet molding compound (SMC) manufacturing, bulk molding compound...

40 CFR 63.5790 - What parts of my plant does this subpart cover?

Code of Federal Regulations, 2013 CFR

2013-07-01

... 40 Protection of Environment 13 2013-07-01 2012-07-01 true What parts of my plant does this... Composites Production What This Subpart Covers § 63.5790 What parts of my plant does this subpart cover? (a... casting, polymer casting, pultrusion, sheet molding compound (SMC) manufacturing, bulk molding compound...

Chrysler Upset Protrusion Joining Techniques for Joining Dissimilar Metals

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

Logan, Stephen

The project goal was to develop and demonstrate a robust, cost effective, and versatile joining technique, known as Upset Protrusion Joining (UPJ), for joining challenging dissimilar metal com-binations, especially those where one of the metals is a die cast magnesium (Mg) component. Since two of the key obstacles preventing more widespread use of light metals (especially in high volume automotive applications) are 1) a lack of robust joining techniques and 2) susceptibility to galvanic corrosion, and since the majority of the joint combinations evaluated in this project include die cast Mg (the lightest structural metal) as one of the twomore » materials being joined, and since die casting is the most common and cost effective process for producing Mg components, then successful project completion provides a key enabler to high volume application of lightweight materials, thus potentially leading to reduced costs, and encouraging implementation of lightweight multi-material vehicles for significant reductions in energy consumption and reduced greenhouse gas emissions. Eco-nomic benefits to end-use consumers are achieved primarily via the reduction in fuel consumption. Unlike currently available commercial processes, the UPJ process relies on a very robust mechanical joint rather than intermetallic bonding, so the more cathodic material can be coated prior to joining, thus creating a robust isolation against galvanic attack on the more anodic material. Additionally, since the UPJ protrusion is going through a hole that can be pre-drilled or pre-punched prior to coating, the UPJ process is less likely to damage the coating when the joint is being made. Further-more, since there is no additional cathodic material (such as a steel fastener) used to create the joint, there is no joining induced galvanic activity beyond that of the two parent materials. In accordance with its originally proposed plan, this project has successfully developed process variants of UPJ to enable joining of Mg die castings to aluminum (Al) and steel sheet components of various thicknesses, strengths and coating configurations. While most development focused on the simpler round boss version of the process, an additional phase of the work focused on devel-opment of an oval boss version to support applications with narrow flanges, while yet another vari-ant of the process, known as Upset Cast Riveting (UCR), was developed and evaluated for joining mixed metals that may not necessarily include Mg or Al die cast components. Although each varia-tion posed unique challenges described later in the report, all variations were successfully produced and evaluated, and each could be further developed for specific types of commercial applications. In this project, UPJ performed favorably against the benchmark self-pierce riveting (SPR) process in Mg AM60B to Al 6013 combinations although significant corrosion challenges were observed in both processes, especially for the bare Mg to bare Al configurations. Additional challenges were observed in joining Mg to steel with the UPJ process (SPR was not evaluated for this combination as it was not considered viable). To pass FCA’s specified corrosion tests with Mg/steel combina-tions, new steel treatments were evaluated, as well as adhesives and sealed edges. These showed significant improvement. In general, UPJ performed very well in Mg to Al 6016 combinations, even in corrosion evaluation of the bare Mg to bare Al configuration (again, SPR was not evaluated for this material combination as the 1.1 mm thick Al6016 sheet thickness was considered too thin for the SPR process). The improvement in corrosion performance of the Mg to Al 6016 combina-tion over the Mg to Al 6013 combination was thought to be a result of the lower copper content in the Al 6016 alloy. Oval boss joints showed substantial improvement in all joint strength criteria compared to 8.0-mm diameter round boss joints but were not evaluated for corrosion performance. The improved joint strength is likely a result of larger shear area. Cosmetic corrosion performance of all test assemblies (UPJ, UCR and SPR) was a challenge due to exposed edges and crevices al-lowing undercutting of the coatings. In real world component applications, the exposed edges, so prevalent on the joining test coupons, would be less prevalent and easier to protect.« less

Simulation-Driven Design Approach for Design and Optimization of Blankholder

NASA Astrophysics Data System (ADS)

Sravan, Tatipala; Suddapalli, Nikshep R.; Johan, Pilthammar; Mats, Sigvant; Christian, Johansson

2017-09-01

Reliable design of stamping dies is desired for efficient and safe production. The design of stamping dies are today mostly based on casting feasibility, although it can also be based on criteria for fatigue, stiffness, safety, economy. Current work presents an approach that is built on Simulation Driven Design, enabling Design Optimization to address this issue. A structural finite element model of a stamping die, used to produce doors for Volvo V70/S80 car models, is studied. This die had developed cracks during its usage. To understand the behaviour of stress distribution in the stamping die, structural analysis of the die is conducted and critical regions with high stresses are identified. The results from structural FE-models are compared with analytical calculations pertaining to fatigue properties of the material. To arrive at an optimum design with increased stiffness and lifetime, topology and free-shape optimization are performed. In the optimization routine, identified critical regions of the die are set as design variables. Other optimization variables are set to maintain manufacturability of the resultant stamping die. Thereafter a CAD model is built based on geometrical results from topology and free-shape optimizations. Then the CAD model is subjected to structural analysis to visualize the new stress distribution. This process is iterated until a satisfactory result is obtained. The final results show reduction in stress levels by 70% with a more homogeneous distribution. Even though mass of the die is increased by 17 %, overall, a stiffer die with better lifetime is obtained. Finally, by reflecting on the entire process, a coordinated approach to handle such situations efficiently is presented.

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.

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Alloy with metallic glass and quasi-crystalline properties

DOEpatents

Xing, Li-Qian; Hufnagel, Todd C.; Ramesh, Kaliat T.

2004-02-17

An alloy is described that is capable of forming a metallic glass at moderate cooling rates and exhibits large plastic flow at ambient temperature. Preferably, the alloy has a composition of (Zr, Hf).sub.a Ta.sub.b Ti.sub.c Cu.sub.d Ni.sub.e Al.sub.f, where the composition ranges (in atomic percent) are 45.ltoreq.a.ltoreq.70, 3.ltoreq.b.ltoreq.7.5, 0.ltoreq.c.ltoreq.4, 3.ltoreq.b+c.ltoreq.10, 10.ltoreq.d.ltoreq.30, 0.ltoreq.e.ltoreq.20, 10.ltoreq.d+e.ltoreq.35, and 5.ltoreq.f.ltoreq.15. The alloy may be cast into a bulk solid with disordered atomic-scale structure, i.e., a metallic glass, by a variety of techniques including copper mold die casting and planar flow casting. The as-cast amorphous solid has good ductility while retaining all of the characteristic features of known metallic glasses, including a distinct glass transition, a supercooled liquid region, and an absence of long-range atomic order. The alloy may be used to form a composite structure including quasi-crystals embedded in an amorphous matrix. Such a composite quasi-crystalline structure has much higher mechanical strength than a crystalline structure.

Processing of sintered alpha SiC

NASA Technical Reports Server (NTRS)

Storm, R. S.

1984-01-01

Processing methods of sintered alpha SiC for engine applications are developed in a cost effective manner, using a submicron sized powder blended with sintering aids (boron and carbon). The processes for forming a green powder compact, such as dry pressing, cold isostatic pressing and green machining, slip casting, aqueous extrusion, plastic extrusion, and injection molding, are described. Dry pressing is the simplest route to component fabrication, and is carried out at approximately 10,000 psi pressure, while in the cold isostatic method the pressure could go as high as 20,000 psi. Surfactants are added to control settling rates and casting characteristics in the slip casting. The aqueous extrusion process is accomplished by a hydraulic ram forcing the aqueous mixture through a die. The plastic forming processes of extrusion and injection molding offer the potential of greater diversity in shape capacity. The physical properties of sintered alpha SiC (hardness, Young's modulus, shear modulus, and thermal diffusivity) are extensively tested. Corrosion resistance test results of silicon carbide are included.

Energy efficient engine high-pressure turbine single crystal vane and blade fabrication technology report

NASA Technical Reports Server (NTRS)

Giamei, A. F.; Salkeld, R. W.; Hayes, C. W.

1981-01-01

The objective of the High-Pressure Turbine Fabrication Program was to demonstrate the application and feasibility of Pratt & Whitney Aircraft-developed two-piece, single crystal casting and bonding technology on the turbine blade and vane configurations required for the high-pressure turbine in the Energy Efficient Engine. During the first phase of the program, casting feasibility was demonstrated. Several blade and vane halves were made for the bonding trials, plus solid blades and vanes were successfully cast for materials evaluation tests. Specimens exhibited the required microstructure and chemical composition. Bonding feasibility was demonstrated in the second phase of the effort. Bonding yields of 75 percent for the vane and 30 percent for the blade were achieved, and methods for improving these yield percentages were identified. A bond process was established for PWA 1480 single crystal material which incorporated a transient liquid phase interlayer. Bond properties were substantiated and sensitivities determined. Tooling die materials were identified, and an advanced differential thermal expansion tooling concept was incorporated into the bond process.

Self-disinfecting Alginate vs Conventional Alginate: Effect on Surface Hardness of Gypsum Cast-An in vitro Study.

PubMed

Madhavan, Ranjith; George, Navia; Thummala, Niharika R; Ravi, S V; Nagpal, Ajay

2017-11-01

For the construction of any dental prosthesis, accurate impressions are necessary. Hence, we undertook the present study to evaluate and compare the surface hardness of gypsum casts poured from impressions made using conventional alginate and self-disinfecting alginate. A total of 30 impressions of stainless steel die were made, out of which 15 impressions were made with conventional alginate and 15 were made with self-disinfecting alginate and poured using Type III dental stone. Thirty stone specimens were subjected for hardness testing. Data were analyzed using independent samples t-test to compare the mean surface hardness. Difference in surface hardness was statistically insignificant (p > 0.05). Surface hardness of gypsum casts poured using impressions made from self-disinfecting alginate and conventional alginates were comparable. Self-disinfecting alginates may be employed in clinical practice as safe and effective materials to overcome the infection control issues without compromising on the properties of the material.

Epoxy-resin patterns speed shell-molding of aluminum parts

NASA Technical Reports Server (NTRS)

1965-01-01

Half patterns cast from commercial epoxy resin containing aluminum powder are used for shell-molding of aluminum parts. The half patterns are cast in plastic molds of the original wooden pattern. Ten serviceable sand resin molds are made from each epoxy pattern.

Effects of resistance form on attachment strength of resin-retained castings.

PubMed

Wilkes, P W; Shillingburg, H T; Johnson, D L

2000-01-01

This study evaluated the effects of tooth preparation design on resistance to dislodgment of a resin-bonded fixed partial denture (RBFPD). The variations of tooth preparation tested included axial coverage, retentive grooves, and an occlusal rest. Patterns of the tooth preparation designs were prepared and cast in a base metal alloy. Retainer patterns were waxed to refractory casts of metal dies, cast, finished and then bonded to the dies. The complete assemblies were loaded to failure on an Instron mechanical testing machine, and analysis indicated that retainers with occlusal rests were the most resistant. Grooves provided no statistically significant increase in resistance to failure of the cement. Increased axial coverage did not increase resistance to dislodgment. Successful fixed partial dentures (FPDs) depend on cast retainers to resist displacement of the restoration during function. Introduction of resin-bonded restorations opened the possibility of FPDs with minimal reduction of abutments. Specific questions concerning long term success and tooth preparation designs were prominent concerns. The influence of resistance form on overall stability of a restoration was also of particular interest. Buonocore established the foundation for retention of composite resins to acid-pitted enamel. Rochette used this technology to bond perforated cast metal splints to periodontally compromised teeth. A mechanical interlock was created as composite resin engaged these perforations and sustained the cast splint to acid-etched enamel. Howe adapted this design for replacement of anterior teeth by adding porcelain to a metal ceramic framework and then bonding the framework to abutments without tooth preparations. The advantages of these procedures were their conservative nature, esthetics, and ease of rebonding after dislodgment. Livaditis and Thompson adapted the procedure proposed by Tanaka of corrosion-pitting the bonding surface of a base metal alloy. They increased the surface area to be bonded, eliminated the perforations to improve rigidity of the framework, and described tooth preparation modifications of the abutments. They suggested an occlusal rest, establishment of guide planes through axial reduction, and a proximal extension to the facial surface to resist lingual displacement. Simonson, et al., based their anterior tooth preparation design on the configuration suggested by Livaditis which included a slight chamfer finish line plus reduction of the lingual surface to provide a thicker metal framework. Barrack introduced an inlay type tooth preparation for the occlusal rest plus shallow vertical proximal grooves, and Meiers used grooves as an esthetic alternative to proximal extensions. Clinical studies and surveys have identified specific variables involved with success and failure, while in vitro studies have evaluated framework designs, bonding agents, and methods for pitting the metal surface. This study evaluated resistance of RBFPDs to dislodgment of different tooth preparation designs.

40 CFR 464.15 - Pretreatment standards for existing sources.

Code of Federal Regulations, 2011 CFR

2011-07-01

....0095 Oil and grease (for alternate monitoring) 0.363 0.121 (c) Die Casting Operations. PSES Pollutant... Total phenols 0.0074 0.0026 TTO 0.0308 0.01 Oil and grease (for alternate monitoring) 0.259 0.0864 (d...) 8.48 4.63 Lead (T) 8.7 4.3 Zinc (T) 12.6 4.74 TTO 18.1 5.91 Oil and grease (for alternate monitoring...

Comparison the Marginal and Internal Fit of Metal Copings Cast from Wax Patterns Fabricated by CAD/CAM and Conventional Wax up Techniques.

PubMed

Vojdani, M; Torabi, K; Farjood, E; Khaledi, Aar

2013-09-01

Metal-ceramic crowns are most commonly used as the complete coverage restorations in clinical daily use. Disadvantages of conventional hand-made wax-patterns introduce some alternative ways by means of CAD/CAM technologies. This study compares the marginal and internal fit of copings cast from CAD/CAM and conventional fabricated wax-patterns. Twenty-four standardized brass dies were prepared and randomly divided into 2 groups according to the wax-patterns fabrication method (CAD/CAM technique and conventional method) (n=12). All the wax-patterns were fabricated in a standard fashion by means of contour, thickness and internal relief (M1-M12: representative of CAD/CAM group, C1-C12: representative of conventional group). CAD/CAM milling machine (Cori TEC 340i; imes-icore GmbH, Eiterfeld, Germany) was used to fabricate the CAD/CAM group wax-patterns. The copings cast from 24 wax-patterns were cemented to the corresponding dies. For all the coping-die assemblies cross-sectional technique was used to evaluate the marginal and internal fit at 15 points. The Student's t- test was used for statistical analysis (α=0.05). The overall mean (SD) for absolute marginal discrepancy (AMD) was 254.46 (25.10) um for CAD/CAM group and 88.08(10.67) um for conventional group (control). The overall mean of internal gap total (IGT) was 110.77(5.92) um for CAD/CAM group and 76.90 (10.17) um for conventional group. The Student's t-test revealed significant differences between 2 groups. Marginal and internal gaps were found to be significantly higher at all measured areas in CAD/CAM group than conventional group (p< 0.001). Within limitations of this study, conventional method of wax-pattern fabrication produced copings with significantly better marginal and internal fit than CAD/CAM (machine-milled) technique. All the factors for 2 groups were standardized except wax pattern fabrication technique, therefore, only the conventional group results in copings with clinically acceptable margins of less than 120um.

Comparison the Marginal and Internal Fit of Metal Copings Cast from Wax Patterns Fabricated by CAD/CAM and Conventional Wax up Techniques

PubMed Central

Vojdani, M; Torabi, K; Farjood, E; Khaledi, AAR

2013-01-01

Statement of Problem: Metal-ceramic crowns are most commonly used as the complete coverage restorations in clinical daily use. Disadvantages of conventional hand-made wax-patterns introduce some alternative ways by means of CAD/CAM technologies. Purpose: This study compares the marginal and internal fit of copings cast from CAD/CAM and conventional fabricated wax-patterns. Materials and Method: Twenty-four standardized brass dies were prepared and randomly divided into 2 groups according to the wax-patterns fabrication method (CAD/CAM technique and conventional method) (n=12). All the wax-patterns were fabricated in a standard fashion by means of contour, thickness and internal relief (M1-M12: representative of CAD/CAM group, C1-C12: representative of conventional group). CAD/CAM milling machine (Cori TEC 340i; imes-icore GmbH, Eiterfeld, Germany) was used to fabricate the CAD/CAM group wax-patterns. The copings cast from 24 wax-patterns were cemented to the corresponding dies. For all the coping-die assemblies cross-sectional technique was used to evaluate the marginal and internal fit at 15 points. The Student’s t- test was used for statistical analysis (α=0.05). Results: The overall mean (SD) for absolute marginal discrepancy (AMD) was 254.46 (25.10) um for CAD/CAM group and 88.08(10.67) um for conventional group (control). The overall mean of internal gap total (IGT) was 110.77(5.92) um for CAD/CAM group and 76.90 (10.17) um for conventional group. The Student’s t-test revealed significant differences between 2 groups. Marginal and internal gaps were found to be significantly higher at all measured areas in CAD/CAM group than conventional group (p< 0.001). Conclusion: Within limitations of this study, conventional method of wax-pattern fabrication produced copings with significantly better marginal and internal fit than CAD/CAM (machine-milled) technique. All the factors for 2 groups were standardized except wax pattern fabrication technique, therefore, only the conventional group results in copings with clinically acceptable margins of less than 120um. PMID:24724133

Novel method for titanium crown casting using a combination of wax patterns fabricated by a CAD/CAM system and a non-expanded investment.

PubMed

Zhang, Zutai; Tamaki, Yukimichi; Hotta, Yasuhiro; Miyazaki, Takashi

2006-07-01

For titanium casting, most commercial investments for titanium recommend casting at a low mold temperature to reduce oxidation. However, the thermal expansion values of the molds at low casting temperatures may be insufficient. The purpose of the current study was to investigate the possibility of obtaining accurate titanium crown casts using wax pattern fabricated by a CAD/CAM system with a non-expanded mold. Three types of experimental magnesia-based investments (A, B and C) were made and their properties were evaluated for dental use. Two kinds of wax patterns for full-coverage coping crowns (S-0: cement space of 0 microm; S-20: cement space of 20 microm) were fabricated using a commercial CAD/CAM system. A traditional method (TM) using inlay wax was performed for comparison. The investment for titanium casting was decided from the fundamental data of experimental investments. Titanium crowns were replaced on the stone die and the thickness of the cement layer was evaluated. There were no significant differences for the setting time and setting expansion among the experimental investments, but the aluminous cement content played a role in hardening and contracting the mold. The fit of the titanium crowns differed significantly between the TM and the CAD/CAM system. The ranges of thickness obtained from the TM, S-0 and S-20 were 20.78-357.88 microm, 25.12-107.46 microm and 17.84-58.92 microm, respectively. High quality titanium crown casting was obtained using a combination of wax patterns fabricated by a CAD/CAM system and a non-expanded MgO-based investment.

A Comparative Evaluation of the Linear Dimensional Accuracy of Four Impression Techniques using Polyether Impression Material.

PubMed

Manoj, Smita Sara; Cherian, K P; Chitre, Vidya; Aras, Meena

2013-12-01

There is much discussion in the dental literature regarding the superiority of one impression technique over the other using addition silicone impression material. However, there is inadequate information available on the accuracy of different impression techniques using polyether. The purpose of this study was to assess the linear dimensional accuracy of four impression techniques using polyether on a laboratory model that simulates clinical practice. The impression material used was Impregum Soft™, 3 M ESPE and the four impression techniques used were (1) Monophase impression technique using medium body impression material. (2) One step double mix impression technique using heavy body and light body impression materials simultaneously. (3) Two step double mix impression technique using a cellophane spacer (heavy body material used as a preliminary impression to create a wash space with a cellophane spacer, followed by the use of light body material). (4) Matrix impression using a matrix of polyether occlusal registration material. The matrix is loaded with heavy body material followed by a pick-up impression in medium body material. For each technique, thirty impressions were made of a stainless steel master model that contained three complete crown abutment preparations, which were used as the positive control. Accuracy was assessed by measuring eight dimensions (mesiodistal, faciolingual and inter-abutment) on stone dies poured from impressions of the master model. A two-tailed t test was carried out to test the significance in difference of the distances between the master model and the stone models. One way analysis of variance (ANOVA) was used for multiple group comparison followed by the Bonferroni's test for pair wise comparison. The accuracy was tested at α = 0.05. In general, polyether impression material produced stone dies that were smaller except for the dies produced from the one step double mix impression technique. The ANOVA revealed a highly significant difference for each dimension measured (except for the inter-abutment distance between the first and the second die) between any two groups of stone models obtained from the four impression techniques. Pair wise comparison for each measurement did not reveal any significant difference (except for the faciolingual distance of the third die) between the casts produced using the two step double mix impression technique and the matrix impression system. The two step double mix impression technique produced stone dies that showed the least dimensional variation. During fabrication of a cast restoration, laboratory procedures should not only compensate for the cement thickness, but also for the increase or decrease in die dimensions.

Nonaqueous slip casting of high temperature ceramic superconductors using an investment casting technique

NASA Technical Reports Server (NTRS)

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

1993-01-01

A process for slip casting ceramic articles that does not employ parting agents and affords the casting of complete, detailed, precision articles that do not possess parting lines is presented. This process is especially useful for high temperature superconductors and water-sensitive ceramics. 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 mold of the calcium sulfate-bonded investment material. The shell mold is cooled to room temperature, and a ceramic slip, created by dispersing a ceramic powder in an organic liquid, is poured therein. After a ceramic shell of desired thickness or a solid article has set up in the shell mold, excess ceramic slip is poured out. The shell mold is misted with water and peeled away from the ceramic article, after which the ceramic is fired to provide a complete, detailed, precision, high temperature superconductive ceramic article without parting lines. The casting technique may take place in the presence of a magnetic field to orient the ceramic powders during the casting process.

Causes of Cracking in Quenching of the Parts Made of Steels and Cast Iron and Recommendations for Their Removal: A Review

NASA Astrophysics Data System (ADS)

Kuznetsov, A. A.; Rudnev, V. I.

2017-12-01

The domestic and foreign experience on revealing the causes of quenching cracking and its prevention is generalized. We consider the works performed on the machine parts made of carbon and alloyed pearlitic steel and quenchable cast irons.

40 CFR 464.15 - Pretreatment standards for existing sources.

Code of Federal Regulations, 2013 CFR

2013-07-01

... 0.029 0.0095 Oil and grease (for alternate monitoring) 0.363 0.121 (c) Die Casting Operations. PSES... Total phenols 0.0074 0.0026 TTO 0.0308 0.01 Oil and grease (for alternate monitoring) 0.259 0.0864 (d...) 8.48 4.63 Lead (T) 8.7 4.3 Zinc (T) 12.6 4.74 TTO 18.1 5.91 Oil and grease (for alternate monitoring...

40 CFR 464.15 - Pretreatment standards for existing sources.

Code of Federal Regulations, 2012 CFR

2012-07-01

... 0.029 0.0095 Oil and grease (for alternate monitoring) 0.363 0.121 (c) Die Casting Operations. PSES... Total phenols 0.0074 0.0026 TTO 0.0308 0.01 Oil and grease (for alternate monitoring) 0.259 0.0864 (d...) 8.48 4.63 Lead (T) 8.7 4.3 Zinc (T) 12.6 4.74 TTO 18.1 5.91 Oil and grease (for alternate monitoring...

40 CFR 464.15 - Pretreatment standards for existing sources.

Code of Federal Regulations, 2014 CFR

2014-07-01

... 0.029 0.0095 Oil and grease (for alternate monitoring) 0.363 0.121 (c) Die Casting Operations. PSES... Total phenols 0.0074 0.0026 TTO 0.0308 0.01 Oil and grease (for alternate monitoring) 0.259 0.0864 (d...) 8.48 4.63 Lead (T) 8.7 4.3 Zinc (T) 12.6 4.74 TTO 18.1 5.91 Oil and grease (for alternate monitoring...

Euros, Pounds and Albion at Arms: European Monetary Policy and British Defence in the 21st Century

DTIC Science & Technology

2004-09-01

Shakespeare , Hamlet , Prince of Denmark, act 1, scene 2. 2 William Shakespeare , Richard the Second, act 2, scene 1. 3 Hugo Young, This Blessed Plot: Britain...THIS PAGE INTENTIONALLY LEFT BLANK 1 I. INTRODUCTION Queen: Good Hamlet , cast thy nighted colour...tis common. All that lives must die, Passing through nature to eternity. Hamlet : Ay, madam, it is common. Queen: If it

The Impacts of Industrial Robots

DTIC Science & Technology

1981-11-01

plastics, ’and strain gauges are used to measure very small forces at a number of points on the robot’s "end effector. Except for the simplest on-off...devices, tactile sensors are not yet found on commercially available robots. Forces are sensed by using strain gauges or piezoelectric sensors to...tools: deburring, drilling , grinding,milling,routing machines ii. plastic materialsformirg and injection machines iii. metal die casting machines iv

ACES. Accelerated Corrosion Expert Simulator

DTIC Science & Technology

2010-02-01

Composites Coating Systems Organic Inorganic Ceramic Materials 22 Inputs and Dimensions Xi Thickness Hardness Strength Ductility Abrasion Resistance...GPU 25 T-Handle Latch 10-Year ACT Material/ Coating Configuration Die Cast Zinc T-Handle Carbon Steel Pin CS Shank CS T-Washer Carbon Steel Dish E- coat ...CARC Zinc Plating Cadmium Plated BoltE- coat /CARC CS Panel CS Panel O-Ring E- coat /CARC Original (10-year ACT) Design Green Flag Color Qualitative

Management and Case Outcome of Gastric Impaction in Four Raptors: A Case Series.

PubMed

Applegate, Jeffrey R; Van Wettere, Arnaud; Christiansen, Emily F; Degernes, Laurel A

2017-03-01

Four captive raptors, an American kestrel ( Falco sparverius ), peregrine falcon ( Falco peregrinus ), golden eagle ( Aquila chrysaetos ), and barn owl ( Tyto alba ), were diagnosed with ventricular and/or proventricular foreign material impactions consisting of artificial turf substrate, paper and plastic substrate, grass, and newspaper. Partial or total anorexia was reported in all birds and decreased casting in 2 birds. Survey radiographs confirmed presence of gastric enlargement in all 4 birds. The kestrel and eagle were treated unsuccessfully with gastroscopy and gastric lavage, respectively, followed by surgical intervention to remove the ventricular impactions. Both birds died of undetermined causes after surgery. The peregrine falcon died before medical or surgical intervention was started, and the owl was managed successfully with oral mineral oil and liquid diet to facilitate egestion of the foreign material as a pellet. Lead poisoning was suspected as the predisposing cause for foreign body ingestion in the eagle, but underlying causes for pica in the other birds were not determined. Radiographs can provide useful diagnostic information in sick raptors that exhibit vomiting or changes in appetite or casting frequency, and may help guide treatment decisions of impacted birds. Careful consideration of substrate, enrichment items, and access to potential foreign material that could be ingested may be the best pre-emptive management strategy in captive raptors.

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 minute. As we spread these simulation techniques to the balance of our business, from blank de-stacking to the racking of parts, we anticipate continued reduction in lead-time and engineering expense while improving quality and start-up execution. The author will provide an overview of technology and business evolution of the math-based process that brought an historical transition and revitalization to the die and stamping industry in the past decade. Finally, the author will give an outlook for future business needs and technology development directions.

Silicon ribbon growth by a capillary action shaping technique

NASA Technical Reports Server (NTRS)

Schwuttke, G. H.; Schwuttke, G. H.; Ciszek, T. F.; Kran, A.

1977-01-01

Substantial improvements in ribbon surface quality are achieved with a higher melt meniscus than that attainable with the film-fed (EFG) growth technique. A capillary action shaping method is described in which meniscus shaping for the desired ribbon geometry occurs at the vertex of a wettable die. As ribbon growth depletes the melt meniscus, capillary action supplies replacement material. Topics discussed cover experimental apparatus and growth procedures; die materials investigations, fabrication and evaluation; process development for 25 mm, 38 mm, 50 mm and 100 mm silicon ribbons; and long grain direct solidification of silicon. Methods for the structural and electrical characterization of cast silicon ribbons are assessed as well as silicon ribbon technology for the 1978 to 1986 period.

An Accelerated Method for Soldering Testing

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

Han, Qingyou; Xu, Hanbing; Ried, Paul

2007-01-01

An accelerated method for testing die soldering has been developed. High intensity ultrasonic vibrations have been applied to simulate the die casting conditions such as high pressure and high molten metal velocity on the pin. The soldering tendency of steels and coated pins has been examined. The results suggest that in the low carbon steel/Al system, the onset of soldering is 60 times faster with ultrasonic vibration than that without ultrasonic vibration. In the H13/A380 system, the onset of soldering reaction is accelerated to between 30-60 times. Coatings significantly reduce the soldering tendency. For purposes of this study, several commercialmore » coatings from Balzers demonstrated the potential for increasing the service life of core pins between 15 and 180 times.« less

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…

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

Nick Cannell; Dr. Mark Samonds; Adi Sholapurwalla

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

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

NASA Astrophysics Data System (ADS)

Li, Ben Q.

1995-05-01

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

40 CFR 464.01 - Applicability.

Code of Federal Regulations, 2010 CFR

2010-07-01

... MOLDING AND CASTING POINT SOURCE CATEGORY General Provisions § 464.01 Applicability. (a) This part applies to metal molding and casting facilities that discharge or may discharge pollutants to waters of the...

Centrifugal casting of ZA8 zinc alloy and composite A356/silicon carbide: Study and modeling of phases' and particles' segregation

NASA Astrophysics Data System (ADS)

Balout, Bahaa

Centrifugation is a casting technology that allows the production of cylindrical and graduated parts with different mechanical properties through the section. The need for materials with good quality and specific mechanical properties has been driven this technology in order to produce different types of materials such as zinc alloys and graduated metal matrix composites reinforced by hard and wear resistant particles. The goal of this research project is to study and model the eutectic macrosegregation, the solidification speed, and the speeds of solidification fronts during centrifugal casting of ZA8 zinc-aluminum alloy in order to improve the part quality and increase its strength and field reliability. Moreover, the segregation of the particles during centrifugal casting of an aluminum matrix composite reinforced by silicon carbide particles (A356/SiC) is also studied to improve and control the graduation of the parts. The cooling rate, the speed, acceleration/deceleration, displacement, and segregation of the particles across the section will be modeled by discretization of Stokes' law in time in order to take into consideration the change in the centrifugal radius and melt viscosity during cooling process. This study will allow the control of the graduation degree of particles across the section in order to improve the properties and wear resistance of the composite. This composite can be used in systems where friction is critical and load is high (reinforcements of parts for the cylinders of pneumatic systems). The results show that the maximum macrosegregation zone of the eutectic across the casting section corresponds to the last point of solidification. The eutectic macrosegregation produced during centrifugal casting of thin walled part is a normal segregation which varies depending on the solidification speed and the ratio between the speeds of solidification fronts. On the other hand, it was found that the position and volume fraction of the particles on the outer/inner casting surface and across the section varies whether the viscosity of the liquid metal used and the centrifugal radius are considered constant or variable during the modeling. Modeling the particles' segregation while discretizing, in time, the particles' velocities gives more consistent results compared to those obtained experimentally. Key-words: centrifugal casting, composite, macrosegregation, solidification.

Performance Steel Castings

DTIC Science & Technology

2012-09-30

Development of Sand Properties 103 Advanced Modeling Dataset.. 105 High Strength Low Alloy (HSLA) Steels 107 Steel Casting and Engineering Support...to achieve the performance goals required for new systems. The dramatic reduction in weight and increase in capability will require high performance...for improved weapon system reliability. SFSA developed innovative casting design and manufacturing processes for high performance parts. SFSA is

Evaluation of the new TAMZ titanium alloy for dental cast application.

PubMed

Zhang, Y M; Guo, T W; Li, Z C

2000-12-01

To reveal the potential of the new titanium alloy as dental prosthodontic materials. Dental castings of TAMZ alloy were investigated in the casting machine specially designed for titanium. A mesh pattern was used to count the castability value. The mechanical properties were measured by means of a universal testing machine. Optical micrography was done on the exposed cross-section of TAMZ alloy casting. From the surface to the inner part the Knoop hardness in reacted layer of TAMZ alloy casting was measured. The structure and elemental analyses of the reacted layer were made by SEM and element line scanning observation. The castability value (Cv = 98%) and the tensile test (sigma b = 850 Mpa, sigma 0.2 = 575 Mpa, delta = 7.33%) data were collected. The castings microstructure showed main alpha phase and small beta phase. Knoop hardness in the surface reacted layer was greater than that in the inner part. From the SEM and element line scanning observation, there are three different layers in the surface reacted layer of the TAMZ alloy castings, and higher level of element of O, Al, Si and Zr were found in the reacted layer while the Si permeated deeper than others. TAMZ alloy can be accepted as a material for dental alloy in prosthodontics.

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.

A comparison of the accuracy of polyether, polyvinyl siloxane, and plaster impressions for long-span implant-supported prostheses.

PubMed

Hoods-Moonsammy, Vyonne J; Owen, Peter; Howes, Dale G

2014-01-01

The purpose of this study was to compare the capacity of different impression materials to accurately reproduce the positions of five implant analogs on a master model by comparing the resulting cast with the stainless steel master model. The study was motivated by the knowledge that distortions can occur during impression making and the pouring of casts and that this distortion may produce inaccuracies of subsequent restorations, especially long-span castings for implant superstructures. The master model was a stainless steel model with five implant analogs. The impression materials used were impression plaster (Plastogum, Harry J Bosworth), a polyether (Impregum Penta, 3M ESPE), and two polyvinyl siloxane (PVS) materials (Aquasil Monophase and Aquasil putty with light-body wash, Dentsply). Five impressions were made with each impression material and cast in die stone under strictly controlled laboratory conditions. The positions of the implants on the master model, the impression copings, and the implant analogs in the subsequent casts were measured using a coordinate measuring machine that measures within 4 μm of accuracy. Statistical analyses indicated that distortion occurred in all of the impression materials, but inconsistently. The PVS monophase material reproduced the master model most accurately. Although there was no significant distortion between the impressions and the master model or between the impressions and their casts, there were distortions between the master model and the master casts, which highlighted the cumulative effects of the distortions. The polyether material proved to be the most reliable in terms of predictability. The impression plaster displayed cumulative distortion, and the PVS putty with light body showed the least reliability. Some of the distortions observed are of clinical significance and likely to contribute to a lack of passive fit of any superstructure. The inaccuracy of these analog materials and procedures suggested that greater predictability may lie in digital technology.

Die Starter: A New System to Manage Early Feasibility in Sheet Metal Forming

NASA Astrophysics Data System (ADS)

Narainen, Rodrigue; Porzner, Harald

2016-08-01

Die Starter, a new system developed by ESI Group, allows the user to drastically reduce the number of iterations during the early tool process feasibility. This innovative system automatically designs the first quick die face, generating binder and addendum surfaces (NURBS surfaces) by taking account the full die process. Die Starter also improves the initial die face based on feasibility criteria (avoiding splits, wrinkles) by automatically generating the geometrical modifications of the binder and addendum and the bead restraining forces with minimal material usage. This paper presents a description of the new system and the methodology of Die Starter. Some industrial examples are presented from the part geometry to final die face including automatic developed flanges, part on binder and inner binder.

The Effect of Various Finish Line Configurations on the Marginal Seal and Occlusal Discrepancy of Cast Full Crowns After Cementation - An In-vitro Study.

PubMed

Nemane, Vaishali; Akulwar, Ravikumar Suryakanth; Meshram, Suresh

2015-08-01

The marginal fit of crowns is of clinical importance. It is found that marginal and occlusal discrepancies are commonly increased following cementation. The resistance of cementing materials is a factor that prevents cast restorations from being correctly seated. Different finish lines behave differently in facilitating the escape of the cement. When the escape path of the cement decreases, the crown fails to seat further. This study was planned with an aim to evaluate the effect of various finish lines on the marginal seal and occlusal seat of full crown preparations. Six stainless steel metal dies were machined to simulate molar crown preparations. The diameter was 10 mm and height was 6mm. The occlusal surface was kept flat and a small circular dimple was machined for reorientation of the wax pattern and metal copings, margins of various designs were machined accurately. The margins prepared were Group A- 90(0)C shoulder, Group B- Rounded shoulder, Group C- 45 degree sloped shoulder, Group D- Chamfer, Group E- Long chamfer, Group F- Feather edge. Full cast metal crowns of base metal alloy were fabricated over the metal dies. Zinc phosphate luting cement was used for the cementation. After twenty four hours, the cemented crown and die assembly were embedded in clear acrylic resin so as to hold the assembly together while sectioning. Twenty four hours later, all the samples were sectioned sagitally. The sectioned halves were focused under a stereomicroscope and the cement spaces were measured to the nearest micron. The cement thickness was measured at two points on the occlusal surface and one at each margin. Significant differences were observed in the occlusal seat and marginal seal of all the finish line configurations. The rounded shoulder had the best occlusal seat, followed by 90(0)C shoulder. The occlusal seat and marginal seal afforded by the shoulder finish lines were similar whereas there was a vast difference in the seating and sealing of long chamfer and feather edged preparations. They showed the worst occlusal seat. It was found that the finish lines like shoulder preparations which exhibit poor sealing prior to complete cementation allow good seating whereas margins which seal earlier do not allow escape of cement and hence do not seat completely.

The Effect of Various Finish Line Configurations on the Marginal Seal and Occlusal Discrepancy of Cast Full Crowns After Cementation - An In-vitro Study

PubMed Central

Nemane, Vaishali; Meshram, Suresh

2015-01-01

Background The marginal fit of crowns is of clinical importance. It is found that marginal and occlusal discrepancies are commonly increased following cementation. The resistance of cementing materials is a factor that prevents cast restorations from being correctly seated. Different finish lines behave differently in facilitating the escape of the cement. When the escape path of the cement decreases, the crown fails to seat further. Materials and Methods This study was planned with an aim to evaluate the effect of various finish lines on the marginal seal and occlusal seat of full crown preparations. Six stainless steel metal dies were machined to simulate molar crown preparations. The diameter was 10 mm and height was 6mm. The occlusal surface was kept flat and a small circular dimple was machined for reorientation of the wax pattern and metal copings, margins of various designs were machined accurately. The margins prepared were Group A- 900C shoulder, Group B- Rounded shoulder, Group C- 45 degree sloped shoulder, Group D- Chamfer, Group E- Long chamfer, Group F- Feather edge. Full cast metal crowns of base metal alloy were fabricated over the metal dies. Zinc phosphate luting cement was used for the cementation. After twenty four hours, the cemented crown and die assembly were embedded in clear acrylic resin so as to hold the assembly together while sectioning. Twenty four hours later, all the samples were sectioned sagitally. The sectioned halves were focused under a stereomicroscope and the cement spaces were measured to the nearest micron. The cement thickness was measured at two points on the occlusal surface and one at each margin. Results Significant differences were observed in the occlusal seat and marginal seal of all the finish line configurations. The rounded shoulder had the best occlusal seat, followed by 900C shoulder. The occlusal seat and marginal seal afforded by the shoulder finish lines were similar whereas there was a vast difference in the seating and sealing of long chamfer and feather edged preparations. They showed the worst occlusal seat. Conclusion It was found that the finish lines like shoulder preparations which exhibit poor sealing prior to complete cementation allow good seating whereas margins which seal earlier do not allow escape of cement and hence do not seat completely. PMID:26436039

Cast Iron in The 19th Century Building Equipment

NASA Astrophysics Data System (ADS)

Kwasek, Michał; Piwek, Aleksander

2017-10-01

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

The Production of Porous Hydroxyapatite Scaffolds with Graded Porosity by Sequential Freeze-Casting.

PubMed

Lee, Hyun; Jang, Tae-Sik; Song, Juha; Kim, Hyoun-Ee; Jung, Hyun-Do

2017-03-31

Porous hydroxyapatite (HA) scaffolds with porosity-graded structures were fabricated by sequential freeze-casting. The pore structures, compressive strengths, and biocompatibilities of the fabricated porous HA scaffolds were evaluated. The porosities of the inner and outer layers of the graded HA scaffolds were controlled by adjusting the initial HA contents of the casting slurries. The interface between the dense and porous parts was compact and tightly adherent. The porosity and compressive strengths of the scaffold were controlled by the relative thicknesses of the dense/porous parts. In addition, the porous HA scaffolds showed good biocompatibility in terms of preosteoblast cell attachment and proliferation. The results suggest that porous HA scaffolds with load-bearing parts have potential as bone grafts in hard-tissue engineering.

The Production of Porous Hydroxyapatite Scaffolds with Graded Porosity by Sequential Freeze-Casting

PubMed Central

Lee, Hyun; Jang, Tae-Sik; Song, Juha; Kim, Hyoun-Ee; Jung, Hyun-Do

2017-01-01

Porous hydroxyapatite (HA) scaffolds with porosity-graded structures were fabricated by sequential freeze-casting. The pore structures, compressive strengths, and biocompatibilities of the fabricated porous HA scaffolds were evaluated. The porosities of the inner and outer layers of the graded HA scaffolds were controlled by adjusting the initial HA contents of the casting slurries. The interface between the dense and porous parts was compact and tightly adherent. The porosity and compressive strengths of the scaffold were controlled by the relative thicknesses of the dense/porous parts. In addition, the porous HA scaffolds showed good biocompatibility in terms of preosteoblast cell attachment and proliferation. The results suggest that porous HA scaffolds with load-bearing parts have potential as bone grafts in hard-tissue engineering. PMID:28772735

Improvement of Die Corner Filling in Box-shape Stepped Tubes Hydroforming

NASA Astrophysics Data System (ADS)

Hosseini-Farrash, S. H.; Elyasi, M.; Bakhshi-Jooybari, M.; Gorji, A.

2011-01-01

A new die design to improve the die corner filling in the hydroforming of square-sectional stepped tubes is presented. The proposed die-set contains two additional bushes, compared to the common tube hydroforming dies. First, the tube is placed into the die, filled with liquid, and sealed with the punches. Then, by increasing the internal pressure, the tube is bulged and contacts the die walls (bulging stage). By maintaining the internal pressure, the two upper and lower bushes move until the die cavity is filled completely (calibration stage). The proposed die was simulated and the results show that sharp corners of the part and relatively complete filling of the die cavity can be obtained by using this die set. In order to verify the results, some experiments have been carried out. The experimental results verified the results obtained from the simulations. The thickness distribution of the part is also investigated and it is shown that fairly uniform thickness distribution can be obtained by using the proposed die set.

Forging Oxide-Dispersion-Strengthened Superalloys

NASA Technical Reports Server (NTRS)

Harf, F. H.; Glasgow, T. K.; Moracz, D. J.; Austin, C. M.

1986-01-01

Cladding of mild steel prevents surface cracking when alloy contacts die. Continual need for improvements in properties of alloys capable of withstanding elevated temperatures. Accomplished by using oxide-dispersion-strengthed superalloys such as Inconel Alloy MA 6000. Elevated tensile properties of forged alloy equal those of hot-rolled MA 6000 bar. Stress-rupture properties somewhat lower than those of bar stock but, at 1,100 degrees C, exceed those of strongest commercial single crystal, directionally solidified and conventionally cast superalloys.

Investigation on the cold rolling and structuring of cold sprayed copper-coated steel sheets

NASA Astrophysics Data System (ADS)

Bobzin, K.; Öte, M.; Wiesner, S.; Gerdt, L.; Senge, S.; Hirt, G.

2017-03-01

A current driving force of research is lightweight design. One of the approaches to reduce the weight of a component without causing an overall stiffness decrease is the use of multi-material components. One of the main challenges of this approach is the low bonding strength between different materials. Focusing on steel-aluminum multi-material components, thermally sprayed copper coatings can come into use as a bonding agent between steel sheets and high pressure die cast aluminum to improve the bonding strength. This paper presents a combination of cold gas spraying of copper coatings and their subsequent structuring by rolling as surface pretreatment method of the steel inserts. Therefore, flat rolling experiments are performed with samples in “as sprayed” and heat treated conditions to determine the influence of the rolling process on the bond strength and the formability of the coating. Furthermore, the influence of the rolling on the roughness and the hardness of the coating was examined. In the next step, the coated surface was structured, to create a surface topology suited for a form closure connection in a subsequent high-pressure die casting process. No cracks were observed after the cold rolling process with a thickness reduction of up to ε = 14 % for heat treated samples. Structuring of heat treated samples could be realized without delamination and cracking.

Finite Element Analysis of Laser Engineered Net Shape (LENS™) Tungsten Clad Squeeze Pins

NASA Astrophysics Data System (ADS)

Sakhuja, Amit; Brevick, Jerald R.

2004-06-01

In the aluminum high-pressure die-casting and indirect squeeze casting processes, local "squeeze" pins are often used to minimize internal solidification shrinkage in heavy casting sections. Squeeze pins frequently fail in service due to molten aluminum adhering to the H13 tool steel pins ("soldering"). A wide variety of coating materials and methods have been developed to minimize soldering on H13. However, these coatings are typically very thin, and experience has shown their performance on squeeze pins is highly variable. The LENS™ process was employed in this research to deposit a relatively thick tungsten cladding on squeeze pins. An advantage of this process was that the process parameters could be precisely controlled in order to produce a satisfactory cladding. Two fixtures were designed and constructed to enable the end and outer diameter (OD) of the squeeze pins to be clad. Analyses were performed on the clad pins to evaluate the microstructure and chemical composition of the tungsten cladding and the cladding-H13 substrate interface. A thermo-mechanical finite element analysis (FEA) was performed to assess the stress distribution as a function of cladding thickness on the pins during a typical casting thermal cycle. FEA results were validated via a physical test, where the clad squeeze pins were immersed into molten aluminum. Pins subjected to the test were evaluated for thermally induced cracking and resistance to soldering of the tungsten cladding.

Thermomechanical properties and fracture of resin-bonded-sand cores - Experimental study and application in aluminium foundry

NASA Astrophysics Data System (ADS)

Menet, Claire; Reynaud, Pascal; Fantozzi, Gilbert; Thibault, Delphine; Laforêt, Adrien

2017-06-01

Sand cores are used to produce internal cavities of metallic cast parts with complex shapes like automotive cylinder heads. Foundry cores are granular materials made of sand grains aggregated with binder bridges. In the cold box coring process, the binder is a polyurethane resin. It is noteworthy that during the casting of the liquid metal, the polymer binder is seriously damaged. This kind of materials has been poorly investigated so far. This study aims for a better understanding of the mechanical behaviour and fracture of cores subjected to various loads and thermal ageing. Particularly, the focus is on the decoring step, which consists in removing the sand by hammering and vibration of the metallic part after casting. This major project, generated from the collaboration of the aluminum casting company Montupet, and two laboratories Centre des Matériaux (CdM) and MATEIS, includes both experimental and numerical activities in order to model the decoring step of cylinder heads based on empiric data. Here, the experimental part of the work is presented.

Computed Tomography For Internal Inspection Of Castings

NASA Technical Reports Server (NTRS)

Hanna, Timothy L.

1995-01-01

Computed tomography used to detect internal flaws in metal castings before machining and otherwise processing them into finished parts. Saves time and money otherwise wasted on machining and other processing of castings eventually rejected because of internal defects. Knowledge of internal defects gained by use of computed tomography also provides guidance for changes in foundry techniques, procedures, and equipment to minimize defects and reduce costs.

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

NASA Technical Reports Server (NTRS)

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

1986-01-01

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

Shear Resistance between Concrete-Concrete Surfaces

NASA Astrophysics Data System (ADS)

Kovačovic, Marek

2013-12-01

The application of precast beams and cast-in-situ structural members cast at different times has been typical of bridges and buildings for many years. A load-bearing frame consists of a set of prestressed precast beams supported by columns and diaphragms joined with an additionally cast slab deck. This article is focused on the theoretical and experimental analyses of the shear resistance at an interface. The first part of the paper deals with the state-of-art knowledge of the composite behaviour of concrete-concrete structures and a comparison of the numerical methods introduced in the relevant standards. In the experimental part, a set of specimens with different interface treatments was tested until failure in order to predict the composite behaviour of coupled beams. The experimental part was compared to the numerical analysis performed by means of FEM basis nonlinear software.

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.

Investigation of the interfacial reactions between steel and aluminum coatings for hybrid casting

NASA Astrophysics Data System (ADS)

Bobzin, K.; Öte, M.; Wiesner, S.; Gerdt, L.

2018-06-01

Coating of AA7075 was applied by means of cold gas spraying on steel substrates of 22MnB5 and DC04 as an interlayer for high pressure die casting of aluminum/steel hybrid components. The morphology and growth kinetics of intermetallic compounds formed at the interface between coating and steel has been investigated. Furthermore, the effect of alloying elements on the formation of the intermetallic phases was analyzed. The coated samples were heat treated by means of induction heating at the temperature T = 550 °C with different dwell times in the range of 10 s < t < 5 min. The reaction layer growth was examined by means of scanning electron microscope (SEM) with energy dispersive spectroscopy (EDS). Additionally, the intermetallic compounds were characterized by means of nanoindentation. Intermetallic compounds of AlFe phases occurred as the major constituent in the reaction zone for different combinations of coating and substrates.

Direct Cast U-6Nb – 2017 Progress on Cylindrical Castings

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

Aikin, Jr., Robert M.

2017-10-04

This report describes work to further develop a sound technical basis and best practices for mold design and process parameters for the Direct Casting of U-6wt%Nb components. One major challenge to the production of U-6Nb components is the propensity for niobium segregation during casting and solidification. This is especially true for cylindrical castings where the vertical side walls allow flotation of Nb resulting in severe inverse macrosegregation. In this work, a small (120 mm diameter by 180 mm tall) and large cylinder (250 mm diameter by 310 mm tall) are examined with a focus on reducing, or eliminating, niobium segregation.more » It is demonstrated that counter gravity casting (top-to-bottom solidification) can be used to minimize segregation in the small cylinder. Attempts to counter gravity cast the large cylinder were unsuccessful, in large part due to size limitations of the current furnace. A path forward for casting of the large cylinders is discussed.« less

Development of Metal Casting Molds By Sol-Gel Technology Using Planetary Resources

NASA Technical Reports Server (NTRS)

Sibille, L.; Sen, S.; Curreri, P.; Stefanescu, D.

2000-01-01

Metals extracted from planetary soils will eventually need to be casted and shaped in-situ to produce useful products. In response to this challenge, we propose to develop and demonstrate the manufacturing of a specific product using Lunar and Martian soil simulants, i.e. a mold for the casting of metal and alloy parts, which will be an indispensable tool for the survival of outposts on the Moon and Mars. Drawing from our combined knowledge of sol-gel and metal casting technologies, we set out to demonstrate the extraordinary potential of mesoporous materials such as aerogels to serve as efficient casting molds as well as fulfilling numerous other needs of an autonomous planetary outpost.

Optimization of Casting Design Parameters on Fabrication of Reliable Semi-Solid Aluminum Suspension Control Arm

NASA Astrophysics Data System (ADS)

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

2017-09-01

The semi-solid casting process has the advantage of providing reliable mechanical aluminum parts that work continuously in dynamic as control arm of the suspension system in automotive vehicles. The quality performance of dynamic control arm is related to casting mold and gating system designs that affect the fluidity of semi-solid metal during filling the mold. Therefore, this study focuses on improvement in mechanical performance, depending on material characterization, and casting design optimization, of suspension control arms made of A357 aluminum semi-solid alloys. Mechanical and design analyses, applied on the suspension arm, showed the occurrence of mechanical failures at unexpected weak points. Metallurgical analysis showed that the main reason lies in the difficult flow of semi-solid paste through the thin thicknesses of a complex geometry. A design modification procedure is applied to the geometry of the suspension arm to avoid this problem and to improve its quality performance. The design modification of parts was carried out by using SolidWorks design software, evaluation of constraints with ABAQUS, and simulation of flow with ProCast software. The proposed designs showed that the modified suspension arm, without ribs and with a central canvas designed as Z, is considered as a perfect casting design showing an increase in the structural strength of the component. In this case, maximum von Mises stress is 199 MPa that is below the yield strength of the material. The modified casting mold design shows a high uniformity and minim turbulence of molten metal flow during semi-solid casting process.

The die is cast: arsenic exposure in early life and disease susceptibility.

PubMed

Thomas, David J

2013-12-16

Early life exposure to arsenic in humans and mice produces similar patterns of disease in later life. Given the long interval between exposure and effect, epigenetic effects of early life exposure to arsenic may account for the development and progression of disease in both species. Mode of action and dosimetric studies in the mouse may help assess the role of age at exposure as a factor in susceptibility to the toxic and carcinogenic effects of arsenic in humans.

Was Sigmund Freud's death hastened?

PubMed

Macleod, Alastair D Sandy

2017-08-01

The terminal illness of Sigmund Freud has been considered by many authors to be an example of physician-enacted euthanasia. A review and a reconsideration of the published literature by Freud's doctors and biographers cast doubt on this opinion. Over his last 48 h, Freud was administered substantial morphine doses to sedate and relieve his pain. However, from a pharmacological perspective, the timing of his death would not be consistent with that of a fatal dose of opioid. Freud died a natural death. © 2017 Royal Australasian College of Physicians.

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

Eric S. Peterson; Jessica Trudeau; Bill Cleary

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 diemore » 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.« less

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

Peterson, E. S.; Trudeau, J.; Cleary, B.

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 diemore » 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.« less

Influence of Custom Trays, Dual-Arch Passive, Flexed Trays and Viscosities of Elastomeric Impression Materials on Working Dies.

PubMed

Arora, Mansi; Kohli, Shivani; Kalsi, Rupali

2016-05-01

Dual arch impression technique signifies an essential improvement in fixed prosthodontics and has numerous benefits over conventional impression techniques. The accuracy of working dies fabricated from dual arch impression technique remains in question because there is little information available in the literature. This study was conducted to compare the accuracy of working dies fabricated from impressions made from two different viscosities of impression materials using metal, plastic dual arch trays and custom made acrylic trays. The study samples were grouped into two groups based on the viscosity of impression material used i.e. Group I (monophase), whereas Group II consisted of Dual Mix technique using a combination of light and heavy body material. These were further divided into three subgroups A, B and C depending on the type of impression tray used (metal dual arch tray, plastic dual arch tray and custom made tray). Measurements of the master cast were made using profile projector. Descriptive statistics like mean, Standard Deviation (SD) were calculated for all the groups. One way analysis of variance (ANOVA) was used for multiple group comparisons. A p-value of 0.05 or less was considered statistically significant. The gypsum dies obtained with the three types of impression trays using two groups of impression materials were smaller than the master models in dimensions. The plastic dual arch trays produced dies which were the least accurate of the three groups. There was no significant difference in the die dimensions obtained using the two viscosities of impression materials.

Influence of Custom Trays, Dual-Arch Passive, Flexed Trays and Viscosities of Elastomeric Impression Materials on Working Dies

PubMed Central

Kohli, Shivani; Kalsi, Rupali

2016-01-01

Introduction Dual arch impression technique signifies an essential improvement in fixed prosthodontics and has numerous benefits over conventional impression techniques. The accuracy of working dies fabricated from dual arch impression technique remains in question because there is little information available in the literature. Aim This study was conducted to compare the accuracy of working dies fabricated from impressions made from two different viscosities of impression materials using metal, plastic dual arch trays and custom made acrylic trays. Materials and Methods The study samples were grouped into two groups based on the viscosity of impression material used i.e. Group I (monophase), whereas Group II consisted of Dual Mix technique using a combination of light and heavy body material. These were further divided into three subgroups A, B and C depending on the type of impression tray used (metal dual arch tray, plastic dual arch tray and custom made tray). Measurements of the master cast were made using profile projector. Descriptive statistics like mean, Standard Deviation (SD) were calculated for all the groups. One way analysis of variance (ANOVA) was used for multiple group comparisons. A p-value of 0.05 or less was considered statistically significant. Results The gypsum dies obtained with the three types of impression trays using two groups of impression materials were smaller than the master models in dimensions. Conclusion The plastic dual arch trays produced dies which were the least accurate of the three groups. There was no significant difference in the die dimensions obtained using the two viscosities of impression materials. PMID:27437342

Program Evaluation - Automotive Lightweighting Materials Program Research and Development Projects Assessment of Benefits - Case Studies No. 2

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

Das, S.

This report is the second of a series of studies to evaluate research and development (R&D) projects funded by the Automotive Lightweighting Materials (ALM) Program of the Office of Advanced Automotive Technologies (OAAT) of the U.S. Department of Energy (DOE). The objectives of the program evaluation are to assess short-run outputs and long-run outcomes that may be attributable to the ALM R&D projects. The ALM program focuses on the development and validation of advanced technologies that significantly reduce automotive vehicle body and chassis weight without compromising other attributes such as safety, performance, recyclability, and cost. Funded projects range from fundamentalmore » materials science research to applied research in production environments. Collaborators on these projects include national laboratories, universities, and private sector firms, such as leading automobile manufacturers and their suppliers. Three ALM R&D projects were chosen for this evaluation: Design and Product Optimization for Cast Light Metals, Durability of Lightweight Composite Structures, and Rapid Tooling for Functional Prototyping of Metal Mold Processes. These projects were chosen because they have already been completed. The first project resulted in development of a comprehensive cast light metal property database, an automotive application design guide, computerized predictive models, process monitoring sensors, and quality assurance methods. The second project, the durability of lightweight composite structures, produced durability-based design criteria documents, predictive models for creep deformation, and minimum test requirements and suggested test methods for establishing durability properties and characteristics of random glass-fiber composites for automotive structural composites. The durability project supported Focal Project II, a validation activity that demonstrates ALM program goals and reduces the lead time for bringing new technology into the marketplace. Focal projects concentrate on specific classes of materials and nonproprietary components and are done jointly by DOE and the Automotive Composites Consortium of U.S. Council for Automotive Research (USCAR). The third project developed a rapid tooling process that reduces tooling time, originally some 48-52 weeks, to less than 12 weeks by means of rapid generation of die-casting die inserts and development of generic holding blocks, suitable for use with large casting applications. This project was conducted by the United States Automotive Materials Partnership, another USCAR consortium.« less

Improved Slip Casting Of Ceramic Models

NASA Technical Reports Server (NTRS)

Buck, Gregory M.; Vasquez, Peter; Hicks, Lana P.

1994-01-01

Improved technique of investment slip casting developed for making precise ceramic wind-tunnel models. Needed in wind-tunnel experiments to verify predictions of aerothermodynamical computer codes. Ceramic materials used because of their low heat conductivities and ability to survive high temperatures. Present improved slip-casting technique enables casting of highly detailed models from aqueous or nonaqueous solutions. Wet shell molds peeled off models to ensure precise and undamaged details. Used at NASA Langley Research Center to form superconducting ceramic components from nonaqueous slip solutions. Technique has many more applications when ceramic materials developed further for such high-strength/ temperature components as engine parts.

Laboratory evaluation of compressor blades considered for use in CIP/CUP compressors. [GAT2, 214X, X224, and D-15Al alloys

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

Ritchie, K.L.

1976-04-30

Four die-casting alloys, the external-pressure-pin and conventional casting methods, an accelerated aging heat treatment, and an airfoil fillet modification were evaluated for 33F-S1 compressor blades considered for use in axial flow compressors installed during the Cascade Improvement and Uprating Programs at the three gaseous diffusion plants. Based on castability, resonant frequency, resistance to fatigue cracking, and shank breaking load, the ranking of the four alloys from highest to lowest is GAT2, 214X, X224, and D-15. The GAT2 alloy ranked highest in all categories except impact value; the impact values of both X224 and 214X alloys exceeded that of the GAT2more » alloy, thus indicating the latter is relatively more brittle. However, in view of its other excellent properties, including fatigue cracking resistance, GAT2 alloy is worthy of consideration for use in blades for CIP/CUP or Add-on Plant compressors, particularly if castability becomes a problem with the presently used 214X alloy. Use of the external-pressure-pin casting method is not recommended because the resulting casting difficulties cannot be justified by the small increases in shank breaking loads. The airfoil fillet modification, which is a change from the conventional circular fillet to an elliptical fillet, resulted in increases (1.5 to 4.0 percent) in the average resonant frequency and in resistance to fatigue cracking (15 to 100 percent). The results of giving the blades an accelerated aging heat treatment, designed to simulate in excess of 10,000 hours of cascade exposure, showed that overaging had no significant effect on average resonant frequency but that overaging improved blade quality by reducing residual casting stress. (auth)« less

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 mold of the calcium sulfate-bonded investment material. The shell mold is cooled to room temperature, and a ceramic slip is poured therein. After a ceramic shell of desired thickness has set up in the shell mold, excess ceramic slip is poured out. While still wet, the shell mold is peeled from the ceramic shell to expose any delicate or detailed parts, after which the ceramic shell is cured to provide a complete, detailed, precision ceramic article without parting lines.

Cast Ductile Iron 155mm M804 Bodies

DTIC Science & Technology

1990-07-12

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

Apparatus And Method For Producing Single Crystal Metallic Objects

DOEpatents

Huang, Shyh-Chin; Gigliotti, Jr., Michael Francis X.; Rutkowski, Stephen Francis; Petterson, Roger John; Svec, Paul Steven

2006-03-14

A mold is provided for enabling casting of single crystal metallic articles including a part-defining cavity, a sorter passage positioned vertically beneath and in fluid communication with the part-defining cavity, and a seed cavity positioned vertically beneath and in fluid communication with the sorter passage. The sorter passage includes a shape suitable for encouraging a single crystal structure in solidifying molten metal. Additionally, a portion of the mold between the sorter passage and the part-defining cavity includes a notch for facilitating breakage of a cast article proximate the notch during thermal stress build-up, so as to prevent mold breakage or the inclusion of part defects.

Effect of Rotating Mold Speed on Microstructure of Al LM6 Hollow Cylinder Fabricated Using Centrifugal Method

NASA Astrophysics Data System (ADS)

Kohnizio Mahli, Maximus; Jamian, Saifulnizan; Ismail, Al Emran; Nor, Nik Hisyamudin Muhd; Nor, Mohd Khir Mohd; Azhar Kamarudin, Kamarul

2017-10-01

Al LM6 hollow cylinder is fabricated using horizontal centrifugal casting which produce a very fine grain on the outer surface of the structure. In this study, the effect of motor speed and pouring temperature on the microstructure of Al LM6 hollow cylinder is determined. The speed of the motor used during casting are 1300rpm, 1500rpm and 1700rpm and the pouring temperature are 690°C, 710°C and 725°C. The Al LM6 hollow cylinder is produced by pouring the molten Al LM6 into a cylindrical casting mold which is connected with a shaft and it is rotated by motor until it is solidified. Then, the cross-section is observed using OM and SEM/EDS. From the microstructure observation, the distributions of Si are more concentrated at the inner parts and the size of Si is bigger at the inner parts. The result shows that the Si particles at the inner part which is fabricated at the highest motor speed (1700rpm) have the most Si particles compared with the Si particles that are casted with other motor speeds.

Improvements in Fabrication of Sand/Binder Cores for Casting

NASA Technical Reports Server (NTRS)

Bakhitiyarov, Sayavur I.; Overfelt, Ruel A.; Adanur, Sabit

2005-01-01

Three improvements have been devised for the cold-box process, which is a special molding process used to make sand/binder cores for casting hollow metal parts. These improvements are: The use of fiber-reinforced composite binder materials (in contradistinction to the non-fiber-reinforced binders used heretofore), The substitution of a directed-vortex core-blowing subprocess for a prior core-blowing process that involved a movable gassing plate, and The use of filters made from filtration-grade fabrics to prevent clogging of vents. For reasons that exceed the scope of this article, most foundries have adopted the cold-box process for making cores for casting metals. However, this process is not widely known outside the metal-casting industry; therefore, a description of pertinent aspects of the cold-box process is prerequisite to a meaningful description of the aforementioned improvements. In the cold-box process as practiced heretofore, sand is first mixed with a phenolic resin (considered to be part 1 of a three-part binder) and an isocyanate resin (part 2 of the binder). Then by use of compressed air, the mixture is blown into a core box, which is a mold for forming the core. Next, an amine gas (part 3 of the binder) that acts as a catalyst for polymerization of parts 1 and 2 is blown through the core box. Alternatively, a liquid amine that vaporizes during polymerization can be incorporated into the sand/resin mixture. Once polymerization is complete, the amine gas is purged from the core box by use of compressed air. The finished core is then removed from the core box.

Templates Aid Removal Of Defects From Castings

NASA Technical Reports Server (NTRS)

Hendrickson, Robert G.

1992-01-01

Templates used to correlate defects in castings with local wall thicknesses. Placed on part to be inspected after coated with penetrant dye. Positions of colored spots (indicative of defects) noted. Ultrasonic inspector measures thickness of wall at unacceptable defects only - overall inspection not necessary.

Investigating the Evolution of Progressive Die Wear on Uncoated Dp1180 Steel in Production Environment

NASA Astrophysics Data System (ADS)

Wu, W.; Zhou, D. J.; Adamski, D. J.; Young, D.; Wang, Y. W.

2017-09-01

A study of die wear was performed using an uncoated dual phase, 1,180 MPa ultimate tensile strength steel (DP1180) in a progressive die. The objectives of the current study are to evaluate the die durability of various tooling materials and coatings for forming operations on uncoated DP1180 steel and update OEM’s die standards based on the experimental results in the real production environment. In total, 100,800 hits were performed in manufacturing production conditions, where 33 die inserts with the combination of 10 die materials and 9 coatings were investigated. The die inserts were evaluated for surface wear using scanning electron microscopy and characterized in terms of die material and/or coating defects, failure mode, failure initiation and propagation. Surface roughness of the formed parts was characterized using a WYKO NT110 machine. The analytical analysis of the die inserts and formed parts, combined with the failure mode and service life, provide a basis for die material and coating selection for forming AHSS components. The conclusions of this study will guide the selection of die material and coatings for high-volume production of AHSS components.

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.

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

NASA Astrophysics Data System (ADS)

Sobek, M.; Baier, A.; Grabowski, Ł.

2018-01-01

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

Contoured Orifice for Silicon-Ribbon Die

NASA Technical Reports Server (NTRS)

Mackintosh, B. H.

1985-01-01

Die configuration encourages purity and stable growth. Contour of die orifice changes near ribbon edges. As result, silicon ribbon has nearly constant width and little carbon contamination. Die part of furnace being developed to produce high-quality, low-cost material for solar cells.

Effect of the infrastructure material on the failure behavior of prosthetic crowns.

PubMed

Sonza, Queli Nunes; Della Bona, Alvaro; Borba, Márcia

2014-05-01

To evaluate the effect of infrastructure (IS) material on the fracture behavior of prosthetic crowns. Restorations were fabricated using a metal die simulating a prepared tooth. Four groups were evaluated: YZ-C, Y-TZP (In-Ceram YZ, Vita) IS produced by CAD-CAM; IZ-C, In-Ceram Zirconia (Vita) IS produced by CAD-CAM; IZ-S, In-Ceram Zirconia (Vita) IS produced by slip-cast; MC, metal IS (control). The IS were veneered with porcelain and resin cemented to fiber-reinforced composite dies. Specimens were loaded in compression to failure using a universal testing machine. The 30° angle load was applied by a spherical piston, in 37°C distilled water. Fractography was performed using stereomicroscope and SEM. Data were statistically analyzed with Anova and Student-Newman-Keuls tests (α=0.05). Significant differences were found between groups (p=0.022). MC showed the highest mean failure load, statistically similar to YZ-C. There was no statistical difference between YZ-C, IZ-C and IZ-S. MC and YZ-C showed no catastrophic failure. IZ-C and IZ-S showed chipping and catastrophic failures. The fracture behavior is similar to reported clinical failures. Considering the ceramic systems evaluated, YZ-C and MC crowns present greater fracture load and a more favorable failure mode than In-Ceram Zirconia crowns, regardless of the fabrication type (CAD-CAM or slip-cast). Copyright © 2014 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Non-specific effect of measles vaccination on overall child mortality in an area of rural India with high vaccination coverage: a population-based case-control study.

PubMed

Kabir, Zubair; Long, Jean; Reddaiah, Vankadara P; Kevany, John; Kapoor, Suresh K

2003-01-01

To determine whether vaccination against measles in a population with sustained high vaccination coverage and relatively low child mortality reduces overall child mortality. In April and May 2000, a population-based, case-control study was conducted at Ballabgarh (an area in rural northern India). Eligible cases were 330 children born between 1 January 1991 and 31 December 1998 who died aged 12-59 months. A programme was used to match 320 controls for age, sex, family size, and area of residence from a birth cohort of 15 578 born during the same time period. The analysis used 318 matched pairs and suggested that children aged 12-59 months who did not receive measles vaccination in infancy were three times more likely to die than those vaccinated against measles. Children from lower caste households who were not vaccinated in infancy had the highest risk of mortality (odds ratio, 8.9). A 27% increase in child mortality was attributable to failure to vaccinate against measles in the study population. Measles vaccine seems to have a non-specific reducing effect on overall child mortality in this population. If true, children in lower castes may reap the greatest gains in survival. The findings should be interpreted with caution because the nutritional status of the children was not recorded and may be a residual confounder. "All-cause mortality" is a potentially useful epidemiological endpoint for future vaccine trials.

Effect of imaging powder and CAD/CAM stone types on the marginal gap of zirconia crowns.

PubMed

Alghazzawi, Tariq F; Al-Samadani, Khalid H; Lemons, Jack; Liu, Perng-Ru; Essig, Milton E; Bartolucci, Alfred A; Janowski, Gregg M

2015-02-01

To compare the marginal gap using different types of die stones and titanium dies with and without powders for imaging. A melamine tooth was prepared and scanned using a laboratory 3-shape scanner to mill a polyurethane die, which was duplicated into different stones (Jade, Lean, CEREC) and titanium. Each die was sprayed with imaging powders (NP, IPS, Optispray, Vita) to form 15 groups. Ten of each combination of stone/titanium and imaging powders were used to mill crowns. A light-bodied impression material was injected into the intaglio surface of each crown and placed on the corresponding die. Each crown was removed, and the monophase material was injected to form a monophase die, which was cut into 8 sections. Digital images were captured using a stereomicroscope to measure marginal gap. Scanning electron microscopy was used to determine the particle size and shape of imaging powders and stones. Marginal gaps ranged from mean (standard deviation) 49.32 to 1.20 micrometers (3.97-42.41 μm). There was no statistical difference (P > .05) in the marginal gap by any combination of stone/titanium and imaging powders. All of the imaging powders had a similar size and rounded shape, whereas the surface of the stones showed different structures. When a laboratory 3-shape scanner is used, all imaging powders performed the same for scanning titanium abutments. However, there was no added value related to the use of imaging powder on die stone. It is recommended that the selection of stone for a master cast be based on the hysical properties. When a laboratory 3-shape scanner is used, the imaging powder is not required for scanning die stone. Whenever scanning titanium implant abutments, select the least expensive imaging powder. Copyright © 2015 American Dental Association. Published by Elsevier Inc. All rights reserved.

Development, fabrication and test of a high purity silica heat shield

NASA Technical Reports Server (NTRS)

Rusert, E. L.; Drennan, D. N.; Biggs, M. S.

1978-01-01

A highly reflective hyperpure ( 25 ppm ion impurities) slip cast fused silica heat shield material developed for planetary entry probes was successfully scaled up. Process development activities for slip casting large parts included green strength improvements, casting slip preparation, aggregate casting, strength, reflectance, and subscale fabrication. Successful fabrication of a one-half scale Saturn probe (shape and size) heat shield was accomplished while maintaining the silica high purity and reflectance through the scale-up process. However, stress analysis of this original aggregate slip cast material indicated a small margin of safety (MS. = +4%) using a factor of safety of 1.25. An alternate hyperpure material formulation to increase the strength and toughness for a greater safety margin was evaluated. The alternate material incorporates short hyperpure silica fibers into the casting slip. The best formulation evaluated has a 50% by weight fiber addition resulting in an 80% increase in flexural strength and a 170% increase in toughness over the original aggregate slip cast materials with comparable reflectance.

Simulation of cracking cores when molding piston components

NASA Astrophysics Data System (ADS)

Petrenko, Alena; Soukup, Josef

2014-08-01

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

Thermal integrity profiling for augered cast-in-place piles - implementation plan.

DOT National Transportation Integrated Search

2017-08-01

This study was the second in a two-part research program focused on assessing the feasibility of using thermal integrity profiling (TIP) as a quality assurance tool for Augered Cast-In-Place (ACIP) piles. This was made possible by coordinating with t...

An Electron Microscopy Study of Graphite Growth in Nodular Cast Irons

NASA Astrophysics Data System (ADS)

Laffont, L.; Jday, R.; Lacaze, J.

2018-04-01

Growth of graphite during solidification and high-temperature solid-state transformation has been investigated in samples cut out from a thin-wall casting which solidified partly in the stable (iron-graphite) and partly in the metastable (iron-cementite) systems. Transmission electron microscopy has been used to characterize graphite nodules in as-cast state and in samples having been fully graphitized at various temperatures in the austenite field. Nodules in the as-cast material show a twofold structure characterized by an inner zone where graphite is disoriented and an outer zone where it is well crystallized. In heat-treated samples, graphite nodules consist of well-crystallized sectors radiating from the nucleus. These observations suggest that the disoriented zone appears because of mechanical deformation when the liquid contracts during its solidification in the metastable system. During heat-treatment, the graphite in this zone recrystallizes. In turn, it can be concluded that nodular graphite growth mechanism is the same during solidification and solid-state transformation.

Crystalline gamma-Al2O3 physical vapour deposition-coating for steel thixoforging tools.

PubMed

Bobzin, K; Hirt, G; Bagcivan, N; Khizhnyakova, L; Ewering, M

2011-10-01

The process of thixoforming, which has been part of many researches during the last decades, combines the advantages of forging and casting for the shaping of metallic components. But due to the high temperatures of semi-solid steel alloys high demands on the tools are requested. To resists the thermal and mechanical loads (wear, friction, thermal and thermomechanical fatigue) protecting thin films are necessary. In this regard crystalline gamma-Al2O3 deposited via Physical Vapour Deposition (PVD) is a promising candidate: It exhibits high thermal stability, high oxidation resistance and high hot hardness. In the present work the application of a (Ti, Al)N/gamma-Al2O3 coating deposited by means of Magnetron Sputter Ion Plating in an industrial coating unit is presented. The coating was analysed by means of Rockwell test, nanoindentation, and Scanning Electron Microscopy (SEM). The coated tool was tested in thixoforging experiments with steel grade X210CrW12 (AlSI D6). The surface of the coated dies was examined with Scanning Electron Microscope (SEM) after 22, 42, 90 and 170 forging cycles.

Fundamental studies on a novel die concept for round-point shear-clinching

NASA Astrophysics Data System (ADS)

Hörhold, Réjane; Müller, Martin; Merklein, Marion; Meschut, Gerson

2016-10-01

A newly-developed round-point shear-clinching technology could increase the use of different materials like well formable aluminium and hardly formable ultra-high-strength steels (UHSS). This innovative technology joins in a single-stage process without any pilot-hole, surface pre-treatment or auxiliary joining part. The combination of an inner and outer punch realises an indirect cutting operation of the die-sided material, whereas the punch-sided material remains unharmed. The current die-sided tool set acts as a cutting die and enables a radial extrusion of the punch-sided material after being drawn though the created hole in the UHSS. The die has a fixed die depth. After ejecting the joined components, the slug has to be removed from the top of the spring-loaded anvil. The novel die concept investigated in this paper offers the possibility to push the slug continuously through the die in the joining direction. The removed slugs remain inside the die, so manual removal is unnecessary. The one-parted tool is supposed to be more robust than the multi-parted one that is currently used. This paper represents the task to evaluate the geometry of a useful shear-clinching die concept. To reduce the experimental effort, FEM should assist the development of the most promising approach. To quantify the success, conventional shear-clinching with opening die acts as a reference. The results show the high potential and the raison d'être of shear-clinching technologies as a mechanical joining technology for future multimaterial applications especially for UHSS.

Evaluation of the fit of zirconia copings fabricated by direct and indirect digital impression procedures.

PubMed

Lee, Bora; Oh, Kyung Chul; Haam, Daewon; Lee, Joon-Hee; Moon, Hong-Seok

2018-02-07

Intraoral scanners are effective for direct digital impression when dental restorations are fabricated using computer-aided design and computer-aided manufacturing (CAD-CAM); however, if the abutment tooth cannot be dried completely or the prepared margin is placed subgingivally, accurate digital images cannot always be guaranteed. The purpose of this in vitro study was to compare the internal and marginal discrepancies of zirconia copings fabricated directly using an intraoral scanner with those fabricated indirectly with impression scanning. Forty-five resin dies fabricated with a 3-dimensional (3D) printer were divided into 3 groups: direct scanning (DS), impression scanning (IMP), and lost-wax casting (LW). For the DS group, a resin die was scanned with an intraoral scanner (Trios; 3Shape), whereas for the IMP group, impressions made with polyether were scanned with a cast scanner (D700; 3Shape). The zirconia copings were fabricated in the same way in the DS and IMP groups. For the LW group, impressions were made in the same way as in the IMP group, and Ni-Cr alloy copings were fabricated using LW. The marginal and internal discrepancies of the copings were measured by cementing them onto resin dies, embedding them in acrylic resin, and sectioning them in a buccolingual direction. The cement layer was measured, and the Kruskal-Wallis test was used to detect significant differences (α=.05). A nonparametric Friedman test was also performed to compare the measurements of each group by location (α=.05). The mean marginal discrepancies in the DS, IMP, and LW groups were 18.1 ±9.8, 23.2 ±17.2, and 32.3 ±18.6 μm (mean ±standard deviation), respectively. The mean internal discrepancies of the DS, IMP, and LW groups in the axial area were 38.0 ±9.1, 47.0 ±16.3, and 36.5 ±15.8 μm, and those in the occlusal area were 36.7 ±16.9, 33.4 ±21.6, and 44.5 ±31.9 μm, respectively. No statistically significant differences were found in marginal or internal discrepancies among groups (P>.05). Within the limitations of this study, the zirconia copings fabricated with CAD-CAM using different digitization methods and Ni-Cr copings fabricated using the lost-wax technique and casting produced clinically acceptable marginal and internal discrepancies. No significant differences were found among the DS, IMP, and LW groups. Copyright © 2017 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

Life Expectancy Can Explain the Precocity-Longevity Hypothesis Association of Early Career Success and Early Death.

PubMed

McCann, Stewart J H

2015-01-01

The precocity-longevity hypothesis that those who reach career milestones earlier in life have shorter life spans was tested with the 430 men elected to serve in the House of Representatives for the 71st U.S. Congress in 1929-1930 who were alive throughout 1930. There was no tendency for those first serving at an earlier age to die sooner or those serving first at a later age to die later than expected based on individual life expectancy in 1930. Although age at first serving was correlated with death age, the correlation was not significant when expected death age was controlled. The results cast serious doubt on the contention of the precocity-longevity hypothesis that the developmental aspects of the prerequisites, concomitants, and consequences of early career achievement peaks actively enhance the conditions for an earlier death.

The Dying Role: Its Relevance to Improved Patient Care.

PubMed

Noyes, Russell; Clancy, John

2016-01-01

SOCIETY is failing to meet the obligation it has to its dying members. Persons with terminal illnesses suffer isolation and neglect in hospitals, receive overzealous treatment by physicians, and are kept in ignorance of their situation by families and medical personnel. Evidence for these statements has come from observers of the medical care system and from dying patients themselves (Kübler-Ross, 1969; Reynolds and Kalish, 1974; Sudnow, 1967). In the nineteenth century it was common for persons to die in the familiar environs of their homes, surrounded by grieving families from whom they parted in a meaningful manner (Blauner, 1966). Dying persons of today no longer fill a well-defined social role. Instead, the distinction between the roles of sick and dying persons has been lost and, in the resulting confusion, the care of dying people has suffered. The purpose of this article is to clarify the distinction between the dying and sick roles, identify the signs of existing role confusion, suggest ways in which this confusion may be corrected, and show how reestablishment of the dying role can result in improved care of dying people. The important part physicians play in defining sick and dying roles will be emphasized.

The Effect of Casting Ring Liner Length and Prewetting on the Marginal Adaptation and Dimensional Accuracy of Full Crown Castings.

PubMed

Haralur, Satheesh B; Hamdi, Osama A; Al-Shahrani, Abdulaziz A; Alhasaniah, Sultan

2017-01-01

To evaluate the effect of varying cellulose casting ring liner length and its prewetting on the marginal adaptation and dimensional accuracy of full veneer metal castings. The master die was milled in stainless steel to fabricate the wax pattern. Sixty wax patterns were fabricated with a uniform thickness of 1.5 mm at an occlusal surface and 1 mm axial surface, cervical width at 13.5 mm, and 10 mm cuspal height. The samples were divided into six groups ( n = 10). Groups I and II samples had the full-length cellulose prewet and dry ring liner, respectively. The groups III and IV had 2 mm short prewet and dry cellulose ring liner, respectively, whereas groups V and VI were invested in 6 mm short ring liner. The wax patterns were immediately invested in phosphate bonded investment, and casting procedure was completed with nickel-chrome alloy. The castings were cleaned and mean score of measurements at four reference points for marginal adaption, casting height, and cervical width was calculated. The marginal adaption was calculated with Imaje J software, whereas the casting height and cervical width was determined using a digital scale. The data was subjected to one-way analysis of varaince and Tukey post hoc statistical analysis with Statistical Package for the Social Sciences version 20 software. The group II had the best marginal adaption with a gap of 63.786 μm followed by group I (65.185 μm), group IV (87.740 μm), and group III (101.455 μm). A large marginal gap was observed in group V at 188.871 μm. Cuspal height was more accurate with group V (10.428 mm), group VI (10.421 mm), and group II (10.488 mm). The cervical width was approximately similar in group I, group III, and group V. Statistically significant difference was observed in Tukey post hoc analysis between group V and group VI with all the other groups with regards to marginal adaptation. The dry cellulose ring liners provided better marginal adaptation in comparison to prewet cellulose ring liners. Accurate cuspal height was obtained with shorter ring liner in comparison to full-length cellulose ring liners.

The Effect of Casting Ring Liner Length and Prewetting on the Marginal Adaptation and Dimensional Accuracy of Full Crown Castings

PubMed Central

Haralur, Satheesh B.; Hamdi, Osama A.; Al-Shahrani, Abdulaziz A.; Alhasaniah, Sultan

2017-01-01

Aim: To evaluate the effect of varying cellulose casting ring liner length and its prewetting on the marginal adaptation and dimensional accuracy of full veneer metal castings. Materials and Methods: The master die was milled in stainless steel to fabricate the wax pattern. Sixty wax patterns were fabricated with a uniform thickness of 1.5 mm at an occlusal surface and 1 mm axial surface, cervical width at 13.5 mm, and 10 mm cuspal height. The samples were divided into six groups (n = 10). Groups I and II samples had the full-length cellulose prewet and dry ring liner, respectively. The groups III and IV had 2 mm short prewet and dry cellulose ring liner, respectively, whereas groups V and VI were invested in 6 mm short ring liner. The wax patterns were immediately invested in phosphate bonded investment, and casting procedure was completed with nickel-chrome alloy. The castings were cleaned and mean score of measurements at four reference points for marginal adaption, casting height, and cervical width was calculated. The marginal adaption was calculated with Imaje J software, whereas the casting height and cervical width was determined using a digital scale. The data was subjected to one-way analysis of varaince and Tukey post hoc statistical analysis with Statistical Package for the Social Sciences version 20 software. Results: The group II had the best marginal adaption with a gap of 63.786 μm followed by group I (65.185 μm), group IV (87.740 μm), and group III (101.455 μm). A large marginal gap was observed in group V at 188.871 μm. Cuspal height was more accurate with group V (10.428 mm), group VI (10.421 mm), and group II (10.488 mm). The cervical width was approximately similar in group I, group III, and group V. Statistically significant difference was observed in Tukey post hoc analysis between group V and group VI with all the other groups with regards to marginal adaptation. Conclusion: The dry cellulose ring liners provided better marginal adaptation in comparison to prewet cellulose ring liners. Accurate cuspal height was obtained with shorter ring liner in comparison to full-length cellulose ring liners. PMID:28316950

Repair welding of cast iron coated electrodes

NASA Astrophysics Data System (ADS)

Żuk, M.; Górka, J.; Dojka, R.; Czupryński, A.

2017-08-01

Welding cast iron is a complex production procedure. Repair welding was used to repair damaged or poorly made castings. This is due to a tendency to cracking of the material during welding as well as after it. Welding cast iron can be carried out on hot or on cold. Hot welding requires high heat material and the use of welding material in the form of cast iron. In the case of cold welding, it is possible to use different materials. Mostly used filler metals are nickel and copper based. The work shows the course of research concerning repairmen of ductile iron with arc welding method. For the reparation process four types of ESAB company coated electrodes dedicated for cast iron were used with diameter 3.2 and 4 mm: ES 18-8-6B (4mm), EB 150 (4mm), OK NiCl, EŻM. In the cast iron examined during the testing grooves were made using plasma methods, in order to simulate the removed casting flaws. Then the welding process with coated electrodes was executed. The process utilized low welding current row of 100A, so there would only be a small amount of heat delivered to the heat affected zone (HAZ). Short stitches were made, after welding it was hammered, in order to remove stresses. After the repair welding the part of studies commenced which purpose was finding surface defects using visual testing (VT) and penetration testing (PT). In the second part, a series of macro and microscopic studies were executed witch the purpose of disclosuring the structure. Then the hardness tests for welds cross sections were performed. An important aspect of welding cast iron is the colour of the padding weld after welding, more precisely the difference between the base material and padding weld, the use of different materials extra gives the extra ability to select the best variant. The research of four types of coated electrode was executed, based on the demands the best option in terms of aesthetic, strength and hardness.

42 CFR 414.106 - Splints and casts.

Code of Federal Regulations, 2014 CFR

2014-10-01

... 42 Public Health 3 2014-10-01 2014-10-01 false Splints and casts. 414.106 Section 414.106 Public Health CENTERS FOR MEDICARE & MEDICAID SERVICES, DEPARTMENT OF HEALTH AND HUMAN SERVICES (CONTINUED) MEDICARE PROGRAM (CONTINUED) PAYMENT FOR PART B MEDICAL AND OTHER HEALTH SERVICES Fee Schedules for...

Three-Dimensional Computed Tomography as a Method for Finding Die Attach Voids in Diodes

NASA Technical Reports Server (NTRS)

Brahm, E. N.; Rolin, T. D.

2010-01-01

NASA analyzes electrical, electronic, and electromechanical (EEE) parts used in space vehicles to understand failure modes of these components. The diode is an EEE part critical to NASA missions that can fail due to excessive voiding in the die attach. Metallography, one established method for studying the die attach, is a time-intensive, destructive, and equivocal process whereby mechanical grinding of the diodes is performed to reveal voiding in the die attach. Problems such as die attach pull-out tend to complicate results and can lead to erroneous conclusions. The objective of this study is to determine if three-dimensional computed tomography (3DCT), a nondestructive technique, is a viable alternative to metallography for detecting die attach voiding. The die attach voiding in two- dimensional planes created from 3DCT scans was compared to several physical cross sections of the same diode to determine if the 3DCT scan accurately recreates die attach volumetric variability

Cast Metals Coalition Technology Transfer and Program Management Final Report

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

Gwyn, Mike

2009-03-31

The Cast Metals Coalition (CMC) partnership program was funded to ensure that the results of the Department of Energy's (DOE) metalcasting research and development (R&D) projects are successfully deployed into industry. Specifically, the CMC program coordinated the transfer and deployment of energy saving technologies and process improvements developed under separately funded DOE programs and projects into industry. The transition of these technologies and process improvements is a critical step in the path to realizing actual energy savings. At full deployment, DOE funded metalcasting R&D results are projected to save 55% of the energy used by the industry in 1998. Thismore » closely aligns with DOE's current goal of driving a 25% reduction in industrial energy intensity by 2017. In addition to benefiting DOE, these energy savings provide metalcasters with a significant economic advantage. Deployment of already completed R&D project results and those still underway is estimated to return over 500% of the original DOE and industry investment. Energy savings estimates through December 2008 from the Energy-Saving Melting and Revert Reduction Technology (E-SMARRT) portfolio of projects alone are 12 x 1012 BTUs, with a projection of over 50 x 1012 BTUs ten years after program completion. These energy savings and process improvements have been made possible through the unique collaborative structure of the CMC partnership. The CMC team consists of DOE's Office of Industrial Technology, the three leading metalcasting technical societies in the U.S: the American Foundry Society; the North American Die Casting Association; and the Steel Founders Society of America; and the Advanced Technology Institute (ATI), a recognized leader in distributed technology management. CMC provides collaborative leadership to a complex industry composed of approximately 2,100 companies, 80% of which employ less than 100 people, and only 4% of which employ more than 250 people. Without collaboration, 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.« less

New sulphiding method for steel and cast iron parts

NASA Astrophysics Data System (ADS)

Tarelnyk, V.; Martsynkovskyy, V.; Gaponova, O.; Konoplianchenko, Ie; Dovzyk, M.; Tarelnyk, N.; Gorovoy, S.

2017-08-01

A new method for sulphiding steel and cast iron part surfaces by electroerosion alloying (EEA) with the use of a special electrode is proposed, which method is characterized in that while manufacturing the electrode, on its surface, in any known manner (punching, threading, pulling, etc.), there is formed at least a recess to be filled with sulfur as a consistent material, and then there is produced EEA by the obtained electrode without waiting for the consistent material to become dried.

Solidification Based Grain Refinement in Steels

DTIC Science & Technology

2011-09-27

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

Magnesium Front End Research and Development: A Canada-China-USA Collaboration

NASA Astrophysics Data System (ADS)

Luo, Alan A.; Nyberg, Eric A.; Sadayappan, Kumar; Shi, Wenfang

The Magnesium Front End Research & Development (MFERD) project is an effort jointly sponsored by the United States Department of Energy, the United States Automotive Materials Partnership (USAMP), the Chinese Ministry of Science and Technology and Natural Resources Canada (NRCan) to demonstrate the technical and economic feasibility of a magnesium-intensive automotive front end body structure which offers improved fuel economy and performance benefits in a multi-material automotive structure. The project examines novel magnesium automotive body applications and processes, beyond conventional die castings, including wrought components (sheet or extrusions) and high-integrity body castings. This paper outlines the scope of work and organization for the collaborative (tri-country) task teams. The project has the goals of developing key enabling technologies and knowledge base for increased magnesium automotive body applications. The MFERD project began in early 2007 by initiating R&D in the following areas: crashworthiness, NVH, fatigue and durability, corrosion and surface finishing, extrusion and forming, sheet and forming, high-integrity body casting, as well as joining and assembly. Additionally, the MFERD project is also linked to the Integrated Computational Materials Engineering (ICME) project that will investigate the processing/structure/properties relations for various magnesium alloys and manufacturing processes utilizing advanced computer-aided engineering and modeling tools.

Casting and Angling.

ERIC Educational Resources Information Center

Little, Mildred J.; Bunting, Camille

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

Spotted black snake (Pseudechis guttatus) envenomation in a maned wolf (Chrysocyon brachyurus).

PubMed

Portas, Timothy J; Montali, Richard J

2007-09-01

Envenomation by a spotted black snake (Pseudechis guttatus), following multiple bites on the buccal mucosa of a captive maned wolf (Chrysocyon brachyurus), caused the animal's collapse, hemolysis, rhabdomyolysis, local tissue necrosis, hepatic and renal failure, and subsequent death. The wolf died despite intensive supportive care including antivenom administration, fluid support, and a blood transfusion. Gross necropsy findings included myocardial and intestinal hemorrhage, pulmonary congestion, hepatomegaly, and splenomegaly. Microscopic examination of formalin-fixed tissues demonstrated pulmonary and abdominal visceral hemorrhage, acute nephrosis with casts, multifocal hepatic necrosis, and splenic congestion.

Mechanical joining of materials with limited ductility: Analysis of process-induced defects

NASA Astrophysics Data System (ADS)

Jäckel, M.; Coppieters, S.; Hofmann, M.; Vandermeiren, N.; Landgrebe, D.; Debruyne, D.; Wallmersberger, T.; Faes, K.

2017-10-01

The paper shows experimental and numerical analyses of the clinching process of 6xxx series aluminum sheets in T6 condition and the self-pierce riveting process of an aluminum die casting. In the experimental investigations the damage behavior of the materials when using different tool parameters is analyzed. The focus of the numerical investigations is the damage prediction by a comparison of different damage criteria. Moreover, strength-and fatigue tests were carried out to investigate the influence of the joining process-induced damages on the strength properties of the joints.

Research keeps lead and zinc viable in high-tech markets

NASA Astrophysics Data System (ADS)

Cole, Jerome F.

1989-08-01

Lead and zinc have long enjoyed widespread use in a variety of applications. To insure growing markets for the future, however, new applications for these durable metals must be developed. Currently, projects are underway to determine the capabilities of lead for such high-technology uses as earthquake damping and nuclear waste containment. Zinc's capabilities are being developed further, too, particularly in the areas of direct injection die casting, composites and the improvement of coating properties. Other ongoing research initiatives are attempting to better determine the health and environmental influences of these metals.

Effect of second to first normal stress difference ratio at the die exit on neck-in phenomenon in polymeric flat film production

NASA Astrophysics Data System (ADS)

Barborik, Tomas; Zatloukal, Martin

2017-05-01

In this study, viscoelastic modeling of the extrusion film casting process, based on the lD membrane model and modified Leonov constitutive equation, was conducted and the effect of the viscoelastic stress state at the die exit (captured here via second to first normal stress difference ratio) on the unwanted neck-in phenomenon has been analyzed for wide range of Deborah numbers and materials having different level of uniaxial and planar extensional strain hardening. Relevant experimental data for LDPE and theoretical predictions based on multimode eXtended Pom-Pom model acquired from the open literature were used for the validation purposes. It was found that firstly, the predicting capabilities of both constitutive equations for given material and processing conditions are comparable even if the single mode modified Leonov model was used and secondly, the agreement between theoretical and experimental data on neck-in is fairly good. Results of the theoretical study revealed that the viscoelastic stress state at the die exit (i.e. -N2/N1 ratio) increases the level of neck-in if uniaxial extensional strain hardening, planar to uniaxial extensional viscosity ratio and Deborah number increases. It has also been revealed that there exists threshold value for Deborah number and extensional strain hardening below which the neck-in becomes independent on the die exit stress state.

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

NASA Technical Reports Server (NTRS)

Shah, Sandeep; Lee, Jonathan; Bhat, Biliyar; Wells, Doug; Gregg, Wayne; Marsh, Matthew; Genge, Gary; Forbes, John; Salvi, Alex; Cornie, James A.;

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

NASA Technical Reports Server (NTRS)

Shah, Sandeep; Lee, Jonathan; Bhat, Biliyar; Wells, Doug; Gregg, Wayne; Marsh, Matthew; Genge, Gary; Forbes, John; Salvi, Alex; Cornie, James A.;

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-less Net-Shape Pressure Infiltration Casting Technology

NASA Technical Reports Server (NTRS)

Shah, Sandeep; Lee, Jonathan; Bhat, Biliyar; Wells, Doug; Gregg, Wayne; Marsh, Matthew; Genge, Gary; Forbes, John; Salvi, Alex; Cornie, James A.;

Quantitative evaluation of hidden defects in cast iron components using ultrasound activated lock-in vibrothermography.

PubMed

Montanini, R; Freni, F; Rossi, G L

2012-09-01

This paper reports one of the first experimental results on the application of ultrasound activated lock-in vibrothermography for quantitative assessment of buried flaws in complex cast parts. The use of amplitude modulated ultrasonic heat generation allowed selective response of defective areas within the part, as the defect itself is turned into a local thermal wave emitter. Quantitative evaluation of hidden damages was accomplished by estimating independently both the area and the depth extension of the buried flaws, while x-ray 3D computed tomography was used as reference for sizing accuracy assessment. To retrieve flaw's area, a simple yet effective histogram-based phase image segmentation algorithm with automatic pixels classification has been developed. A clear correlation was found between the thermal (phase) signature measured by the infrared camera on the target surface and the actual mean cross-section area of the flaw. Due to the very fast cycle time (<30 s/part), the method could potentially be applied for 100% quality control of casting components.

A comparison between three different pit and fissure sealants with regard to marginal integrity.

PubMed

Fernandes, Kristlee Sabrin; Chalakkal, Paul; de Ataide, Ida de Noronha; Pavaskar, Rajdeep; Fernandes, Precylia Philo; Soni, Harleen

2012-04-01

THE AIM OF THIS STUDY IS TO COMPARE THE OCCURRENCE OF ENAMEL FRACTURES, SEALANT FRACTURES AND MARGINAL FISSURES AFTER PLACEMENT OF THREE SEALANTS: Helioseal F, Conseal F and Clinpro. Thirty individuals between 13 and 15 years of age, diagnosed with pit and fissure caries by visual and DIAGNOdent examination, were chosen for sealant placement on their mandibular molars. The sealants were placed at random, after which, impressions were made with polyvinyl siloxane and casts were fabricated. Dies were prepared, each of which were sputter coated with gold in order to be examined under a scanning electron microscope. The following morphologies were analyzed from dies from each of the sealant groups: Continuous margins, sealant fractures, marginal fissures and enamel fractures. After six months, they were recalled for impression making. Dies were prepared and microscopically analyzed as mentioned. Based on the time of evaluation, there were two groups: Initial group (soon after placement) and final group (after six months). Statistical analysis was done using the paired 't' test and One-way analysis of variance (ANOVA). Clinpro had the greatest fracture resistance, followed by Conseal F and Helioseal F. The occurrence of marginal fissure was found to be least with Clinpro.

Prediction of Shrinkage Porosity Defect in Sand Casting Process of LM25

NASA Astrophysics Data System (ADS)

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

2017-08-01

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

Micro-structure and Air-tightness of Squeeze Casting Motor housing for New Energy Vehicle

NASA Astrophysics Data System (ADS)

Jiang, Y. F.; Kang, Z. Q.; Jiang, W. F.; Wang, K. W.; Sha, D. L.; Li, M. L.; Sun, J.

2018-05-01

In order to improve the performance of automobile parts, the influence of squeeze casting process parameters on casting defects, material structure and air-tightness of aluminum alloy motor housing for new energy vehicle was studied. The results show that the density of the castings increases with the increase in pressure and mold temperature. With increase in pouring temperature, it increases first and then decreases. Pressure has the greatest influence on the density of the castings. Under a certain pressure, with moderate increase in casting temperature and mold temperature, the grain growth begins to increase; the dendrites become less, the new α - Al grains are spherical and granular, the micro-structure is uniform. Also, with increase in pressure, this effect is more pronounced, the air-tightness of castings improve. In conclusion, when the pressure is 110MPa, pouring temperature is 680° C, mold temperature is 280° C, pressure holding for 30s, and punch speed of 0.1m/s, there is no clear shrinkage in the casting, the structure is uniform, the qualified rate of air-tightness of production reaches 86%, and the performance is excellent.

Development of casting investment preventing blackening of noble metal alloys part 1. Application of developed investment for Ag-Pd-Cu-Au alloy.

PubMed

Kakuta, Kiyoshi; Nakai, Akira; Goto, Shin-ichi; Wakamatsu, Yasushi; Yara, Atushi; Miyagawa, Yukio; Ogura, Hideo

2003-03-01

The objective of this study is to develop a casting investment that prevents the blackening of the cast surface of noble metal alloys. The experimental investments were prepared using a gypsum-bonded investment in which the metallic powders such as boron (B), silicon (Si), aluminum (Al) and titanium (Ti) were added as oxidizing agents. An Ag-Pd-Cu-Au alloy was cast into the mold made of the prepared investment. The effect of the addition of each metal powder was evaluated from the color difference between the as-cast surface and the polished surface of the cast specimen. The color of the as-cast surface approached that of the polished surface with increasing B and Al content. A lower mean value in the color difference was obtained at 0.25-1.00 mass% B content. B and Al are useful as an additive in a gypsum-bonded investment to prevent the blackening of an Ag-Pd-Cu-Au alloy. The effects of Si and Ti powder addition could not be found.

Laser welding of removable partial denture frameworks.

PubMed

Brudvik, James S; Lee, Seungbum; Croshaw, Steve N; Reimers, Donald L; Reimers, Dave L

2008-01-01

To identify and measure distortions inherent in the casting process of a Class III mandibular cobalt-chromium (Co-Cr) framework to illustrate the problems faced by the laboratory technician and the clinician and to measure the changes that occur during the correction of the fit discrepancy using laser welding. Five identical castings of a Co-Cr alloy partial denture casting were made and measured between 3 widely separated points using the x, y, and z adjustments of a Nikon Measurescope. The same measurements were made after each of the following clinical and laboratory procedures: sprue removal, sectioning of the casting into 3 parts through the posterior meshwork, fitting the segments to the master cast, picking up the segments using resin, and laser welding of the 3 segments. Measurements of all 5 castings showed a cross-arch decrease after sprue removal, an increase after fitting the segments to the master cast, and a slight decrease after resin pickup and laser welding. Within the limitations of this study, the findings suggest that precise tooth-frame relations can be established by resin pickup and laser welding of segments of Co-Cr removable partial denture frameworks.

Capillarity theory for the fly-casting mechanism

PubMed Central

Trizac, Emmanuel; Levy, Yaakov; Wolynes, Peter G.

2010-01-01

Biomolecular folding and function are often coupled. During molecular recognition events, one of the binding partners may transiently or partially unfold, allowing more rapid access to a binding site. We describe a simple model for this fly-casting mechanism based on the capillarity approximation and polymer chain statistics. The model shows that fly casting is most effective when the protein unfolding barrier is small and the part of the chain which extends toward the target is relatively rigid. These features are often seen in known examples of fly casting in protein–DNA binding. Simulations of protein–DNA binding based on well-funneled native-topology models with electrostatic forces confirm the trends of the analytical theory. PMID:20133683

Evaluation of marginal and internal gap of three-unit metal framework according to subtractive manufacturing and additive manufacturing of CAD/CAM systems.

PubMed

Kim, Dong-Yeon; Kim, Eo-Bin; Kim, Hae-Young; Kim, Ji-Hwan; Kim, Woong-Chul

2017-12-01

To evaluate the fit of a three-unit metal framework of fixed dental prostheses made by subtractive and additive manufacturing. One master model of metal was fabricated. Twenty silicone impressions were made on the master die, working die of 10 poured with Type 4 stone, and working die of 10 made of scannable stone. Ten three-unit wax frameworks were fabricated by wax-up from Type IV working die. Stereolithography files of 10 three-unit frameworks were obtained using a model scanner and three-dimensional design software on a scannable working die. The three-unit wax framework was fabricated using subtractive manufacturing (SM) by applying the prepared stereolithography file, and the resin framework was fabricated by additive manufacturing (AM); both used metal alloy castings for metal frameworks. Marginal and internal gap were measured using silicone replica technique and digital microscope. Measurement data were analyzed by Kruskal-Wallis H test and Mann-Whitney U-test (α=.05). The lowest and highest gaps between premolar and molar margins were in the SM group and the AM group, respectively. There was a statistically significant difference in the marginal gap among the 3 groups ( P <.001). In the marginal area where pontic was present, the largest gap was 149.39 ± 42.30 µm in the AM group, and the lowest gap was 24.40 ± 11.92 µm in the SM group. Three-unit metal frameworks made by subtractive manufacturing are clinically applicable. However, additive manufacturing requires more research to be applied clinically.

Heat Treatment Development for a Rapidly Solidified Heat Resistant Cast Al-Si Alloy

NASA Astrophysics Data System (ADS)

Kasprzak, W.; Chen, D. L.; Shaha, S. K.

2013-07-01

Existing heat treatment standards do not properly define tempers for thin-walled castings that solidified with high solidification rates. Recently emerged casting processes such as vacuum high pressure die casting should not require long solution treatment times due to the fine microstructures arising from rapid solidification rates. The heat treatment studies involving rapidly solidified samples with secondary dendrite arm spacing between 10 and 35 μm were conducted for solution times between 30 min and 9 h and temperatures of 510 and 525 °C and for various aging parameters. The metallurgical analysis revealed that an increase in microstructure refinement could enable a reduction of solution time up to 88%. Solution treatment resulted in the dissolution of Al2Cu and Al5Mg8Si6Cu2, while Fe- and TiZrV-based phases remained partially in the microstructure. The highest strength of approximately 351 ± 9.7 and 309 ± 3.4 MPa for the UTS and YS, respectively, was achieved for a 2-step solution treatment at 510 and 525 °C in the T6 peak aging conditions, i.e., 150 °C for 100 h. The T6 temper did not yield dimensionally stable microstructure since exceeding 250 °C during in-service operation could result in phase transformation corresponding to the over-aging reaction. The microstructure refinement had a statistically stronger effect on the alloy strength than the increase in solutionizing time. Additionally, thermal analysis and dilatometer results were presented to assess the dissolution of phases during solution treatment, aging kinetics as well as dimensional stability.

CASTING DEFECT MODELING IN AN INTEGRATED COMPUTATIONAL MATERIALS ENGINEERING APPROACH

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

Sabau, Adrian S

2015-01-01

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

Development of casting investment preventing blackening of noble metal alloys Part 2. Application of developed investment for type 4 gold alloy.

PubMed

Nakai, Akira; Kakuta, Kiyoshi; Goto, Shin-ichi; Kato, Katuma; Yara, Atushi; Ogura, Hideo

2003-09-01

The objective of this study was to evaluate the efficacy of the developed investment for the prevention of blackening of a cast Type 4 gold and to analyze the oxides on its surface in relation to the blackening of the alloy. The experimental investments were prepared using a gypsum-bonded investment in which boron (B) or aluminum (Al) was added as a reducing agent. A Type 4 gold alloy was cast into the mold made of the prepared investment. The effect of the additives was evaluated from the color difference (deltaE*) between the as-cast surface and the polished surface of the cast specimen. B and Al were effective to prevent the blackening of a Type 4 gold alloy and the color of the as-cast surface approached that of the polished surface with increasing B and Al content. The prevention of the blackening of the gold alloy can be achieved by restraining the formation of CuO.

Manufacture of gradient micro-structures of magnesium alloys using two stage extrusion dies

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

Hwang, Yeong-Maw; Huang, Tze-Hui; Alexandrov, Sergei

2013-12-16

This paper aims to manufacture magnesium alloy metals with gradient micro-structures using hot extrusion process. The extrusion die was designed to have a straight channel part combined with a conical part. Materials pushed through this specially-designed die generate a non-uniform velocity distribution at cross sections inside the die and result in different strain and strain rate distributions. Accordingly, a gradient microstructure product can be obtained. Using the finite element analysis, the forming temperature, effective strain, and effective strain rate distributions at the die exit were firstly discussed for various inclination angles in the conical die. Then, hot extrusion experiments withmore » a two stage die were conducted to obtain magnesium alloy products with gradient micro-structures. The effects of the inclination angle on the grain size distribution at cross sections of the products were also discussed. Using a die of an inclination angle of 15°, gradient micro-structures of the grain size decreasing gradually from 17 μm at the center to 4 μm at the edge of product were achieved.« less

Toxicity Screening of the ToxCast Phase II Chemical Library Using a Zebrafish Developmental Assay (SOT)

EPA Science Inventory

As part of the chemical screening and prioritization research program of the US EPA, the ToxCast Phase II chemicals were assessed using a vertebrate screen for developmental toxicity. Zebrafish embryos (Danio rerio) were exposed in 96-well plates from late-blastula stage (6hr pos...

Development of Aerogel Molds for Metal Casting Using Lunar and Martian Regolith

NASA Technical Reports Server (NTRS)

2003-01-01

In the last few years NASA has set new priorities for research and development of technologies necessary to enable long-term presence on the Moon and Mars. Among these key technologies is what is known as in situ resource utilization, which defines all conceivable usage of mineral, liquid, gaseous, or biological resources on a visited planet. In response to this challenge, we have been focusing on developing and demonstrating the manufacturing of a specific product using Lunar and Martian soil simulants (i.e., a mold for the casting of metal and alloy parts) which will be an indispensable tool for the survival of outposts on the Moon and Mars. In addition, our purpose is to demonstrate the feasibility of using mesoporous materials such as aerogels to serve as efficient casting molds for high quality components in propulsion and other aerospace applications. The first part of the project consists of producing aerogels from the in situ resources available in Martian and Lunar soil. The approach we are investigating is to use chemical processes to solubilize silicates using organic reagents at low temperatures and then use these as precursors in the formation of aerogels for the fabrication of metal casting molds. One set of experiments consists of dissolving silica sources in basic ethylene glycol solution to form silicon glycolates. When ground silica aerogel was used as source material, a clear solution of silicon glycolate was obtained and reacted to form a gel thus proving the feasibility of this approach. The application of this process to Lunar and Martian simulants did not result in the formation of a gel; further study is in progress. In the second method acidified alcohol is reacted with the simulants to form silicate esters. Preliminary results indicate the presence of silicon alkoxide in the product distillation. However, no gel has been obtained so further characterization is ongoing. In the second part of the project, the focus has been on developing a series of aerogel plates suitable for thin plate metal casting and ingot metal castings. The influence of aerogels on thin wall metal castings was studied by placing aerogel plates into the cavities of thin sections of resin bonded sand molds. An 1 based commercial alloy ( 356) containing 7 percent Si was poured into these molds. Post-solidification studies provide evidence that aerogel inserts significantly reduce the cooling rate during solidification. The advantage of a lower rate using aerogel inserts was reflected in the reduction of casting defects such as shrinkage porosity. Quantitative results support the hypothesis that using aerogels as a mold material can offer definite advantages when used as casting thin sections. As a separate effort, silica aerogel with cylindrical cavities have been prepared and will be evaluated for casting commercial alloys.

Non-specific effect of measles vaccination on overall child mortality in an area of rural India with high vaccination coverage: a population-based case-control study.

PubMed Central

Kabir, Zubair; Long, Jean; Reddaiah, Vankadara P.; Kevany, John; Kapoor, Suresh K.

2003-01-01

OBJECTIVE: To determine whether vaccination against measles in a population with sustained high vaccination coverage and relatively low child mortality reduces overall child mortality. METHODS: In April and May 2000, a population-based, case-control study was conducted at Ballabgarh (an area in rural northern India). Eligible cases were 330 children born between 1 January 1991 and 31 December 1998 who died aged 12-59 months. A programme was used to match 320 controls for age, sex, family size, and area of residence from a birth cohort of 15 578 born during the same time period. FINDINGS: The analysis used 318 matched pairs and suggested that children aged 12-59 months who did not receive measles vaccination in infancy were three times more likely to die than those vaccinated against measles. Children from lower caste households who were not vaccinated in infancy had the highest risk of mortality (odds ratio, 8.9). A 27% increase in child mortality was attributable to failure to vaccinate against measles in the study population. CONCLUSION: Measles vaccine seems to have a non-specific reducing effect on overall child mortality in this population. If true, children in lower castes may reap the greatest gains in survival. The findings should be interpreted with caution because the nutritional status of the children was not recorded and may be a residual confounder. "All-cause mortality" is a potentially useful epidemiological endpoint for future vaccine trials. PMID:12764490

Design and optimization of the micro-engine turbine rotor manufacturing using the rapid prototyping technology

NASA Astrophysics Data System (ADS)

Vdovin, R. A.; Smelov, V. G.

2017-02-01

This work describes the experience in manufacturing the turbine rotor for the micro-engine. It demonstrates the design principles for the complex investment casting process combining the use of the ProCast software and the rapid prototyping techniques. At the virtual modelling stage, in addition to optimized process parameters, the casting structure was improved to obtain the defect-free section. The real production stage allowed demonstrating the performance and fitness of rapid prototyping techniques for the manufacture of geometrically-complex engine-building parts.

Wide Strip Casting Technology of Magnesium Alloys

NASA Astrophysics Data System (ADS)

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

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

Porosity and environment

NASA Technical Reports Server (NTRS)

Piwonka, T. S.

1984-01-01

Significant progress was achieved when it was realized that porosity could be analyzed successfully by considering not only heat flow, but also fluid flow within the solidifying casting. Sound castings may be produced by lowering pressure during melting (to allow dissolved gas to escape the melt) and increasing pressure during solidification (to force liquid metal into the mushy zone to feed shrinkage). Such techniques are especially effective if they are combined with chilling of parts of the casting to produce progressive solidification, which shortens the mushy zone and, hence, the distance that metal must travel to feed porosity.

Manufacturing technology methodology for propulsion system parts

NASA Astrophysics Data System (ADS)

McRae, M. M.

1992-07-01

A development history and a current status evaluation are presented for lost-wax casting of such gas turbine engine components as turbine vanes and blades. The most advanced such systems employ computer-integrated manufacturing methods for high process repeatability, reprogramming versatility, and feedback monitoring. Stereolithography-based plastic model 3D prototyping has also been incorporated for the wax part of the investment casting; it may ultimately be possible to produce the 3D prototype in wax directly, or even to create a ceramic mold directly. Nonintrusive inspections are conducted by X-radiography and neutron radiography.

An innovative method for nondestructive analysis of cast iron artifacts at Hopewell Furnace National Historic Site, Pennsylvania

USGS Publications Warehouse

Sloto, Ronald A.; Martin f. Helmke,

2014-01-01

Sampling cast iron produced by the furnace posed two problems. First, verification that the iron was actually cast at Hopewell Furnace was necessary, as some iron objects found at Hopewell may not have originated there. This was accomplished by using artifacts on display at the Hopewell visitor center (fig. 2). All artifacts on display have been positively attributed to the furnace, and stoves produced by the furnace are easily recognized by the name “Hopewell” cast into them. The second problem was the analysis of the trace metal content of the cast iron, because it was not possible to break off part of a historically important artifact and send it to a laboratory for analysis. This problem was solved when the USGS collaborated with West Chester University, which owns a portable X-ray fluorescence (XRF) spectrometer.

Fit of cast commercially pure titanium and Ti-6Al-4V alloy crowns before and after marginal refinement by electrical discharge machining.

PubMed

Contreras, Edwin Fernando Ruiz; Henriques, Guilherme Elias Pessanha; Giolo, Suely Ruiz; Nobilo, Mauro Antonio Arruda

2002-11-01

Titanium has been suggested as a replacement for alloys currently used in single-tooth restorations and fixed partial dentures. However, difficulties in casting have resulted in incomplete margins and discrepancies in marginal fit. This study evaluated and compared the marginal fit of crowns fabricated from a commercially pure titanium (CP Ti) and from Ti-6Al-4V alloy with crowns fabricated from a Pd-Ag alloy that served as a control. Evaluations were performed before and after marginal refinement by electrical discharge machining (EDM). Forty-five bovine teeth were prepared to receive complete cast crowns. Stone and copper-plated dies were obtained from impressions. Fifteen crowns were cast with each alloy (CP Ti, Ti-6Al-4V, and Pd-Ag). Marginal fit measurements (in micrometers) were recorded at 4 reference points on each casting with a traveling microscope. Marginal refinement with EDM was conducted on the titanium-based crowns, and measurements were repeated. Data were analyzed with the Kruskal-Wallis test, paired t test, and independent t test at a 1% probability level. The Kruskal-Wallis test showed significant differences among mean values of marginal fit for the as-cast CP Ti crowns (mean [SD], 83.9 [26.1] microm) and the other groups: Ti-6Al-4V (50.8 [17.2] microm) and Pd-Ag (45.2 [10.4] microm). After EDM marginal refinement, significant differences were detected among the Ti-6Al-4V crowns (24.5 [10.9] microm) and the other 2 groups: CP Ti (50.6 [20.0] microm) and Pd-Ag (not modified by EDM). Paired t test results indicated that marginal refinement with EDM effectively improved the fit of CP Ti crowns (from 83.9 to 50.6 microm) and Ti-6Al-4V crowns (from 50.8 to 24.5 microm). However, the difference in improvement between the two groups was not significant by t test. Within the limitations of this study, despite the superior results for Ti-6Al-4V, both groups of titanium-based crowns had clinically acceptable marginal fits. After EDM marginal refinement, the fit of cast CP Ti and Ti-6Al-4V crowns improved significantly.

49 CFR 179.220-18 - Bottom outlets.

Code of Federal Regulations, 2011 CFR

2011-10-01

...-shaped breakage groove shall be cut (not cast) in the upper part of the outlet nozzle at a point... nozzle extends below the bottom of the outer shell, a V-shaped breakage groove shall be cut (not cast) in... projection of the bottom outlet equipment may not be more than that allowed by appendix E of the AAR...

Investigation of optimal chemical composition of cast aluminum alloys for vibrational mechanical-chemical polishing and deposition of protective and decorative coatings

NASA Astrophysics Data System (ADS)

Ivanov, V. V.; Popov, S. I.; Kirichek, A. V.

2018-03-01

The article suggests the technology of vibration finishing processing of aluminum alloys with simultaneous coating. On the basis of experimental studies, cast alloys, working media, operating modes of equipment, activating solutions were chosen. The practical application of the developed technology on real parts is shown.

Die Deformation Measurement System during Sheet Metal Forming

NASA Astrophysics Data System (ADS)

Funada, J.; Takahashi, S.; Fukiharu, H.

2011-08-01

In order to reduce affection to the earth environment, it is necessary to lighten the vehicles. For this purpose, high tensile steels are applied. Because of high strength, high forming force is required for producing automotive sheet metal parts. In this situation, since the dies are elastic, they are deformed during forming parts. For reducing die developing period, sheet metal forming simulation is widely applied. In the numerical simulation, rigid dies are usually used for shortening computing time. It means that the forming conditions in the actual forming and the simulation are different. It will make large errors in the results between actual forming and simulation. It can be said that if contact pressure between dies and a sheet metal in the simulation can be reproduced in the actual forming, the differences of forming results between them can also been reduced. The basic idea is to estimate die shape which can produce the same distribution as computed from simulation with rigid dies. In this study, die deformation analyses with Finite Element Method as basic technologies are evaluated. For example, simple shape and actual dies elastic contact problems were investigated. The contact width between simple shape dies was investigated. The computed solutions were in good agreement with experimental results. The one case of the actual dies in two cases was also investigated. Bending force was applied to the blank holder with a mechanical press machine. The methodology shown with applying inductive displacement sensor for measuring die deformation during applying force was also proposed.

Effect of metal selection and porcelain firing on the marginal accuracy of titanium-based metal ceramic restorations.

PubMed

Shokry, Tamer E; Attia, Mazen; Mosleh, Ihab; Elhosary, Mohamed; Hamza, Tamer; Shen, Chiayi

2010-01-01

Titanium is the most biocompatible metal used for dental casting; however, there is concern about its marginal accuracy after porcelain application since this aspect has direct influence on marginal fit. The purpose of this study was to determine the effect that metal selection and the porcelain firing procedure have on the marginal accuracy of metal ceramic prostheses. Cast CP Ti, milled CP Ti, cast Ti-6Al-7Nb, and cast Ni-Cr copings (n=5) were fired with compatible porcelains (Triceram for titanium-based metals and VITA VMK 95 for Ni-Cr alloy). The Ni-Cr alloy fired with its porcelain served as the control. Photographs of metal copings placed on a master die were made. Marginal discrepancy was determined on the photographs using an image processing program at 8 predetermined locations before airborne-particle abrasion for porcelain application, after firing of the opaque layer, and after firing of the dentin layer. Repeated-measures 2-way ANOVA was used to investigate the effect of metal selection and firing stage, and paired t tests were used to determine the effect of each firing stage within each material group (alpha=.05). ANOVA showed that both metal selection and firing stage significantly influenced the measured marginal discrepancy (P<.001), and there was interaction between the 2 variables (P<.001). Student-Newman-Keuls multiple comparison tests showed that there were significant differences between any 2 metals compared, at each stage of measurement. Paired t tests showed that significant changes in marginal discrepancy occurred with opaque firing on milled CP Ti (P=.017) and cast Ti-6Al-7Nb alloy (P=.003). Titanium copings fabricated by CAD/CAM demonstrated the least marginal discrepancy among all groups, while the base metal (Ni-Cr) groups exhibited the most discrepancy of all groups tested. Copyright 2010 The Editorial Council of the Journal of Prosthetic Dentistry. Published by Mosby, Inc. All rights reserved.

Cyp15F1: a novel cytochrome P450 gene linked to juvenile hormone-dependent caste differention in the termite Reticulitermes flavipes.

PubMed

Tarver, Matthew R; Coy, Monique R; Scharf, Michael E

2012-07-01

Termites are eusocial insects that jointly utilize juvenile hormone (JH), pheromones, and other semiochemicals to regulate caste differentiation and achieve caste homeostasis. Prior EST sequencing from the symbiont-free gut transcriptome of Reticulitermes flavipes unexpectedly revealed a number of unique cytochrome P450 (Cyp) transcripts, including fragments of a Cyp15 family gene (Cyp15F1) with homology to other insect Cyp15s that participate in JH biosynthesis. The present study investigated the role of Cyp15F1 in termite caste polyphenism and specifically tested the hypothesis that it plays a role in JH-dependent caste differentiation. After assembling the full-length Cyp15F1 cDNA sequence, we (i) determined its mRNA tissue expression profile, (ii) investigated mRNA expression changes in response to JH and the caste-regulatory primer pheromones γ-cadinene (CAD) and γ-cadinenal (ALD), and (iii) used RNA interference (RNAi) in combination with caste differentiation bioassays to investigate gene function at the phenotype level. Cyp15F1 has ubiquitous whole-body expression (including gut tissue); is rapidly and sustainably induced from 3 h to 48 h by JH, CAD, and ALD; and functions at least in part by facilitating JH-dependent soldier caste differentiation. These findings provide the second example of a termite caste regulatory gene identified through the use of RNAi, and significantly build upon our understanding of termite caste homeostatic mechanisms. These results also reinforce the concept of environmental caste determination in termites by revealing how primer pheromones, as socioenvironmental factors, can directly influence Cyp15 expression and caste differentiation. © 2012 Wiley Periodicals, Inc.

Energy Saving Melting and Revert Reduction Technology (Energy-SMARRT): Light Metals Permanent Mold Casting

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

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 alloymore » 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.« less

Development and utilization of USGS ShakeCast for rapid post-earthquake assessment of critical facilities and infrastructure

USGS Publications Warehouse

Wald, David J.; Lin, Kuo-wan; Kircher, C.A.; Jaiswal, Kishor; Luco, Nicolas; Turner, L.; Slosky, Daniel

2017-01-01

The ShakeCast system is an openly available, near real-time post-earthquake information management system. ShakeCast is widely used by public and private emergency planners and responders, lifeline utility operators and transportation engineers to automatically receive and process ShakeMap products for situational awareness, inspection priority, or damage assessment of their own infrastructure or building portfolios. The success of ShakeCast to date and its broad, critical-user base mandates improved software usability and functionality, including improved engineering-based damage and loss functions. In order to make the software more accessible to novice users—while still utilizing advanced users’ technical and engineering background—we have developed a “ShakeCast Workbook”, a well documented, Excel spreadsheet-based user interface that allows users to input notification and inventory data and export XML files requisite for operating the ShakeCast system. Users will be able to select structure based on a minimum set of user-specified facility (building location, size, height, use, construction age, etc.). “Expert” users will be able to import user-modified structural response properties into facility inventory associated with the HAZUS Advanced Engineering Building Modules (AEBM). The goal of the ShakeCast system is to provide simplified real-time potential impact and inspection metrics (i.e., green, yellow, orange and red priority ratings) to allow users to institute customized earthquake response protocols. Previously, fragilities were approximated using individual ShakeMap intensity measures (IMs, specifically PGA and 0.3 and 1s spectral accelerations) for each facility but we are now performing capacity-spectrum damage state calculations using a more robust characterization of spectral deamnd.We are also developing methods for the direct import of ShakeMap’s multi-period spectra in lieu of the assumed three-domain design spectrum (at 0.3s for constant acceleration; 1s or 3s for constant velocity and constant displacement at very long response periods). As part of ongoing ShakeCast research and development, we will also explore the use of ShakeMap IM uncertainty estimates and evaluate the assumption of employing multiple response spectral damping values rather than the single 5%-damped value currently employed. Developing and incorporating advanced fragility assignments into the ShakeCast Workbook requires related software modifications and database improvements; these enhancements are part of an extensive rewrite of the ShakeCast application.

Rapid manufacturing of metallic Molds for parts in Automobile

NASA Astrophysics Data System (ADS)

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

1998-03-01

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

An innovative method for nondestructive analysis of cast iron artifacts at Hopewell Furnace National Historic Site, Pennsylvania

USGS Publications Warehouse

Sloto, R.A.; Helmke, M.F.

2011-01-01

Iron ore containing elevated concentrations of trace metals was smelted at Hopewell Furnace during its 113 years of operation (1771-1883). For this study, we sampled iron ore, cast iron furnace products, slag, soil, groundwater, streamflow, and streambed sediment to determine the fate of trace metals released into the environment during the iron-smelting process. Standard techniques were used to sample and analyze all media except cast iron. We analyzed the trace-metal content of the cast iron using a portable X-ray fluorescence spectrometer, which provided rapid, on-site, nondestructive analyses for 23 elements. The artifacts analyzed included eight cast iron stoves, a footed pot, and a kettle in the Hopewell Furnace museum. We measured elevated concentrations of arsenic, copper, lead, and zinc in the cast iron. Lead concentrations as great as 3,150 parts per million were measured in the stoves. Cobalt was detectable but not quantifiable because of interference with iron. Our study found that arsenic, cobalt, and lead were not released to soil or slag, which could pose a significant health risk to visitors and employees. Instead, our study demonstrates these heavy metals remained with the cast iron and were removed from the site.

Slip casting and extruding shapes of rhemium with metal oxide additives. Part 2: Development of grain stabilized rhenium parts for resistojets

NASA Technical Reports Server (NTRS)

Barr, Francis A.; Page, Russell J.

1987-01-01

The adaptation of the powdered particle process used for pure metal oxides to the coprocessing of rhenium oxides suitable to produce pure miniature resistojet hardware has been successful. Both slip casting and extrusion processes were used. The metal oxide ZrO2 was stabilized into the cubic phase with Y2O3, for use as a potentially grain stabilizing additive to rhenium. Straight meter long tubing in two sizes are reported. Tubing suitable for resistojet ohmic heater use of fully fired dimensions of nominally 3.8 mm o.d. x 2.2 mm i.d.. and 1.26 mm o.d. x .45 mm i.d. with 0, 0.5, 1.0 and 5.0% zirconia additives were produced for further study. Photomicrographs of these are discussed. The addition of the metal oxide zirconia to rhenium resulted in more dense and less porous parts. The additions of phase stabilized zirconia most likely act as a sintering aid. Tubes of varying diameter were slip cast which were representative of miniature pressure cases.

The use of magnesium in lightweight lithium-ion battery packs

NASA Astrophysics Data System (ADS)

Neelameggham, Neale R.

2009-04-01

The analysis of recently announced battery packs for plug-in hybrid electric vehicles (PHEV) shows that the design of the series-parallel combinations is being over-complicated. The proven energy densities of lithium-ion cells from about 200 Wh/kg are being reduced to 90 Wh/kg. The majority of the weight increase seems to be for thermal management. Simpler battery pack designs based on electro-refining pot rooms using self-contained rectangular lithium-ion cells with air cooling inside of die-cast magnesium cell tanks would help avoid hauling dead weight in PHEV by providing considerable weight reduction.

Resistance against bacterial leakage of four luting agents used for cementation of complete cast crowns.

PubMed

Zmener, Osvaldo; Pameijer, Cornelis H; Hernández, Sandra

2014-02-01

To assess the sealing properties of four luting materials used for cementation of full cast crowns. 40 human premolars were prepared with a chamfer finish line. Stone dies were fabricated and copings were waxed, invested and cast in gold. Ten samples (n = 10) were randomly assigned to four groups. In two groups, resin modified glass-ionomer cements were used, ACTIVA BioACTIVE-CEMENT/BASE/LINER and FujiCem2; the third group received the self-adhesive resin cement Embrace WetBond, while the fourth group served as control with a zinc phosphate cement. After cementation, excess cement was removed followed by bench-set for 10 minutes. All samples were stored in water at 37 degrees C and subjected to thermal cycling (x2000 between 5 and 55 degrees C). Subsequently the occlusal surface was reduced exposing the dentin. After sterilization the specimens were subjected to bacterial microleakage with E. faecalis in a dual chamber apparatus for a period of 60 days. Bacterial leakage was checked daily. Data were analyzed using the Kaplan-Meyer survival test. Significant pairwise differences were analyzed using the Log Rank test and the Fishers' exact test at P < 0.05. ACTIVA BioACTIVE-CEMENT/BASE/LINER, FujiCem2 and Embrace WetBond showed the lowest microleakage scores and differed statistically significantly (P < 0.05) from zinc phosphate cement.

Effect of various putty-wash impression techniques on marginal fit of cast crowns.

PubMed

Nissan, Joseph; Rosner, Ofir; Bukhari, Mohammed Amin; Ghelfan, Oded; Pilo, Raphael

2013-01-01

Marginal fit is an important clinical factor that affects restoration longevity. The accuracy of three polyvinyl siloxane putty-wash impression techniques was compared by marginal fit assessment using the nondestructive method. A stainless steel master cast containing three abutments with three metal crowns matching the three preparations was used to make 45 impressions: group A = single-step technique (putty and wash impression materials used simultaneously), group B = two-step technique with a 2-mm relief (putty as a preliminary impression to create a 2-mm wash space followed by the wash stage), and group C = two-step technique with a polyethylene spacer (plastic spacer used with the putty impression followed by the wash stage). Accuracy was assessed using a toolmaker microscope to measure and compare the marginal gaps between each crown and finish line on the duplicated stone casts. Each abutment was further measured at the mesial, buccal, and distal aspects. One-way analysis of variance was used for statistical analysis. P values and Scheffe post hoc contrasts were calculated. Significance was determined at .05. One-way analysis of variance showed significant differences among the three impression techniques in all three abutments and at all three locations (P < .001). Group B yielded dies with minimal gaps compared to groups A and C. The two-step impression technique with 2-mm relief was the most accurate regarding the crucial clinical factor of marginal fit.

Evolution of Primary Fe-Rich Compounds in Secondary Al-Si-Cu Alloys

NASA Astrophysics Data System (ADS)

Fabrizi, Alberto; Capuzzi, Stefano; Timelli, Giulio

Although iron is usually added in die cast Al-Si foundry alloys to prevent die soldering, primary Fe-rich particles are generally considered as "hardspot" inclusions which compromise the mechanical properties of the alloy, namely ductility and toughness. As there is no economical methods to remove the Fe excess in secondary Al-Si alloys at this time, the control of solidification process and chemical composition of the alloy is a common industrial practice to overcome the negative effects connected with the presence of Fe-rich particles. In this work, the size and morphology as well as the nucleation density of primary Fe-rich particles have been studied as function of cooling rate and alloy chemical composition for secondary Al-Si-Cu alloys. The solidification experiments were carried out using differential scanning calorimetry whereas morphology investigations were conducted using optical and scanning electron microscopy. Mcrosegregations and chemical composition of primary Fe-rich particles were examined by energy dispersive spectroscopy.

Evaluation of marginal and internal gap of three-unit metal framework according to subtractive manufacturing and additive manufacturing of CAD/CAM systems

PubMed Central

Kim, Dong-Yeon; Kim, Eo-Bin; Kim, Hae-Young; Kim, Ji-Hwan

2017-01-01

PURPOSE To evaluate the fit of a three-unit metal framework of fixed dental prostheses made by subtractive and additive manufacturing. MATERIALS AND METHODS One master model of metal was fabricated. Twenty silicone impressions were made on the master die, working die of 10 poured with Type 4 stone, and working die of 10 made of scannable stone. Ten three-unit wax frameworks were fabricated by wax-up from Type IV working die. Stereolithography files of 10 three-unit frameworks were obtained using a model scanner and three-dimensional design software on a scannable working die. The three-unit wax framework was fabricated using subtractive manufacturing (SM) by applying the prepared stereolithography file, and the resin framework was fabricated by additive manufacturing (AM); both used metal alloy castings for metal frameworks. Marginal and internal gap were measured using silicone replica technique and digital microscope. Measurement data were analyzed by Kruskal-Wallis H test and Mann-Whitney U-test (α=.05). RESULTS The lowest and highest gaps between premolar and molar margins were in the SM group and the AM group, respectively. There was a statistically significant difference in the marginal gap among the 3 groups (P<.001). In the marginal area where pontic was present, the largest gap was 149.39 ± 42.30 µm in the AM group, and the lowest gap was 24.40 ± 11.92 µm in the SM group. CONCLUSION Three-unit metal frameworks made by subtractive manufacturing are clinically applicable. However, additive manufacturing requires more research to be applied clinically. PMID:29279766

Caste load and the evolution of reproductive skew.

PubMed

Holman, Luke

2014-01-01

Reproductive skew theory seeks to explain how reproduction is divided among group members in animal societies. Existing theory is framed almost entirely in terms of selection, though nonadaptive processes must also play some role in the evolution of reproductive skew. Here I propose that a genetic correlation between helper fecundity and breeder fecundity may frequently constrain the evolution of reproductive skew. This constraint is part of a wider phenomenon that I term "caste load," which is defined as the decline in mean fitness caused by caste-specific selection pressures, that is, differential selection on breeding and nonbreeding individuals. I elaborate the caste load hypothesis using quantitative and population genetic arguments and individual-based simulations. Although selection can sometimes erode genetic correlations and resolve caste load, this may be constrained when mutations have similar pleiotropic effects on breeder and helper traits. I document evidence for caste load, identify putative genomic adaptations to it, and suggest future research directions. The models highlight the value of considering adaptation within the boundaries imposed by genetic architecture and incidentally reaffirm that monogamy promotes the evolutionary transition to eusociality.

A GridPix-based X-ray detector for the CAST experiment

NASA Astrophysics Data System (ADS)

Krieger, C.; Kaminski, J.; Lupberger, M.; Desch, K.

2017-09-01

The CAST experiment has been searching for axions and axion-like particles for more than 10 years. The continuous improvements in the detector designs have increased the physics reach of the experiment far beyond what was originally conceived. As part of this development, a new detector based on a GridPix readout had been developed in 2014 and was mounted on the CAST experiment during the end of the data taking period of 2014 and the complete period in 2015. We report on the detector design, its advantages and the performance during both periods.

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

NASA Astrophysics Data System (ADS)

Niknezhad, Setareh

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

O

NASA Astrophysics Data System (ADS)

Donnellan, Karen

My work is driven by the metaphysical and the potential for healing through the manipulation of energy. Points of research include the enso (the only symbol used in Zen Buddhism), which uses the circle as a symbol of wholeness, divinity, and enlightenment. The writings of Alex Grey, Eckhart Tolle and the work of Ann Hamilton will also be investigated. I plan to create work from turned wooden vortex forms, the shapes of which are based on the movement of energy within the body. These objects will be transformed from wood, through rubber, wax, plaster, iron, bronze to cast, and blown glass. This transformation through materials is becoming a metaphor for the continuous transformation of universal light and energy. As part of my material research, I will exploit various casting techniques including kiln casting, hot casting, and pate de verre. Photography, film, and projection also will be explored. Conceptually, the process will become an integral part of the work where involved, repetitive methods will be treated as a meditation or mantra and will, in turn, add a performative dimension to the work. It is through these meditative practices that I intend to imbue the work with healing energies.

Paleoseismic observations of an onshore transform boundary: The Magallanes-Fagnano fault, Tierra del Fuego, Argentina

USGS Publications Warehouse

Costa, C.H.; Smalley, R.; Schwartz, D.P.; Stenner, Heidi D.; Ellis, M.; Ahumada, E.A.; Velasco, M.S.

2006-01-01

We present preliminary information on the geomorphologic features and paleoseismic record associated with the ruptures of two Ms 7.8 earthquakes that struck Tierra del Fuego and the southernmost continental margin of South America on December 17, 1949. The fault scarp was surveyed in several places cast of Lago Fagnano and a trench across a secondary fault trace of the Magallanes-Fagnano fault was excavated at the Ri??o San Pablo. The observed deformation in a 9 kyr-old peat bog sequence suggests evidence for two, and possibly three pre-1949 paleoearthquakes is preserved in the stratigraphy. The scarp reaches heights up to 11 m in late Pleistocene-Holocence(?) deposits, but the vertical component of the 1949 events was always less than ???1 m. This observation also argues for the occurrence of previous events during the Quaternary. Along die part of the fault we investigated east of Lago Fagnano, the horizontal component of the 1949 rupture does not exceed 4 m and is likely lower than 0.4 m, which is consistent with the kinematics of a local releasing bend, or at the end of a strike-slip rupture zone. ?? 2006 Revista de la Asociacio??n Geolo??gica Argentina.

Morphology and Performance of 5Cr5MoV Casting Die Steel in the Process of Surfacing

NASA Astrophysics Data System (ADS)

Song, Yulai; Kong, Xiangrui; Yang, Pengcong; Fu, Hongde; Wang, Xuezhu

2017-12-01

To investigate the microstructures and mechanical properties of the deposited metal on surface of die steel, two layer of weld-seam were prepared on the surface of 5Cr5MoV die steel by arc surfacing. The surface microstructures and microhardness were characterized by scanning electron microscopy, energy dispersive spectrometer and Vickers microhardness tester, respectively. The effect of load on the abrasion resistance and wear mechanism of the base metal and surfacing metal was studied by pin-on-disk tribometer. The results showed that martensite and retained austenite exist in weld-seam, both of them grow up in the form of dendrites and equiaxed grains and microhardness reach 774.2HV. The microstructures of the quenching zone mainly consist of martensite and retained austenite, while tempered martensite is the dominant phase in partial quenching zone. The abrasion resistance of the surfacing metal is superior to the base metal based on the results of wear test. The wear rates of surfacing metal and base metal raise with the increase of load. The wear rates of base metal raise extremely when the load reach 210N. Both of two kinds of materials have the similar wear mechanism, namely, abrasive wear at low load, oxidative wear and adhesive wear at high load.

Computer aided system for parametric design of combination die

NASA Astrophysics Data System (ADS)

Naranje, Vishal G.; Hussein, H. M. A.; Kumar, S.

2017-09-01

In this paper, a computer aided system for parametric design of combination dies is presented. The system is developed using knowledge based system technique of artificial intelligence. The system is capable to design combination dies for production of sheet metal parts having punching and cupping operations. The system is coded in Visual Basic and interfaced with AutoCAD software. The low cost of the proposed system will help die designers of small and medium scale sheet metal industries for design of combination dies for similar type of products. The proposed system is capable to reduce design time and efforts of die designers for design of combination dies.

Heat Treatment of Thixo-Formed Hypereutectic X210CrW12 Tool Steel

NASA Astrophysics Data System (ADS)

Rogal, Łukasz; Dutkiewicz, Jan

2012-12-01

Steel is a particularly challenging material to semisolid process because of the high temperatures involved and the potential for surface oxidation. Hot-rolled X210CrW12 tool steel was applied as a feedstock for thixoforming. The samples were heated up to 1525 K (1250 °C) to obtain 30 pct of the liquid phase. They were pressed in the semisolid state into a die preheated up to 473 K (200 °C) using a device based on a high-pressure die casting machine. As a result, a series of main bucket tooth thixo-casts for a mining combine was obtained. The microstructure of the thixo-cast consisted of austenite globular grains (average grain size 46 μm) surrounded by a eutectic mixture (ferrite, austenite, and M7C3 carbides). The average hardness of primary austenite grains was 470 HV0.02 and that of eutectic 551 HV0.02. The X-ray analysis confirmed the presence of 11.8 pct α-Fe, 82.4 pct γ-Fe, and 5.8 pct M7C3 carbides in the thixo-cast samples. Thermal and dilatometric effects were registered in the solid state, and the analysis of curves enabled the determination of characteristic temperatures of heat treatment: 503 K, 598 K, 693 K, 798 K, 828 K, 903 K, and 953 K (230 °C, 325 °C, 420 °C, 525 °C, 555 °C, 630 °C, 680 °C). The thixo-casts were annealed at these temperatures for 2 hours. During annealing in the temperature range 503 K to 693 K (230 °C to 420 °C), the hardness of primary globular grains continuously decreased down to 385HV0.02. The X-ray diffraction showed a slight shift of peaks responsible for the tension release. Moreover, after the treatment at 693 K (420 °C), an additional peak from precipitated carbides was observed in the X-ray diffraction. Thin plates of perlite (average hardness 820 HV0.02) with carbide precipitates appeared at the boundaries of globular grains at 798 K (525 °C). They occupied 17 pct of the grain area. Plates of martensite were found in the center of grains, while the retained austenite was observed among them (average hardness of center grains was 512 HV0.02). A nearly complete decomposition of metastable austenite was achieved after tempering at 828 K (555 °C) due to prevailing lamellar pearlite structure starting at grain boundaries and the martensite located in the center of the grains. The X-ray analysis confirmed the presence of 3.4 pct γ-Fe, 84.6 pct α-Fe, and 12 pct M7C3 carbides. The dilatometric analysis showed that the transformation of metastable austenite into martensite took place during cooling from 828 K (555 °C). The additional annealing at 523 K (250 °C) for 2 hours after heat treatment at 828 K (555 °C) caused the precipitation of carbides from the martensite. After tempering at 903 K (630 °C), the thixo-cast microstructure showed globular grains consisting mainly of thick lamellar perlite of the average hardness 555 HV0.02.

7 CFR 760.404 - Eligible livestock.

Code of Federal Regulations, 2010 CFR

2010-01-01

..., goats, swine, poultry, deer, or reindeer and meet all the conditions in paragraph (c) of this section... part of a farming operation on the day they died; and (3) Before dying, not have been produced or maintained for reasons other than commercial use as part of a farming operation, such non-eligible uses being...

Accuracy of a reformulated fast-set vinyl polysiloxane impression material using dual-arch trays.

PubMed

Kang, Alex H; Johnson, Glen H; Lepe, Xavier; Wataha, John C

2009-05-01

A common technique used for making crown impressions involves use of a vinyl polysiloxane impression material in combination with a dual-arch tray. A leading dental manufacturer has reformulated its vinyl polysiloxane (VPS) impression line, but the accuracy of the new material has not been verified. The purpose of this study was to assess the accuracy of reformulated VPS impression materials using the single-step dual-arch impression technique. Dual-arch impressions were made on a typodont containing a master stainless steel standard crown preparation die, from which gypsum working dies were formed, recovered, and measured. The impression materials evaluated were Imprint 3 Penta Putty with Quick Step Regular Body (IP-0); Imprint 3 Penta Quick Step Heavy Body with Quick Step Light Body (IP-1); Aquasil Ultra Rigid Fast Set with LV Fast Set (AQ-1); and Aquasil Ultra Heavy Fast Set with XLV Fast Set (AQ-2) (n=10). All impressions were disinfected with CaviCide spray for 10 minutes prior to pouring with type IV gypsum. Buccolingual (BL), mesiodistal (MD), and occlusogingival (OG) dimensions were measured and compared to the master die using an optical measuring microscope. Linear dimensional change was also assessed for IP-0 and AQ-1 at 1 and 24 hours based on ANSI/ADA Specification No. 19. Single-factor ANOVA with Dunnett's T3 multiple comparisons was used to compare BL, MD, and OG changes, with hypothesis testing at alpha=.05. A repeated-measures ANOVA was used to compare linear dimensional changes. There were statistical differences among the 4 impression systems for 3 of 4 dimensions of the master die. IP-0 working dies were significantly larger in MD and OG-L dimensions but significantly smaller in the BL dimension. IP-1 working dies were significantly smaller in the BL dimension compared to the master die. With the exception of IP-0, differences detected were small and clinically insignificant. No significant differences were observed for linear dimensional change. The single-step dual-arch impression technique produced working dies that were smaller in 3 of the 4 dimensions measured and may require additional die relief to achieve appropriate fit of cast restorations. Overall accuracy was acceptable for all impression groups with the exception of IP-0.

Development of a CFD code for casting simulation

NASA Technical Reports Server (NTRS)

Murph, Jesse E.

1993-01-01

Because of high rejection rates for large structural castings (e.g., the Space Shuttle Main Engine Alternate Turbopump Design Program), a reliable casting simulation computer code is very desirable. This code would reduce both the development time and life cycle costs by allowing accurate modeling of the entire casting process. While this code could be used for other types of castings, the most significant reductions of time and cost would probably be realized in complex investment castings, where any reduction in the number of development castings would be of significant benefit. The casting process is conveniently divided into three distinct phases: (1) mold filling, where the melt is poured or forced into the mold cavity; (2) solidification, where the melt undergoes a phase change to the solid state; and (3) cool down, where the solidified part continues to cool to ambient conditions. While these phases may appear to be separate and distinct, temporal overlaps do exist between phases (e.g., local solidification occurring during mold filling), and some phenomenological events are affected by others (e.g., residual stresses depend on solidification and cooling rates). Therefore, a reliable code must accurately model all three phases and the interactions between each. While many codes have been developed (to various stages of complexity) to model the solidification and cool down phases, only a few codes have been developed to model mold filling.

Genetic affinities among the lower castes and tribal groups of India: inference from Y chromosome and mitochondrial DNA.

PubMed

Thanseem, Ismail; Thangaraj, Kumarasamy; Chaubey, Gyaneshwer; Singh, Vijay Kumar; Bhaskar, Lakkakula V K S; Reddy, B Mohan; Reddy, Alla G; Singh, Lalji

2006-08-07

India is a country with enormous social and cultural diversity due to its positioning on the crossroads of many historic and pre-historic human migrations. The hierarchical caste system in the Hindu society dominates the social structure of the Indian populations. The origin of the caste system in India is a matter of debate with many linguists and anthropologists suggesting that it began with the arrival of Indo-European speakers from Central Asia about 3500 years ago. Previous genetic studies based on Indian populations failed to achieve a consensus in this regard. We analysed the Y-chromosome and mitochondrial DNA of three tribal populations of southern India, compared the results with available data from the Indian subcontinent and tried to reconstruct the evolutionary history of Indian caste and tribal populations. No significant difference was observed in the mitochondrial DNA between Indian tribal and caste populations, except for the presence of a higher frequency of west Eurasian-specific haplogroups in the higher castes, mostly in the north western part of India. On the other hand, the study of the Indian Y lineages revealed distinct distribution patterns among caste and tribal populations. The paternal lineages of Indian lower castes showed significantly closer affinity to the tribal populations than to the upper castes. The frequencies of deep-rooted Y haplogroups such as M89, M52, and M95 were higher in the lower castes and tribes, compared to the upper castes. The present study suggests that the vast majority (> 98%) of the Indian maternal gene pool, consisting of Indio-European and Dravidian speakers, is genetically more or less uniform. Invasions after the late Pleistocene settlement might have been mostly male-mediated. However, Y-SNP data provides compelling genetic evidence for a tribal origin of the lower caste populations in the subcontinent. Lower caste groups might have originated with the hierarchical divisions that arose within the tribal groups with the spread of Neolithic agriculturalists, much earlier than the arrival of Aryan speakers. The Indo-Europeans established themselves as upper castes among this already developed caste-like class structure within the tribes.

Genetic affinities among the lower castes and tribal groups of India: inference from Y chromosome and mitochondrial DNA

PubMed Central

Thanseem, Ismail; Thangaraj, Kumarasamy; Chaubey, Gyaneshwer; Singh, Vijay Kumar; Bhaskar, Lakkakula VKS; Reddy, B Mohan; Reddy, Alla G; Singh, Lalji

2006-01-01

Background India is a country with enormous social and cultural diversity due to its positioning on the crossroads of many historic and pre-historic human migrations. The hierarchical caste system in the Hindu society dominates the social structure of the Indian populations. The origin of the caste system in India is a matter of debate with many linguists and anthropologists suggesting that it began with the arrival of Indo-European speakers from Central Asia about 3500 years ago. Previous genetic studies based on Indian populations failed to achieve a consensus in this regard. We analysed the Y-chromosome and mitochondrial DNA of three tribal populations of southern India, compared the results with available data from the Indian subcontinent and tried to reconstruct the evolutionary history of Indian caste and tribal populations. Results No significant difference was observed in the mitochondrial DNA between Indian tribal and caste populations, except for the presence of a higher frequency of west Eurasian-specific haplogroups in the higher castes, mostly in the north western part of India. On the other hand, the study of the Indian Y lineages revealed distinct distribution patterns among caste and tribal populations. The paternal lineages of Indian lower castes showed significantly closer affinity to the tribal populations than to the upper castes. The frequencies of deep-rooted Y haplogroups such as M89, M52, and M95 were higher in the lower castes and tribes, compared to the upper castes. Conclusion The present study suggests that the vast majority (>98%) of the Indian maternal gene pool, consisting of Indio-European and Dravidian speakers, is genetically more or less uniform. Invasions after the late Pleistocene settlement might have been mostly male-mediated. However, Y-SNP data provides compelling genetic evidence for a tribal origin of the lower caste populations in the subcontinent. Lower caste groups might have originated with the hierarchical divisions that arose within the tribal groups with the spread of Neolithic agriculturalists, much earlier than the arrival of Aryan speakers. The Indo-Europeans established themselves as upper castes among this already developed caste-like class structure within the tribes. PMID:16893451

Final Technical Report: Intensive Quenching Technology for Heat Treating and Forging Industries

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

Aronov, Michael A.

2005-12-21

Intensive quenching (IQ) process is an alternative way of hardening (quenching) steel parts through the use of highly agitated water and then still air. It was developed by IQ Technologies, Inc. (IQT) of Akron, Ohio. While conventional quenching is usually performed in environmentally unfriendly oil or water/polymer solutions, the IQ process uses highly agitated environmentally friendly water or low concentration water/mineral salt solutions. The IQ method is characterized by extremely high cooling rates of steel parts. In contrast to conventional quenching, where parts cool down to the quenchant temperature and usually have tensile or neutral residual surface stresses at themore » end of quenching. The IQ process is interrupted when the part core is still hot and when there are maximum compressive stresses deep into the parts, thereby providing hard, ductile, better wear resistant parts. The project goal was to advance the patented IQ process from feasibility to commercialization in the heat-treating and forging industries to reduce significantly energy consumption and environmental impact, to increase productivity and to enhance economic competitiveness of these industries as well as Steel, Metal Casting and Mining industries. To introduce successfully the IQ technology in the U.S. metal working industry, the project team has completed the following work over the course of this project: A total of 33 manufacturers of steel products provided steel parts for IQ trails. IQT conducted IQ demonstrations for 34 different steel parts. Our customers tested intensively quenched parts in actual field conditions to evaluate the product service life and performance improvement. The data obtained from the field showed the following: Service life (number of holes punched) of cold-work punches (provided by EHT customer and made of S5 shock-resisting steel) was improved by two to eight times. Aluminum extrusion dies provided by GAM and made of hot work H-13 steel outperformed the standard dies by at least 50%. Dies provided by an AST customer, made of plain carbon 1045 steel and used for pellet manufacturing outperformed the standard dies by more than 100%. Concrete crusher liner wear plates provided by an EHT customer and made of 1045 steel, had the same surface hardness as the plates made of more expensive, pre-hardened high alloy HARDOX-500 material supplied by a Swedish company and used currently by the EHT customer. The 1045 material intensively quenched wear plates are currently in the field. Concrete block molding machine wear plates provided by an IQT customer and made of 8620 steel were processed at the AST production IQ system using a 40% reduced carburization cycle. An effective case depth in the intensively quenched wear plates was the same as in the standard, oil quenched parts. Base keys provided by an EHT customer and made of 8620 steel were processed using a 40% reduced carburization cycle. The intensively quenched parts showed the same performance as standard parts. IQT introduced the IQ process in heat treat practices of three commercial heat-treating shops: Akron Steel Treating Co., Summit Heat Treating Co. and Euclid Heat Treating Co. CWRU conducted a material characterization study for a variety of steels to develop a database to support changing/modification of recognized standards for quenching steel parts. IQT conducted a series of IQ workshops, published seven technical papers and participated in ASM Heat Treating Society conference and exposition and in Furnace North America Show. IQT designed and built a fully automated new IQ system installed at the Center for Intensive Quenching. This system includes the following major components: a stand-alone 1,900-gallon IQ water system, a 24'' x 24'' atmosphere pit furnace, and an automated load transfer mechanism. IQT established a ''Center for Intensive Quenching'' at the AST facilities. The 4,000 square feet Center includes the following equipment: High-velocity single part quenching IQ unit developed and built previously under EMTEC CT-65 project. The unit is equipped with a neutral salt bath furnace and a high-temperature, electric-fired, atmosphere, box furnace. New 1,900 gallon IQ system with a 24'' x 24'' atmosphere pit furnace and a load transfer mechanism. Shaker hearth furnace equipped with an IQ water tank and with a chiller to maintain the required water temperature. Potential Savings for USA Heat Treating Industry IQ Process Benefit/Annual Benefit for USA Heat Treating Industry Full elimination or 30% reduction of the carburization cycle Savings of 1,800 billion Btu of energy Cost reduction by $600,000,000 Reduction of CO2 emissions by 148,000 ton Part weight reduction by 5% Savings in material cost of $70,000,000 Savings of 300 billion Btu of energy« less

Genetic evidence on the origins of Indian caste populations.

PubMed

Bamshad, M; Kivisild, T; Watkins, W S; Dixon, M E; Ricker, C E; Rao, B B; Naidu, J M; Prasad, B V; Reddy, P G; Rasanayagam, A; Papiha, S S; Villems, R; Redd, A J; Hammer, M F; Nguyen, S V; Carroll, M L; Batzer, M A; Jorde, L B

2001-06-01

The origins and affinities of the approximately 1 billion people living on the subcontinent of India have long been contested. This is owing, in part, to the many different waves of immigrants that have influenced the genetic structure of India. In the most recent of these waves, Indo-European-speaking people from West Eurasia entered India from the Northwest and diffused throughout the subcontinent. They purportedly admixed with or displaced indigenous Dravidic-speaking populations. Subsequently they may have established the Hindu caste system and placed themselves primarily in castes of higher rank. To explore the impact of West Eurasians on contemporary Indian caste populations, we compared mtDNA (400 bp of hypervariable region 1 and 14 restriction site polymorphisms) and Y-chromosome (20 biallelic polymorphisms and 5 short tandem repeats) variation in approximately 265 males from eight castes of different rank to approximately 750 Africans, Asians, Europeans, and other Indians. For maternally inherited mtDNA, each caste is most similar to Asians. However, 20%-30% of Indian mtDNA haplotypes belong to West Eurasian haplogroups, and the frequency of these haplotypes is proportional to caste rank, the highest frequency of West Eurasian haplotypes being found in the upper castes. In contrast, for paternally inherited Y-chromosome variation each caste is more similar to Europeans than to Asians. Moreover, the affinity to Europeans is proportionate to caste rank, the upper castes being most similar to Europeans, particularly East Europeans. These findings are consistent with greater West Eurasian male admixture with castes of higher rank. Nevertheless, the mitochondrial genome and the Y chromosome each represents only a single haploid locus and is more susceptible to large stochastic variation, bottlenecks, and selective sweeps. Thus, to increase the power of our analysis, we assayed 40 independent, biparentally inherited autosomal loci (1 LINE-1 and 39 Alu elements) in all of the caste and continental populations (approximately 600 individuals). Analysis of these data demonstrated that the upper castes have a higher affinity to Europeans than to Asians, and the upper castes are significantly more similar to Europeans than are the lower castes. Collectively, all five datasets show a trend toward upper castes being more similar to Europeans, whereas lower castes are more similar to Asians. We conclude that Indian castes are most likely to be of proto-Asian origin with West Eurasian admixture resulting in rank-related and sex-specific differences in the genetic affinities of castes to Asians and Europeans.

Genetic Evidence on the Origins of Indian Caste Populations

PubMed Central

Bamshad, Michael; Kivisild, Toomas; Watkins, W. Scott; Dixon, Mary E.; Ricker, Chris E.; Rao, Baskara B.; Naidu, J. Mastan; Prasad, B.V. Ravi; Reddy, P. Govinda; Rasanayagam, Arani; Papiha, Surinder S.; Villems, Richard; Redd, Alan J.; Hammer, Michael F.; Nguyen, Son V.; Carroll, Marion L.; Batzer, Mark A.; Jorde, Lynn B.

2001-01-01

The origins and affinities of the ∼1 billion people living on the subcontinent of India have long been contested. This is owing, in part, to the many different waves of immigrants that have influenced the genetic structure of India. In the most recent of these waves, Indo-European-speaking people from West Eurasia entered India from the Northwest and diffused throughout the subcontinent. They purportedly admixed with or displaced indigenous Dravidic-speaking populations. Subsequently they may have established the Hindu caste system and placed themselves primarily in castes of higher rank. To explore the impact of West Eurasians on contemporary Indian caste populations, we compared mtDNA (400 bp of hypervariable region 1 and 14 restriction site polymorphisms) and Y-chromosome (20 biallelic polymorphisms and 5 short tandem repeats) variation in ∼265 males from eight castes of different rank to ∼750 Africans, Asians, Europeans, and other Indians. For maternally inherited mtDNA, each caste is most similar to Asians. However, 20%–30% of Indian mtDNA haplotypes belong to West Eurasian haplogroups, and the frequency of these haplotypes is proportional to caste rank, the highest frequency of West Eurasian haplotypes being found in the upper castes. In contrast, for paternally inherited Y-chromosome variation each caste is more similar to Europeans than to Asians. Moreover, the affinity to Europeans is proportionate to caste rank, the upper castes being most similar to Europeans, particularly East Europeans. These findings are consistent with greater West Eurasian male admixture with castes of higher rank. Nevertheless, the mitochondrial genome and the Y chromosome each represents only a single haploid locus and is more susceptible to large stochastic variation, bottlenecks, and selective sweeps. Thus, to increase the power of our analysis, we assayed 40 independent, biparentally inherited autosomal loci (1 LINE-1 and 39 Alu elements) in all of the caste and continental populations (∼600 individuals). Analysis of these data demonstrated that the upper castes have a higher affinity to Europeans than to Asians, and the upper castes are significantly more similar to Europeans than are the lower castes. Collectively, all five datasets show a trend toward upper castes being more similar to Europeans, whereas lower castes are more similar to Asians. We conclude that Indian castes are most likely to be of proto-Asian origin with West Eurasian admixture resulting in rank-related and sex-specific differences in the genetic affinities of castes to Asians and Europeans. PMID:11381027

Assessment of early attrition using an ordinary flatbed scanner.

PubMed

Van't Spijker, Arie; Kreulen, Cees M; Bronkhorst, Ewald M; Creugers, Nico H J

2012-07-01

The aim of this study was to assess a two-dimensional method to monitor occlusal tooth wear quantitatively using a commercially available ordinary flatbed scanner. A flatbed scanner, measuring software and gypsum casts were used. In Part I, two observers (A and B) independently traced scans of marked wear facets of ten sets of casts in two sessions (test and retest). In Part II, three other sets of casts were duplicated and two observers (C and D) marked wear facets and traced the scanned images independently. Intra- and inter-observer agreement was determined comparing measured values (mm(2)) in paired T-tests. Duplicate measurement errors (DME) were calculated. In Part I the test and retest values (10 casts, 218 teeth) of observer A and B did not differ significantly (A: p = 0.289; B: p = 0.666); correlation coefficients were 0.998 (A) and 0.999 (B). "Tracing wear facets" showed a DME of 0.30 mm(2) for observer A and 0.15 mm(2) for observer B. In Part II, assessment of 70 teeth resulted in correlation coefficients of 0.994 for observer C and 0.997 for observer D; no differences between test and retest values were found for C (p = 0.061), although D differed significantly (p = 0.000). The DME for "marking and tracing wear facets" was 0.39 mm(2) (C) and 0.27 mm(2) (D). DME for inter-observer agreement were 0.45 mm(2) (test) and 0.42 mm(2) (re-test). We conclude that marking and tracing of occlusal wear facets to assess occlusal tooth wear quantitatively can be done accurately and reproducibly. Copyright © 2012 Elsevier Ltd. All rights reserved.

Numerical Simulation of The Mediterranean Sea Using Diecast: Interaction Between Basin, Sub-basin and Local Scale Features and Natural Variability.

NASA Astrophysics Data System (ADS)

Fernández, V.; Dietrich, D. E.; Haney, R. L.; Tintoré, J.

In situ and satellite data obtained during the last ten years have shown that the circula- tion in the Mediterranean Sea is extremely complex in space, with significant features ranging from mesoscale to sub-basin and basin scale, and highly variable in time, with mesoscale to seasonal and interannual signals. Also, the steep bottom topography and the variable atmospheric conditions from one sub-basin to another, make the circula- tion to be composed of numerous energetic and narrow coastal currents, density fronts and mesoscale structures that interact at sub-basin scale with the large scale circula- tion. To simulate numerically and better understand these features, besides high grid resolution, a low numerical dispersion and low physical dissipation ocean model is required. We present the results from a 1/8z horizontal resolution numerical simula- tion of the Mediterranean Sea using DieCAST ocean model, which meets the above requirements since it is stable with low general dissipation and uses accurate fourth- order-accurate approximations with low numerical dispersion. The simulations are carried out with climatological surface forcing using monthly mean winds and relax- ation towards climatological values of temperature and salinity. The model reproduces the main features of the large basin scale circulation, as well as the seasonal variabil- ity of sub-basin scale currents that are well documented by observations in straits and channels. In addition, DieCAST brings out natural fronts and eddies that usually do not appear in numerical simulations of the Mediterranean and that lead to a natural interannual variability. The role of this intrinsic variability in the general circulation will be discussed.

Tensile Properties and Fracture Behavior of Aluminum Alloy Foam Fabricated from Die Castings without Using Blowing Agent by Friction Stir Processing Route

PubMed Central

Hangai, Yoshihiko; Kamada, Hiroto; Utsunomiya, Takao; Kitahara, Soichiro; Kuwazuru, Osamu; Yoshikawa, Nobuhiro

2014-01-01

Al foam has been used in a wide range of applications owing to its light weight, high energy absorption and high sound insulation. One of the promising processes for fabricating Al foam involves the use of a foamable precursor. In this study, ADC12 Al foams with porosities of 67%–78% were fabricated from Al alloy die castings without using a blowing agent by the friction stir processing route. The pore structure and tensile properties of the ADC12 foams were investigated and compared with those of commercially available ALPORAS. From X-ray computed tomography (X-ray CT) observations of the pore structure of ADC12 foams, it was found that they have smaller pores with a narrower distribution than those in ALPORAS. Tensile tests on the ADC12 foams indicated that as their porosity increased, the tensile strength and tensile strain decreased, with strong relation between the porosity, tensile strength, and tensile strain. ADC12 foams exhibited brittle fracture, whereas ALPORAS exhibited ductile fracture, which is due to the nature of the Al alloy used as the base material of the foams. By image-based finite element (FE) analysis using X-ray CT images corresponding to the tensile tests on ADC12 foams, it was shown that the fracture path of ADC12 foams observed in tensile tests and the regions of high stress obtained from FE analysis correspond to each other. Therefore, it is considered that the fracture behavior of ADC12 foams in relation to their pore structure distribution can be investigated by image-based FE analysis. PMID:28788573

Estimation of surface area concentration of workplace incidental nanoparticles based on number and mass concentrations

NASA Astrophysics Data System (ADS)

Park, J. Y.; Ramachandran, G.; Raynor, P. C.; Kim, S. W.

2011-10-01

Surface area was estimated by three different methods using number and/or mass concentrations obtained from either two or three instruments that are commonly used in the field. The estimated surface area concentrations were compared with reference surface area concentrations (SAREF) calculated from the particle size distributions obtained from a scanning mobility particle sizer and an optical particle counter (OPC). The first estimation method (SAPSD) used particle size distribution measured by a condensation particle counter (CPC) and an OPC. The second method (SAINV1) used an inversion routine based on PM1.0, PM2.5, and number concentrations to reconstruct assumed lognormal size distributions by minimizing the difference between measurements and calculated values. The third method (SAINV2) utilized a simpler inversion method that used PM1.0 and number concentrations to construct a lognormal size distribution with an assumed value of geometric standard deviation. All estimated surface area concentrations were calculated from the reconstructed size distributions. These methods were evaluated using particle measurements obtained in a restaurant, an aluminum die-casting factory, and a diesel engine laboratory. SAPSD was 0.7-1.8 times higher and SAINV1 and SAINV2 were 2.2-8 times higher than SAREF in the restaurant and diesel engine laboratory. In the die casting facility, all estimated surface area concentrations were lower than SAREF. However, the estimated surface area concentration using all three methods had qualitatively similar exposure trends and rankings to those using SAREF within a workplace. This study suggests that surface area concentration estimation based on particle size distribution (SAPSD) is a more accurate and convenient method to estimate surface area concentrations than estimation methods using inversion routines and may be feasible to use for classifying exposure groups and identifying exposure trends.

Tensile Properties and Fracture Behavior of Aluminum Alloy Foam Fabricated from Die Castings without Using Blowing Agent by Friction Stir Processing Route.

PubMed

Hangai, Yoshihiko; Kamada, Hiroto; Utsunomiya, Takao; Kitahara, Soichiro; Kuwazuru, Osamu; Yoshikawa, Nobuhiro

2014-03-21

Al foam has been used in a wide range of applications owing to its light weight, high energy absorption and high sound insulation. One of the promising processes for fabricating Al foam involves the use of a foamable precursor. In this study, ADC12 Al foams with porosities of 67%-78% were fabricated from Al alloy die castings without using a blowing agent by the friction stir processing route. The pore structure and tensile properties of the ADC12 foams were investigated and compared with those of commercially available ALPORAS. From X-ray computed tomography (X-ray CT) observations of the pore structure of ADC12 foams, it was found that they have smaller pores with a narrower distribution than those in ALPORAS. Tensile tests on the ADC12 foams indicated that as their porosity increased, the tensile strength and tensile strain decreased, with strong relation between the porosity, tensile strength, and tensile strain. ADC12 foams exhibited brittle fracture, whereas ALPORAS exhibited ductile fracture, which is due to the nature of the Al alloy used as the base material of the foams. By image-based finite element (FE) analysis using X-ray CT images corresponding to the tensile tests on ADC12 foams, it was shown that the fracture path of ADC12 foams observed in tensile tests and the regions of high stress obtained from FE analysis correspond to each other. Therefore, it is considered that the fracture behavior of ADC12 foams in relation to their pore structure distribution can be investigated by image-based FE analysis.

40 CFR Table 5 to Subpart Wwww of... - Alternative Organic HAP Emissions Limits for Open Molding, Centrifugal Casting, and SMC...

Code of Federal Regulations, 2014 CFR

2014-07-01

... 40 Protection of Environment 13 2014-07-01 2014-07-01 false Alternative Organic HAP Emissions Limits for Open Molding, Centrifugal Casting, and SMC Manufacturing Operations Where the Standards Are Based on a 95 Percent Reduction Requirement 5 Table 5 to Subpart WWWW of Part 63 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED)...

Next-generation casting technologies and their adaptation and development in Russia: I. at the beginning of a new technological paradigm

NASA Astrophysics Data System (ADS)

Semenov, A. B.; Gavrilenko, A. E.; Semenov, B. I.

2016-12-01

The up-to-date methods of powder metallurgy and casting technology are considered. They can be used to apply the design and technological solutions that are intended to form parts with the optimum space configuration, to deLcrease the number of assembly elements, and to decrease the number of mechanical and welded joints in units.

40 CFR Table 11 to Subpart Wwww of... - Data Requirements for New and Existing Continuous Lamination and Continuous Casting Lines...

Code of Federal Regulations, 2010 CFR

2010-07-01

... Continuous Lamination and Continuous Casting Lines Complying With a Percent Reduction Limit or a Lbs/Ton...: Reinforced Plastic Composites Production Pt. 63, Subpt. WWWW, Table 11 Table 11 to Subpart WWWW of Part 63... With a Percent Reduction Limit or a Lbs/Ton Limit on an Averaging Basis As required in § 63.5865, in...

40 CFR Table 10 to Subpart Wwww of... - Data Requirements for New and Existing Continuous Lamination Lines and Continuous Casting Lines...

Code of Federal Regulations, 2014 CFR

2014-07-01

... 40 Protection of Environment 13 2014-07-01 2014-07-01 false Data Requirements for New and Existing Continuous Lamination Lines and Continuous Casting Lines Complying With a Percent Reduction Limit on a Per Line Basis 10 Table 10 to Subpart WWWW of Part 63 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) AIR PROGRAMS ...

40 CFR Table 10 to Subpart Wwww of... - Data Requirements for New and Existing Continuous Lamination Lines and Continuous Casting Lines...

Code of Federal Regulations, 2012 CFR

2012-07-01

... 40 Protection of Environment 13 2012-07-01 2012-07-01 false Data Requirements for New and Existing Continuous Lamination Lines and Continuous Casting Lines Complying With a Percent Reduction Limit on a Per Line Basis 10 Table 10 to Subpart WWWW of Part 63 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) AIR PROGRAMS ...

Numerically modeling oxide entrainment in the filling of castings: The effect of the webber number

NASA Astrophysics Data System (ADS)

Cuesta, Rafael; Delgado, Angel; Maroto, Antonio; Mozo, David

2006-11-01

In the casting of aluminum alloys and, in general, in the casting of film-forming alloys, the entrainment of oxides into the bulk liquid severely reduces the strength of the cast part. To avoid this, the melt velocity must be kept below a certain value, namely critical velocity, which is widely assumed to be 0.5 m/s. In this paper the authors investigate, by means of fluid-dynamic computer simulation, the dependence of critical veiocity on geometrical features of the running channels and thermophysical properties of the molten metal. For each of the geometries studied, once the critical velocity is exceeded, the amount of oxide entrained in the liquid is quantified. The analysis of the results reveals that surface entrainment is much more related to the non-dimensional Webber number than to melt velocity.

Magnetically assisted slip casting of bioinspired heterogeneous composites

NASA Astrophysics Data System (ADS)

Le Ferrand, Hortense; Bouville, Florian; Niebel, Tobias P.; Studart, André R.

2015-11-01

Natural composites are often heterogeneous to fulfil functional demands. Manufacturing analogous materials remains difficult, however, owing to the lack of adequate and easily accessible processing tools. Here, we report an additive manufacturing platform able to fabricate complex-shaped parts exhibiting bioinspired heterogeneous microstructures with locally tunable texture, composition and properties, as well as unprecedentedly high volume fractions of inorganic phase (up to 100%). The technology combines an aqueous-based slip-casting process with magnetically directed particle assembly to create programmed microstructural designs using anisotropic stiff platelets in a ceramic, metal or polymer functional matrix. Using quantitative tools to control the casting kinetics and the temporal pattern of the applied magnetic fields, we demonstrate that this approach is robust and can be exploited to design and fabricate heterogeneous composites with thus far inaccessible microstructures. Proof-of-concept examples include bulk composites with periodic patterns of microreinforcement orientation, and tooth-like bilayer parts with intricate shapes exhibiting site-specific composition and texture.

BIRTH ORDER, STAGE OF INFANCY AND INFANT MORTALITY IN INDIA.

PubMed

Mishra, S K; Ram, Bali; Singh, Abhishek; Yadav, Awdhesh

2017-10-02

Using data from India's National Family Health Survey, 2005-06 (NFHS-3), this article examines the patterns of relationship between birth order and infant mortality. The analysis controls for a number of variables, including mother's characteristics such as age at the time of survey, current place of residence (urban/rural), years of schooling, religion, caste, and child's sex and birth weight. A modest J-shaped relationship between birth order of children and their risk of dying in the neonatal period is found, suggesting that although both first- and last-born children are at a significantly greater risk of dying compared with those in the middle, last-borns (i.e. fourth and higher order births) are at the worst risk. However, in the post-neonatal period first-borns are not as vulnerable, but the risk increases steadily with the addition of successive births and last-borns are at much greater risk, even worse than those in the neonatal period. Although the strength of relationship between birth order and mortality is attenuated after the potential confounders are taken into account, the relationship between the two variables remains curvilinear in the neonatal period and direct in the post-neonatal period. There are marked differences in these patterns by the child's sex. While female children are less prone to the risk of dying in the neonatal period in comparison with male children, the converse is true in the post-neonatal period. Female children not only run higher risks of dying in the post-neonatal period, but also become progressively more vulnerable with an increase in birth order.

40 CFR Table 10 to Subpart Wwww of... - Data Requirements for New and Existing Continuous Lamination Lines and Continuous Casting Lines...

Code of Federal Regulations, 2010 CFR

2010-07-01

... 40 Protection of Environment 12 2010-07-01 2010-07-01 true Data Requirements for New and Existing Continuous Lamination Lines and Continuous Casting Lines Complying With a Percent Reduction Limit on a Per Line Basis 10 Table 10 to Subpart WWWW of Part 63 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) AIR PROGRAMS (CONTINUE...

40 CFR Table 10 to Subpart Wwww of... - Data Requirements for New and Existing Continuous Lamination Lines and Continuous Casting Lines...

Code of Federal Regulations, 2011 CFR

2011-07-01

... 40 Protection of Environment 12 2011-07-01 2009-07-01 true Data Requirements for New and Existing Continuous Lamination Lines and Continuous Casting Lines Complying With a Percent Reduction Limit on a Per Line Basis 10 Table 10 to Subpart WWWW of Part 63 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) AIR PROGRAMS (CONTINUE...

40 CFR Table 10 to Subpart Wwww of... - Data Requirements for New and Existing Continuous Lamination Lines and Continuous Casting Lines...

Code of Federal Regulations, 2013 CFR

2013-07-01

... 40 Protection of Environment 13 2013-07-01 2012-07-01 true Data Requirements for New and Existing Continuous Lamination Lines and Continuous Casting Lines Complying With a Percent Reduction Limit on a Per Line Basis 10 Table 10 to Subpart WWWW of Part 63 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) AIR PROGRAMS (CONTINUE...

Experimental und numerical investigations on cooling efficiency of Air-Mist nozzles on steel during continuous casting

NASA Astrophysics Data System (ADS)

Arth, G.; Taferner, M.; Bernhard, C.; Michelic, S.

2016-07-01

Cooling strategies in continuous casting of steel can vary from rapid cooling to slow cooling, mainly controlled by adjusting the amount of water sprayed onto the surface of the product. Inadequate adjustment however can lead to local surface undercooling or reheating, leading to surface and inner defects. This paper focuses on cooling efficiency of Air-Mist nozzles on casted steel and the experimental and numerical prediction of surface temperature distributions over the product width. The first part explains the determination of heat transfer coefficients (HTC) on laboratory scale, using a so called nozzle measuring stand (NMS). Based on measured water distributions and determined HTC's for air-mist nozzles using the NMS, surface temperatures are calculated by a transient 2D-model on a simple steel plate, explained in the second part of this paper. Simulations are carried out varying water impact density and spray water distribution, consequently influencing the local HTC distribution over the plate width. Furthermore, these results will be interpreted with regard to their consequence for surface and internal quality of the cast product. The results reveal the difficulty of correct adjustment of the amount of sprayed water, concurrent influencing water distribution and thus changing HTC distribution and surface temperature.

Aerophagia induced by the nasal obstruction on experimental animals.

PubMed

Nakajima, K; Ohi, G

1977-04-01

The excessive accumulation of gas in the gastrointestinal tracts was invariably induced on experimental animals (mice, rats, guinea pigs, hamsters and rabbits) by simply obstructing nasal passages. The analysis of the gas showed the almost identical composition to the ambient air or flutus which was largely due to swallowed air. Also the numerous small foams were found on and underneath the epithelial lining of small intestine. The pathological evaluation was done both macroscopically and microscopically. Dying animals after nasal obstruction showed hemorrhagic and necrotic changes in the jejunum and ileum. This observation may cast some light to the pathogenesis of necrotizing enterocolitis in human neonatal.

Combined effects of cerium and cooling rate on microstructure and mechanical properties of AZ91 magnesium alloy

NASA Astrophysics Data System (ADS)

Cai, Huisheng; Guo, Feng; Su, Juan

2018-01-01

The specimens of AZ91-xCe(x = 0, 0.3, 0.6, 0.9, 1.2, mass fraction wt%) with different thicknesses were prepared by die casting process, their as-cast microstructure and room temperature mechanical properties were investigated to analyze the change rule of microstructure and mechanical properties of AZ91 magnesium alloy under combined effects of cooling rate and cerium content. The results show that, the microstructure and mechanical properties of AZ91 magnesium alloy were twofold influenced by cooling rate and cerium content. With the increase of cooling rate and Ce content, the average as-cast grain size is evidently refined; the amount of β-Mg17Al12 decreases and distribution becomes discrete. While decreasing cooling rate or increasing Ce content, Al4Ce phase is more and the morphology tends to strip and needle from granular and short rod-like. The tensile strength and elongation of AZ91-xCe magnesium alloy are improved with increasing cooling rate. With the increase of Ce content, the tensile strength and elongation of AZ91-xCe magnesium alloy increased first and decreased afterwards, besides the action of Ce to improve tensile strength and elongation is more evident under faster cooling rate. Mechanical properties of samples are optimal in this work, when Ce content is 0.96% and cooling rate is 39.6 K s-1, tensile strength (259.7 MPa) and elongation (5.5%) are reached maximum, respectively.

Joseph Carpue's file drawer experiment - A murder mystery from 1801.

PubMed

Freshwater, M Felix

2015-12-01

Today unpublished or "file drawer" experiments are the impetus for trial registration and reporting of all results. In 1801, Joseph Carpue, the father of modern plastic surgery, did a file drawer experiment for Benjamin West, who was President of the Royal Academy of Arts. George III had commissioned West to create the largest stained glass window ever created whose theme, the Crucifixion, was based upon Michelangelo's drawing. Subsequently, West suffered a series of political, professional and economic setbacks. In the summer of 1801, West's project was delayed. By the fall, West hoped that independent scientific confirmation of his design could salvage the project. West approached Carpue who obtained a murderer's fresh corpse that he crucified and documented the results with plaster casts created by sculptor Thomas Banks. Carpue's experiment showed that West's window design wrongly depicted the Crucifixion because West had posed the hands and shoulders incorrectly. West died in 1820 without ever being associated with Carpue's experiment. Carpue's obituary in The Lancet in 1846 contained Carpue's handwritten note that described the experiment but not West's Royal commission. As no records or publications associate the cast with West project, this can be considered to be a file drawer experiment. After 1801, West made further drawings of the Crucifixion that showed the figures in the same position as the cast. Nineteenth century auction catalogues suggest that West made a corrected Crucifixion painting, but its current location remains a mystery.

9 CFR 82.20 - General restrictions.

Code of Federal Regulations, 2014 CFR

2014-01-01

... interstate: (a) Live poultry infected with chlamydiosis; (b) Dead poultry that were infected with chlamydiosis when they died, and parts of dead poultry that were infected with chlamydiosis when they died; and...

[A surface reacted layer study of titanium-zirconium alloy after dental casting].

PubMed

Zhang, Y; Guo, T; Li, Z; Li, C

2000-10-01

To investigate the influence of the mold temperature on the surface reacted layer of Ti-Zr alloy castings. Ti-Zr alloy was casted into a mold which was made of a zircon (ZrO2.SiO2) for inner coating and a phosphate-bonded material for outer investing with a casting machine (China) designed as vacuum, pressure and centrifuge. At three mold temperatures (room temperature, 300 degrees C, 600 degrees C) the Ti-Zr alloy was casted separately. The surface roughness of the castings was calculated by instrument of smooth finish (China). From the surface to the inner part the Knoop hardness and thickness in reacted layer of Ti-Zr alloy casting was measured. The structure of the surface reacted layer was analysed by SEM. Elemental analyses of the interfacial zone of the casting was made by element line scanning observation. The surface roughness of the castings was increased significantly with the mold temperature increasing. At a higher mold temperature the Knoop hardness of the reactive layer was increased. At the three mold temperature the outmost surface was very hard, and microhardness data decreased rapidly where they reached constant values. The thickness was about 85 microns for castings at room temperature and 300 degrees C, 105 microns for castings at 600 degrees C. From the SEM micrograph of the Ti-Zr alloy casting, the surface reacted layer could be divided into three different layers. The first layer was called non-structure layer, which thickness was about 10 microns for room temperature group, 20 microns for 300 degrees C and 25 microns for 600 degrees C. The second layer was characterized by coarse-grained acicular crystal, which thickness was about 50 microns for three mold temperatures. The third layer was Ti-Zr alloy. The element line scanning showed non-structure layer with higher level of element of O, Al, Si and Zr, The higher the mold temperature during casting, the deeper the Si permeating and in the second layer the element Si could also be found. The mold temperature is one of the major factors influencing to casting quality. In order to reduce the surface reacted layer of Ti-Zr alloy castings, the lower mold temperature and the investment without Si should be chosen.

Show Them You Really Want the Job

ERIC Educational Resources Information Center

Perlmutter, David D.

2012-01-01

Showing that one really "wants" the job entails more than just really wanting the job. An interview is part Broadway casting call, part intellectual dating game, part personality test, and part, well, job interview. When there are 300 applicants for a position, many of them will "fit" the required (and even the preferred) skills listed in the job…

High Strength and Wear Resistant Aluminum Alloy for High Temperature Applications

NASA Technical Reports Server (NTRS)

Lee, Jonathan A.; Munafo, Paul M. (Technical Monitor)

2002-01-01

In this paper, a new high strength and wear resistant aluminum cast alloy invented by NASA-MSFC for high temperature applications will be presented. Developed to meet U.S. automotive legislation requiring low-exhaust emission, the novel NASA 398 aluminum-silicon alloy offers dramatic improvement in tensile and fatigue strengths at elevated temperatures (500 F-800 F), enabling new pistons to utilize less material, which can lead to reducing part weight and cost as well as improving performance. NASA 398 alloy also offers greater wear resistance, surface hardness, dimensional stability, and lower thermal expansion compared to conventional aluminum alloys for several commercial and automotive applications. The new alloy can be produced economically using permanent steel molds from conventional gravity casting or sand casting. The technology was developed to stimulate the development of commercial aluminum casting products from NASA-developed technology by offering companies the opportunity to license this technology.

Critical Thinking on the Introduction of Digitization Within Engineering Training Systems in the Manufacturing Stage of Cast Parts

NASA Astrophysics Data System (ADS)

Lehene, T. R.; Samoilă, V.; Soporan, V. F.; Pădurețu, S.; Vescan, M. M.

2018-06-01

The paper aims to present a methodology for the analysis of the engineering training systems at the manufacturing stage of castings through critical engineering thinking. Its use [4, 5] requires the development of procedures capable of responding to the problems faced by engineering training in terms of acquiring the tools and procedures. The structure of the analysis took into consideration the following aspects: the motivation to use the proposed procedure, considerations on the engineering behavior, the design of the reasoning adapted to the analysis of the engineering training systems, the determination of the correlations in the processes of obtaining the cast products, the definition and calibration of the digital experiment, the definition and analysis of the factors influencing the last solidification area (the nature of the alloy, the shape of the mold and the casting geometry).

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

NASA Astrophysics Data System (ADS)

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

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

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.

Progress on high-performance rapid prototype aluminum mirrors

NASA Astrophysics Data System (ADS)

Woodard, Kenneth S.; Myrick, Bruce H.

2017-05-01

Near net shape parts can be produced using some very old processes (investment casting) and the relatively new direct metal laser sintering (DMLS) process. These processes have significant advantages for complex blank lightweighting and costs but are not inherently suited for producing high performance mirrors. The DMLS process can provide extremely complex lightweight structures but the high residual stresses left in the material results in unstable mirror figure retention. Although not to the extreme intricacy of DMLS, investment casting can also provide complex lightweight structures at considerably lower costs than DMLS and even conventional wrought mirror blanks but the less than 100% density for casting (and also DMLS) limits finishing quality. This paper will cover the progress that has been made to make both the DMLS and investment casting processes into viable near net shape blank options for high performance aluminum mirrors. Finish and figure results will be presented to show performance commensurate with existing conventional processes.

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.

Ultra-high vacuum compatible induction-heated rod casting furnace

NASA Astrophysics Data System (ADS)

Bauer, A.; Neubauer, A.; Münzer, W.; Regnat, A.; Benka, G.; Meven, M.; Pedersen, B.; Pfleiderer, C.

2016-06-01

We report the design of a radio-frequency induction-heated rod casting furnace that permits the preparation of polycrystalline ingots of intermetallic compounds under ultra-high vacuum compatible conditions. The central part of the system is a bespoke water-cooled Hukin crucible supporting a casting mold. Depending on the choice of the mold, typical rods have a diameter between 6 mm and 10 mm and a length up to 90 mm, suitable for single-crystal growth by means of float-zoning. The setup is all-metal sealed and may be baked out. We find that the resulting ultra-high vacuum represents an important precondition for processing compounds with high vapor pressures under a high-purity argon atmosphere up to 3 bars. Using the rod casting furnace, we succeeded to prepare large high-quality single crystals of two half-Heusler compounds, namely, the itinerant antiferromagnet CuMnSb and the half-metallic ferromagnet NiMnSb.

Ultra-high vacuum compatible induction-heated rod casting furnace.

PubMed

Bauer, A; Neubauer, A; Münzer, W; Regnat, A; Benka, G; Meven, M; Pedersen, B; Pfleiderer, C

2016-06-01

We report the design of a radio-frequency induction-heated rod casting furnace that permits the preparation of polycrystalline ingots of intermetallic compounds under ultra-high vacuum compatible conditions. The central part of the system is a bespoke water-cooled Hukin crucible supporting a casting mold. Depending on the choice of the mold, typical rods have a diameter between 6 mm and 10 mm and a length up to 90 mm, suitable for single-crystal growth by means of float-zoning. The setup is all-metal sealed and may be baked out. We find that the resulting ultra-high vacuum represents an important precondition for processing compounds with high vapor pressures under a high-purity argon atmosphere up to 3 bars. Using the rod casting furnace, we succeeded to prepare large high-quality single crystals of two half-Heusler compounds, namely, the itinerant antiferromagnet CuMnSb and the half-metallic ferromagnet NiMnSb.

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

NASA Astrophysics Data System (ADS)

Perrier, Frédéric; Desrayaud, Christophe; Bouvier, Véronique

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

9 CFR 82.20 - General restrictions.

Code of Federal Regulations, 2012 CFR

2012-01-01

... moved interstate: (a) Live poultry infected with chlamydiosis; (b) Dead poultry that were infected with chlamydiosis when they died, and parts of dead poultry that were infected with chlamydiosis when they died; and...

9 CFR 82.20 - General restrictions.

Code of Federal Regulations, 2011 CFR

2011-01-01

... moved interstate: (a) Live poultry infected with chlamydiosis; (b) Dead poultry that were infected with chlamydiosis when they died, and parts of dead poultry that were infected with chlamydiosis when they died; and...

9 CFR 82.20 - General restrictions.

Code of Federal Regulations, 2013 CFR

2013-01-01

... moved interstate: (a) Live poultry infected with chlamydiosis; (b) Dead poultry that were infected with chlamydiosis when they died, and parts of dead poultry that were infected with chlamydiosis when they died; and...

9 CFR 82.20 - General restrictions.

Code of Federal Regulations, 2010 CFR

2010-01-01

... moved interstate: (a) Live poultry infected with chlamydiosis; (b) Dead poultry that were infected with chlamydiosis when they died, and parts of dead poultry that were infected with chlamydiosis when they died; and...

Dimensional accuracy of resultant casts made by a monophase, one-step and two-step, and a novel two-step putty/light-body impression technique: an in vitro study.

PubMed

Caputi, Sergio; Varvara, Giuseppe

2008-04-01

Dimensional accuracy when making impressions is crucial to the quality of fixed prosthodontic treatment, and the impression technique is a critical factor affecting this accuracy. The purpose of this in vitro study was to compare the dimensional accuracy of a monophase, 1- and 2-step putty/light-body, and a novel 2-step injection impression technique. A stainless steel model with 2 abutment preparations was fabricated, and impressions were made 15 times with each technique. All impressions were made with an addition-reaction silicone impression material (Aquasil) and a stock perforated metal tray. The monophase impressions were made with regular body material. The 1-step putty/light-body impressions were made with simultaneous use of putty and light-body materials. The 2-step putty/light-body impressions were made with 2-mm-thick resin-prefabricated copings. The 2-step injection impressions were made with simultaneous use of putty and light-body materials. In this injection technique, after removing the preliminary impression, a hole was made through the polymerized material at each abutment edge, to coincide with holes present in the stock trays. Extra-light-body material was then added to the preliminary impression and further injected through the hole after reinsertion of the preliminary impression on the stainless steel model. The accuracy of the 4 different impression techniques was assessed by measuring 3 dimensions (intra- and interabutment) (5-mum accuracy) on stone casts poured from the impressions of the stainless steel model. The data were analyzed by 1-way ANOVA and Student-Newman-Keuls test (alpha=.05). The stone dies obtained with all the techniques had significantly larger dimensions as compared to those of the stainless steel model (P<.01). The order for highest to lowest deviation from the stainless steel model was: monophase, 1-step putty/light body, 2-step putty/light body, and 2-step injection. Significant differences among all of the groups for both absolute dimensions of the stone dies, and their percent deviations from the stainless steel model (P<.01), were noted. The 2-step putty/light-body and 2-step injection techniques were the most dimensionally accurate impression methods in terms of resultant casts.

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

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

Sabau, Adrian S

2008-04-01

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

Energy-Saving Melting and Revert Reduction Technology (E-SMARRT): Final Summary Report

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

White, Thornton C

2014-03-31

Energy-Saving Melting and Revert Reduction Technology (E-SMARRT) is a balanced portfolio of R&D tasks that address energy-saving opportunities in the metalcasting industry. E-SMARRT was created to: • Improve important capabilities of castings • Reduce carbon footprint of the foundry industry • Develop new job opportunities in manufacturing • Significantly reduce metalcasting process energy consumption and includes R&D in the areas of: • Improvements in Melting Efficiency • Innovative Casting Processes for Yield Improvement/Revert Reduction • Instrumentation and Control Improvement • Material properties for Casting or Tooling Design Improvement The energy savings and process improvements developed under E-SMARRT have been mademore » possible through the unique collaborative structure of the E-SMARRT partnership. The E-SMARRT team consisted of DOE’s Office of Industrial Technology, the three leading metalcasting technical associations in the U.S: the American Foundry Society; the North American Die Casting Association; and the Steel Founders’ Society of America; and SCRA Applied R&D, doing business as the Advanced Technology Institute (ATI), a recognized leader in distributed technology management. This team provided collaborative leadership to a complex industry composed of approximately 2,000 companies, 80% of which employ less than 100 people, and only 4% of which employ more than 250 people. Without collaboration, these new processes and technologies that enable energy efficiencies and environment-friendly improvements would have been slow to develop and had trouble obtaining a broad application. The E-SMARRT R&D tasks featured low-threshold energy efficiency improvements that are attractive to the domestic industry because they do not require major capital investment. The results of this portfolio of projects are significantly reducing metalcasting process energy consumption while improving the important capabilities of metalcastings. Through June 2014, the E-SMARRT program predicts an average annual estimated savings of 59 Trillion BTUs per year over a 10 year period through Advanced Melting Efficiencies and Innovative Casting Processes. Along with these energy savings, an estimated average annual estimate of CO2 reduction per year over a ten year period is 3.56 Million Metric Tons of Carbon Equivalent (MM TCE).« less

Grain refinement and texture development of cast bismuth-antimony alloy via severe plastic deformation

NASA Astrophysics Data System (ADS)

Im, Jae-Taek

The purpose of this work was to study learn about grain refinement mechanisms and texture development in cast n-type Bi90Sb10 alloy caused by severe plastic deformation. The practical objective is to produce a fine grained and textured microstructure in Bi90Sb10 alloy with enhanced thermoelectric performance and mechanical strength. In the study, twelve millimeter diameter cast bars of Bi90Sb 10 alloy were encapsulated in square cross section aluminum 6061 alloy containers. The composite bars were equal channel angular (ECAE) extruded through a 90 degree angle die at high homologous temperature. Various extrusion conditions were studied including punch speed (0.1, 0.3 and 0.6 in/min), extrusion temperature (220, 235 and 250°C), number of extrusion passes (1, 2 and 4), route (A, BC and C), and exit channel area reduction ratio (half and quarter area of inlet channel). The affect of an intermediate long term heat treatment (for 100 hours at 250°C under 10-3 torr vacuum) was explored. Processed materials were characterized by optical microscopy, x-ray diffraction, energy dispersive spectroscopy, wavelength dispersive spectroscopy and scanning electron microscopy. Texture was analyzed using the {006} reflection plane to identify the orientation of the basal poles in processed materials. The cast grains were irregularly shaped, had a grain size of hundreds-of-microns to millimeters, and showed inhomogeneous chemical composition. Severe plastic deformation refines the cast grains through dynamic recrystallization and causes the development of a bimodal microstructure consisting of fine grains (5-30 micron) and coarse grains (50-300 micron). ECAE processing of homogenizied Bi-Sb alloy causes grain refinement and produces a more uniform microstructure. Texture results show that ECAE route C processing gives a similar or slightly stronger texture than ECAE route A processing. In both cases, the basal-plane poles become aligned with the shear direction. Reduction area exit channel extrusion is more effective for both grain refinement and texture enhancement than simple ECAE processing.

The Angry Dying Patient.

PubMed

Houston, Robert E.

1999-02-01

Over 25 years ago, Kubler-Ross identified anger as a predictable part of the dying process. When the dying patient becomes angry in the clinical setting, all types of communication become strained. Physicians can help the angry dying patient through this difficult time by using 10 rules of engagement. When physicians engage and empathize with these patients, they improve the patient's response to pain and they reduce patient suffering. When physicians educate patients on their normal responses to dying and enlist them in the process of family reconciliation, they can impact the end-of-life experience in a positive way.

The Angry Dying Patient

PubMed Central

Houston, Robert E.

1999-01-01

Over 25 years ago, Kubler-Ross identified anger as a predictable part of the dying process. When the dying patient becomes angry in the clinical setting, all types of communication become strained. Physicians can help the angry dying patient through this difficult time by using 10 rules of engagement. When physicians engage and empathize with these patients, they improve the patient's response to pain and they reduce patient suffering. When physicians educate patients on their normal responses to dying and enlist them in the process of family reconciliation, they can impact the end-of-life experience in a positive way. PMID:15014699

Rapid prototype fabrication processes for high-performance thrust cells

NASA Technical Reports Server (NTRS)

Hunt, K.; Chwiedor, T.; Diab, J.; Williams, R.

1994-01-01

The Thrust Cell Technologies Program (Air Force Phillips Laboratory Contract No. F04611-92-C-0050) is currently being performed by Rocketdyne to demonstrate advanced materials and fabrication technologies which can be utilized to produce low-cost, high-performance thrust cells for launch and space transportation rocket engines. Under Phase 2 of the Thrust Cell Technologies Program (TCTP), rapid prototyping and investment casting techniques are being employed to fabricate a 12,000-lbf thrust class combustion chamber for delivery and hot-fire testing at Phillips Lab. The integrated process of investment casting directly from rapid prototype patterns dramatically reduces design-to-delivery cycle time, and greatly enhances design flexibility over conventionally processed cast or machined parts.

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

NASA Astrophysics Data System (ADS)

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

2018-06-01

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

Timing of Getter Material Addition in Cementitious Wasteforms

NASA Astrophysics Data System (ADS)

Lawter, A.; Qafoku, N. P.; Asmussen, M.; Neeway, J.; Smith, G. L.

2015-12-01

A cementitious waste form, Cast Stone, is being evaluated as a possible supplemental immobilization technology for the Hanford sites's low activity waste (LAW), which contains radioactive 99Tc and 129I, as part of the tank waste cleanup mission. Cast Stone is made of a dry blend 47% blast furnace slag, 45% fly ash, and 8% ordinary Portland cement, mixed with a low-activity waste (LAW). To improve the retention of Tc and/or I in Cast Stone, materials with a high affinity for Tc and/or I, termed "getters," can be added to provide a stable domain for the radionuclides of concern. Previous testing conducted with a variety of getters has identified Tin(II)-Apatite and Silver Exchanged Zeolite as promising candidates for Tc and I, respectively. Investigation into the sequence in which getters are added to Cast Stone was performed following two methods: 1) adding getters to the Cast Stone dry blend, and then mixing with liquid waste, and 2) adding getters to the liquid waste first, followed by addition of the Cast Stone dry blend. Cast Stone monolith samples were prepared with each method and leach tests, following EPA method 1315, were conducted in either distilled water or simulated vadose zone porewater for a period of up to 63 days. The leachate was analyzed for Tc, I, Na, NO3-, NO2- and Cr with ICP-MS, ICP-OES and ion chromatography and the results indicated that the Cast Stone with getter addition in the dry blend mix (method 1) has lower rates of Tc and I leaching. The mechanisms of radionuclide release from the Cast Stone were also investigated with a variety of solid phase characterization techniques of the monoliths before and after leaching, such as XRD, SEM/EDS, TEM/SAED and other spectroscopic techniques.

25 Jahre - Institut fuer Geodaesie, Teil 1: Wissenschaftliche Beitraege und Berichte (25 Years - Institute of Geodesy, Part 1: Scientific Contributions and Reports)

DTIC Science & Technology

2000-01-01

R.: Contribution to the Theory of Robust Estimation. PhD-Thesis, Univ. of California, Berkely 1968 HEISTER, H., HOLLMANN, R. u. LANG, M.: Multipath...AVN 106, S. 128-133, 1999 RCHRNOSSL, H., BRUNNER , F. u. RoTHACHER, M.: Modellierung der troposph4drischen Korrekturflur Deformationsmessungen mit GPS...fiber die Entwicklungen in Theorie und Praxis berichtet, die die Erwartung begrUnden, dass die GeodAtische Astronomie in der GeodAsie kinftig wieder eine

A Review of the Relationship Between Socioeconomic Position and the Early-Life Predictors of Obesity.

PubMed

Cameron, Adrian J; Spence, Alison C; Laws, Rachel; Hesketh, Kylie D; Lioret, Sandrine; Campbell, Karen J

2015-09-01

A range of important early-life predictors of later obesity have been identified. Children of lower socioeconomic position (SEP) have a steeper weight gain trajectory from birth with a strong socioeconomic gradient in child and adult obesity prevalence. An assessment of the association between SEP and the early-life predictors of obesity has been lacking. The review involved a two-stage process: Part 1, using previously published systematic reviews, we developed a list of the potentially modifiable determinants of obesity observable in the pre-natal, peri-natal or post-natal (pre-school) periods; and part 2, conducting a literature review of evidence for socioeconomic patterning in the determinants identified in part 1. Strong evidence was found for an inverse relationship between SEP and (1) pre-natal risk factors (pre-pregnancy maternal body mass index (BMI), diabetes and pre-pregnancy diet), (2) antenatal/peri natal risk factors (smoking during pregnancy and low birth weight) and (3) early-life nutrition (including breastfeeding initiation and duration, early introduction of solids, maternal and infant diet quality, and some aspects of the home food environment), and television viewing in young children. Less strong evidence (because of a lack of studies for some factors) was found for paternal BMI, maternal weight gain during pregnancy, child sleep duration, high birth weight and lack of physical activity in young children. A strong socioeconomic gradient exists for the majority of the early-life predictors of obesity suggesting that the die is cast very early in life (even pre-conception). Lifestyle interventions targeting disadvantaged women at or before child-bearing age may therefore be particularly important in reducing inequality. Given the likely challenges of reaching this target population, it may be that during pregnancy and their child's early years are more feasible windows for engagement.

For Whom the Bell Tolls: A Special Journal Issue on Smoking Control and an Interview With Dr Harry Lando.

PubMed

Terry, Paul E

2018-06-01

Opioid addiction has been cast as a "disease of despair."1 I agree, but I wonder still: If tobacco and opioids were on a spectrum relative to the relief they provide from social, emotional, financial, and other sources of pain in the lives of the disenfranchised, could it be that they are indeed 2 sides of the same coin? For individuals in despair, pain relief is a complicit actor in what will become pleasure seeking and, for smokers, vice versa. Every year, almost as many people are dying by incidentally being near smokers as are dying by accidentally overdosing. Our opioid epidemic has been declared a national public health emergency, though the annual death toll from tobacco is 10 times greater. How should we reconcile this? As is extraordinarily represented in my interview with Dr Harry Lando and as is evident from the range of articles on tobacco control in this special issue, tobacco addiction research draws from every corner of psychology, sociology, philosophy, and other disciplines intent on understanding the human condition.

Faster, Less Expensive Dies Using RSP Tooling

NASA Astrophysics Data System (ADS)

Knirsch, James R.

2007-08-01

RSP Tooling is an indirect spray form additive process that can produce production tooling for virtually any forming process and from virtually any metal. In the past 24 months a significant amount of research and development has been performed. This resulted in an increase in the basic metallurgical understanding of what transpires during the rapid solidification of the metal, significant improvements in the production machine up time, ceramic developments that have improved finish, process changes that have resulted in a shorter lead time for tool delivery, and the testing of many new alloys. RSP stands for Rapid Solidification Process and is the key to the superior metallurgical properties that result from the technology. Most metals that are sprayed in the process leave the machine with the same physical properties as the same metal normally achieves through heat treatment and in some cases the properties are superior. Many new applications are being pursued including INVAR tools for aerospace composite materials, and bimetallic tools made from tool steel and beryllium copper for die casting and plastic injection molding. Recent feasibility studies have been performed with tremendous success.

Review of Research Work on Ti-BASED Composite Coatings

NASA Astrophysics Data System (ADS)

Gabbitas, Brian; Salman, Asma; Zhang, Deliang; Cao, Peng

The service life of industrial components is limited predominantly by Chemical corrosion/mechanical wear. The project is concerned with the investigation of the capability of Ti(Al,O)/Al2O3 coatings to improve the service life of tool steel (H13) used for dies in aluminium high pressure die casting. This paper gives a general review on the research work conducted at the University of Waikato on producing and evaluating the titanium/alumina based composite coatings. The powder feedstocks for making the composite coatings were produced by high energy mechanical milling of a mixture of Al and TiO2 powders in two different molar ratios followed by a thermal reaction process. The feedstocks were then thermally sprayed using a high velocity air-fuel (HVAF) technique on H13 steel substrates to produce a Ti(Al,O)/Al2O3 composite coatings. The performance of the coating was assessed in terms of thermal shock resistance and reaction kinetics with molten aluminium. The composite powders and coatings were characterized using scanning electron microscopy (SEM), optical microscopy and X-ray diffractometry (XRD).

40 CFR 63.5790 - What parts of my plant does this subpart cover?

Code of Federal Regulations, 2011 CFR

2011-07-01

... 40 Protection of Environment 12 2011-07-01 2009-07-01 true What parts of my plant does this... Production What This Subpart Covers § 63.5790 What parts of my plant does this subpart cover? (a) This..., polymer casting, pultrusion, sheet molding compound (SMC) manufacturing, bulk molding compound (BMC...

The use of injection-corrosive method in the study of extraorganic bloodstream of human intact stomach.

PubMed

Hryn, V H; Svintsytska, N L; Piliuhin, V; Ustenko, R L; Katsenko, A L

Functional and morphological state of the organs and tissues mainly depends on the adequate blood supply and lymph movement, function of which is integrated by the nervous system. A crucial link in the morphogenesis of the gastric lesions is the intensity of vascularization, as well as the fact that in its venous part the gastric bloodstream is almost entirely included into the portal vein system. Knowledge of the anatomy of the normal human stomach conditions is of indispensable practical value, since they are required for the proper interpretation of the pathological changes occurred in it. To obtain the spatial visual information about the angioarchitecture of the extraorganic bloodstream of human intact stomach deep in the gastric wall. 10 post-autopsy adult total stomach specimens of patients, died for the reasons not associated with manifested gastrointestinal diseases have been analyzed. The specimens were extracted during the dissection together with portions of lesser and greater omentum, and segment of aorta with celiac trunk. To neutralize the acidic contents of the stomach, its cavity was washed by 4% sodium bicarbonate solution with subsequent wash in warm running water. The vascular injection method with subsequent corrosion of soft tissues was used in investigation of gastric bloodstream. On the basis of the investigations the advantages of the countercurrent-crossing method of injection of extraorganic vessels to fill the bloodstream of human stomach have been discussed. Positive results of the suggested technique for morphological study of blood vessels have been noted. The three-dimensional spatial organization of the extraorganic bloodstream of the intact stomach can be studied on the basis of the injection-corrosive casts. Thus, the use of the suggested method enables to obtain the fine three-dimensional reproduction of extraorganic bloodstream of the human stomach. The obtained high-quality casts, in turn, are used for the subsequent morphological studies of the intact stomach.

Uniqueness of the anterior dentition three-dimensionally assessed for forensic bitemark analysis.

PubMed

Franco, A; Willems, G; Souza, Phc; Coucke, W; Thevissen, P

2017-02-01

The uniqueness of the human dentition (UHD) is an important concept in the comparative process in bitemark analysis. During this analysis, the incisal edges of the suspects' teeth are matched with the bitemarks collected from the victim's body or crime scenes. Despite playing an essential part to exclude suspects, the UHD contained in the involved incisal tooth edges remains an assumption on bitemark level. The present study was aimed, first, to investigate three-dimensionally (3D) the UHD within different quantities of dental material from the incisal edges; second, to test these outcomes in a bidimensional (2D) simulation. Four-hundred forty-five dental casts were collected to compose 4 study groups: I - randomly-selected subjects, II - orthodontically treated subjects, III - twins and IV - orthodontically treated twins. Additionally, 20 dental casts were included to create threshold groups on subjects from whom the dental impressions were taken at 2 different moments (Group V). All the dental casts were digitalized with an automated motion device (XCAD 3D ® (XCADCAM Technology ® , São Paulo, SP, Brazil). The digital cast files (DCF) were integrated in Geomagic Studio ® (3D Systems ® , Rock Hill, SC, USA) software package (GS) for cropping, automated superimposition and pair-wise comparisons. All the DCF were cropped remaining 3 mm (part 1), 2 mm (part 2) and 1 mm (part 3) from the incisal edges of the anterior teeth. For a 2D validation, slices of 1 mm, not including incisal edges (part 4), were also cropped. These procedures were repeated in Group V, creating specific thresholds for each of the study parts. The 4 study groups were compared with its respective threshold using ANOVA test with statistical significance of 5%. Groups I, II and III did not differ from the corresponding threshold (Group V) in all study parts (p > 0.05). Scientific evidence to support the UHD was not observed in the current study. Bitemark analysis should not be disregarded but considered carefully when the suspects present similar dental alignment and morphology, such as in orthodontically treated subjects and twins, respectively. Copyright © 2017 Elsevier Ltd and Faculty of Forensic and Legal Medicine. All rights reserved.

Energy Saving Melting and Revert Reduction (E-SMARRT): Precision Casting of Steel

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

Dr. Von L. Richards

2011-09-30

This project addresses improvements in metal casting processes by reducing scrap and reducing the cost of production, due to scrap reduction from investment casting and yield improvement offered by lost foam casting as compared to no-bake or green sand molding. The objectives for the investment casting portion of the subtask are to improve knowledge of fracture toughness of mold shells and the sources of strength limiting flaws and to understand the effects of wax reclamation procedures on wax properties. Applying 'clean steel' approaches to pouring technology and cleanliness in investment casting of steel are anticipated to improve incoming materials inspectionmore » procedures as they affect the microstructure and toughness of the shell. This project focused on two areas of study in the production of steel castings to reduce scrap and save energy: (1) Reducing the amount of shell cracking in investment cast steel production; (2) Investigate the potential of lost foam steel casting The basic findings regarding investment casting shell cracking were: (1) In the case of post pouring cracking, this could be related to phase changes in silica upon cooling and could be delayed by pouring arrangement strategies that maintained the shell surface at temperature for longer time. Employing this delay resulted in less adherent oxidation of castings since the casting was cooler at the time o fair exposure. (2) A model for heat transfer through water saturated shell materials under steam pressure was developed. (3) Initial modeling result of autoclave de-waxing indicated the higher pressure and temperature in the autoclave would impose a steeper temperature gradient on the wax pattern, causing some melt flow prior to bulk expansion and decreasing the stress on the green shell. Basic findings regarding lost foam casting of steel at atmospheric pressure: (1) EPS foam generally decomposes by the collapse mode in steel casting. (2) There is an accumulation of carbon pick-up at the end 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.« less

Does the internet change how we die and mourn? Overview and analysis.

PubMed

Walter, Tony; Hourizi, Rachid; Moncur, Wendy; Pitsillides, Stacey

The article outlines the issues that the internet presents to death studies. Part 1 describes a range of online practices that may affect dying, the funeral, grief and memorialization, inheritance and archaeology; it also summarizes the kinds of research that have been done in these fields. Part 2 argues that these new online practices have implications for, and may be illuminated by, key concepts in death studies: the sequestration (or separation from everyday life) of death and dying, disenfranchisement of grief, private grief, social death, illness and grief narratives, continuing bonds with the dead, and the presence of the dead in society. In particular, social network sites can bring dying and grieving out of both the private and public realms and into the everyday life of social networks beyond the immediate family, and provide an audience for once private communications with the dead.

9 CFR 325.21 - Means of conveyance in which dead, dying, disabled, or diseased livestock and parts of carcasses...

Code of Federal Regulations, 2013 CFR

2013-01-01

... 9 Animals and Animal Products 2 2013-01-01 2013-01-01 false Means of conveyance in which dead... INSPECTION AND CERTIFICATION TRANSPORTATION § 325.21 Means of conveyance in which dead, dying, disabled, or... conveyance used by persons subject to § 325.20 for transporting in commerce or importing, any dead, dying...

9 CFR 325.21 - Means of conveyance in which dead, dying, disabled, or diseased livestock and parts of carcasses...

Code of Federal Regulations, 2010 CFR

2010-01-01

... 9 Animals and Animal Products 2 2010-01-01 2010-01-01 false Means of conveyance in which dead... INSPECTION AND CERTIFICATION TRANSPORTATION § 325.21 Means of conveyance in which dead, dying, disabled, or... conveyance used by persons subject to § 325.20 for transporting in commerce or importing, any dead, dying...

9 CFR 325.21 - Means of conveyance in which dead, dying, disabled, or diseased livestock and parts of carcasses...

Code of Federal Regulations, 2012 CFR

2012-01-01

... 9 Animals and Animal Products 2 2012-01-01 2012-01-01 false Means of conveyance in which dead... INSPECTION AND CERTIFICATION TRANSPORTATION § 325.21 Means of conveyance in which dead, dying, disabled, or... conveyance used by persons subject to § 325.20 for transporting in commerce or importing, any dead, dying...

9 CFR 325.21 - Means of conveyance in which dead, dying, disabled, or diseased livestock and parts of carcasses...

Code of Federal Regulations, 2014 CFR

2014-01-01

... 9 Animals and Animal Products 2 2014-01-01 2014-01-01 false Means of conveyance in which dead... INSPECTION AND CERTIFICATION TRANSPORTATION § 325.21 Means of conveyance in which dead, dying, disabled, or... conveyance used by persons subject to § 325.20 for transporting in commerce or importing, any dead, dying...

9 CFR 325.21 - Means of conveyance in which dead, dying, disabled, or diseased livestock and parts of carcasses...

Code of Federal Regulations, 2011 CFR

2011-01-01

... 9 Animals and Animal Products 2 2011-01-01 2011-01-01 false Means of conveyance in which dead... INSPECTION AND CERTIFICATION TRANSPORTATION § 325.21 Means of conveyance in which dead, dying, disabled, or... conveyance used by persons subject to § 325.20 for transporting in commerce or importing, any dead, dying...

Castable Amorphous Metal Mirrors and Mirror Assemblies

NASA Technical Reports Server (NTRS)

Hofmann, Douglas C.; Davis, Gregory L.; Agnes, Gregory S.; Shapiro, Andrew A.

2013-01-01

A revolutionary way to produce a mirror and mirror assembly is to cast the entire part at once from a metal alloy that combines all of the desired features into the final part: optical smoothness, curvature, flexures, tabs, isogrids, low CTE, and toughness. In this work, it has been demonstrated that castable mirrors are possible using bulk metallic glasses (BMGs, also called amorphous metals) and BMG matrix composites (BMGMCs). These novel alloys have all of the desired mechanical and thermal properties to fabricate an entire mirror assembly without machining, bonding, brazing, welding, or epoxy. BMGs are multi-component metal alloys that have been cooled in such a manner as to avoid crystallization leading to an amorphous (non-crystalline) microstructure. This lack of crystal structure and the fact that these alloys are glasses, leads to a wide assortment of mechanical and thermal properties that are unlike those observed in crystalline metals. Among these are high yield strength, carbide-like hardness, low melting temperatures (making them castable like aluminum), a thermoplastic processing region (for improving smoothness), low stiffness, high strength-to-weight ratios, relatively low CTE, density similar to titanium alloys, high elasticity and ultra-smooth cast parts (as low as 0.2-nm surface roughness has been demonstrated in cast BMGs). BMGMCs are composite alloys that consist of a BMG matrix with crystalline dendrites embedded throughout. BMGMCs are used to overcome the typically brittle failure observed in monolithic BMGs by adding a soft phase that arrests the formation of cracks in the BMG matrix. In some cases, BMGMCs offer superior castability, toughness, and fatigue resistance, if not as good a surface finish as BMGs. This work has demonstrated that BMGs and BMGMCs can be cast into prototype mirrors and mirror assemblies without difficulty.

Hierarchical modeling of professional skills in the field of castings manufacture engineering

NASA Astrophysics Data System (ADS)

Samuilă, V.; Soporan, V. F.; Conțiu, G.; Pădurețu, S.; Lehene, T. R.; Vescan, M. M.

2017-06-01

The paper presents a method of hierarchizing professional skills in the manufacturing of molded parts (castings) by using and adapting the FAHP algorithm (Fuzzy Analitical Hierarchy Process). Assessments are made regarding the peculiarities of the professional training process, specifying the activities to be carried out and the competences necessary for their development. The contribution of the design of the method extends to the design of the hierarchy system architecture, the linguistic determination of the importance of each characteristic, the construction of the fuzzy ordering matrices for each stage of the process, the determination of the share of the characteristics for each hierarchy step and establishing the hierarchy of the characteristics taking into account the influences of the others, grouped at the level of the steps and within the global matrix. The research carried out represents the support for generating an instrument of hierarchy of professional competencies that can be used in various professional and institutional contexts. Case study on the hierarchy of professional skills in the manufacturing of molded parts engineering. Keywords: Materials engineering, castings manufacture professional skills, hierarchy, AHP method, standard occupational curriculum.

Sealing properties of three luting agents used for complete cast crowns: a bacterial leakage study.

PubMed

Zmener, O; Pameijer, C H; Rincon, S M H; Serrano, S A; Chaves, C

2013-01-01

To assess the sealing properties of three different luting materials used for cementation of full cast crowns on extracted human premolars. Thirty noncarious human premolars were prepared in a standardized fashion for full cast crown restorations. All margins were placed in dentin. After impressions of the preparations, stone dies were fabricated on which copings were waxed, which were cast in type III alloy using standardized laboratory methods. Teeth were randomly assigned to three groups of 10 samples each (n=10), for which the following cements were used: 1) a resin-modified glass ionomer cement, Rely X Luting Plus (3M ESPE, St Paul, MN, USA); 2) a self-adhesive resin cement, Maxcem Elite (Kerr Corporation, Orange, CA, USA); and 3) a glass ionomer cement, Ketac Cem (3M ESPE), the latter used as control. After cementation the samples were allowed to bench-set for 10 minutes, stored in water at 37°C, subjected to thermal cycling (2000×, between 5°C and 55°C, dwell time 35 seconds), and then stored in sterile phosphate buffer for seven days at 37°C. Subsequently, the occlusal surface was carefully reduced until the dentin was exposed. Finishing on wet sand paper removed the gold flash caused by grinding. After sterilization, the specimens were subjected to bacterial microleakage in a dual chamber apparatus for 60 days. Bacterial leakage was checked daily. Data were analyzed using the Kaplan-Meier survival test. Significant pairwise differences were analyzed using the log-rank test followed by Fisher exact test at a p<0.05 level of significance. Rely X Luting Plus showed the lowest microleakage scores, which statistically differed significantly from Maxcem Elite and Ketac Cem (p<0.05). Rely X Luting Plus cement displayed significantly lower microleakage scores than a self-adhesive resin-based and conventional glass ionomer cement.

Evaluation of outgassing, tear strength, and detail reproduction in alginate substitute materials.

PubMed

Baxter, R T; Lawson, N C; Cakir, D; Beck, P; Ramp, L C; Burgess, J O

2012-01-01

To compare three alginate substitute materials to an alginate impression material for cast surface porosity (outgassing), tear strength, and detail reproduction. Detail reproduction tests were performed following American National Standards Institute/American Dental Association (ANSI/ADA) Specification No. 19. To measure tear strength, 12 samples of each material were made using a split mold, placed in a water bath until testing, and loaded in tension until failure at a rate of 500 mm/min using a universal testing machine. For cast surface porosity testing, five impressions of a Teflon mold with each material were placed in a water bath (37.8°C) for the in-mouth setting time and poured with vacuum-mixed Silky Rock die stone at 5, 10, 30, and 60 minutes from the start of mixing. The gypsum samples were analyzed with a digital microscope for surface porosity indicative of hydrogen gas release by comparing the surface obtained at each interval with four casts representing no, little, some, and significant porosity. Data analysis was performed using parametric and Kruskal-Wallis analysis of variance (ANOVA), Tukey/Kramer post-hoc tests (α=0.05), and individual Mann-Whitney U tests (α=0.0167). All alginate substitute materials passed the detail reproduction test. Tear strength of the alginate substitute materials was significantly better than alginate and formed three statistically different groups: AlgiNot had the lowest tear strength, Algin-X Ultra had the highest tear strength, and Position Penta Quick had intermediate tear strength. Significant variation in outgassing existed between materials and pouring times (p<0.05). All alginate substitute materials exhibited the least outgassing and cast porosity 60 minutes after mixing. Detail reproduction and tear strength of alginate substitute materials were superior to traditional alginate. The outgassing effect was minimal for most materials tested. Alginate substitute materials are superior replacements for irreversible hydrocolloid.

[Evaluating the accuracy of three-dimensional reconstruction of the intercuspal position for dentition casts aided by a mechanical appliance].

PubMed

Hu, Z W; Li, W W; Zhang, X Y; Fan, B L; Wang, Y; Sun, Y C

2016-08-01

To develop a aided mechanical appliance for rapid reconstruction of three-dimensional(3D)relationship of dentition model after scanning and evaluation of its accuracy. The appliance was designed by forward engineering software and fabricated by a high precision computer numerical control(CNC)system. It contained upper and lower body, magnetic pedestal and three pillars. Nine 3 mm diameter hemispheres were distributed equally on the axial surface of each pedestal. Faro Edge 1.8m was used to directly obtain center of each hemisphere(contact method), defined as known center. A pair of die-stone standard dentition model were fixed in intercuspal position and then fixed on the magnetic pedestals with low expansion ratio plaster. Activity 880 dental scanner was used to scan casts after the plaster was completely set. In Geomagic 2012, the centers of each hemisphere were fitted and defined as scanning centers. Scanning centers were aligned to known centers by reference point system to finish the 3D reconstruction of the intercuspal occlusion for the dentition casts. An observation coordinate system was interactively established. The straight-line distances in the X(coronal), Y(saggital), and Z(vertical)between the remaining 6 pairs of center points derived from contact method and fitting method were measured respectively and analyzed using a paired t-test. The differences of the straight-line distances of the remaining 6 pairs of center points between the two methods were X:(-0.05±0.10)mm, Y:(0.02±0.06)mm, and Z:(0.01 ± 0.05)mm. The results of paired t-test showed no significant differences(P>0.05). The mechanical appliance can help to reconstruct 3D jaw relation by scanning single upper and lower dentition model with usual commercial available dental cast scanning system.

Low force cementation.

PubMed

Wilson, P R

1996-07-01

The marginal adaptation of full coverage restorations is adversely affected by the introduction of luting agents of various minimum film thicknesses during the cementation process. The increase in the marginal opening may have long-term detrimental effects on the health of both pulpal and periodontal tissues. The purpose of this study was to determine the effects of varying seating forces (2.5, 12.5, 25 N), venting, and cement types on post-cementation marginal elevation in cast crowns. A standardized cement space of 40 microns was provided between a machined gold crown and a stainless steel die. An occlusal vent was placed that could be opened or closed. The post-cementation crown elevation was measured, following the use of two commercially available capsulated dental cements (Phosphacap, and Ketac-cem Applicap). The results indicate that only the combination of Ketac-Cem Applicap and crown venting produced post-cementation crown elevation of less than 20 microns when 12.5 N seating force was used. Higher forces (25 N) and venting were required for comparable seating when using Phosphacap (19 microns). The amount of force required to allow maximum seating of cast crowns appears to be cement specific, and is reduced by effective venting procedures.

Part I: In-situ fluorometric quantification of microalgal neutral lipids. Part II: Thermal degradation behavior of investment casting polymer patterns

NASA Astrophysics Data System (ADS)

Zhao, Hongfang

Research described in this dissertation covers two topics. Part-I is focused on in-situ determination of neutral lipid content of microalgae using a lipophilic fluorescent dye. The traditional Nile red stain-based method for detecting microalgal intracellular lipids is limited due to varying composition and thickness of rigid cell walls. In this study, the addition of dilute acid and heating of solution, were found to greatly enhance staining efficiency of Nile red for microalgal species evaluated. Oil-in-water (O/W) microemulsion stabilized by a non-ionic surfactant was employed as a pseudo-standard that mimics lipid-bearing microalgal cells suspended in water. The average neutral lipid contents determined were very close to the results obtained by traditional gravimetric method and solid phase extraction. Part II of the dissertation explores thermo-physico-chemical properties of polymeric pattern materials, including expanded polystyrene (EPS) foam, polyurethane foam, and epoxy stereolithography (SLA) patterns, that are used in investment casting. Density, elastic modulus, expansion coefficient, thermal degradation behavior, etc. were experimentally investigated for their effects on metal casting quality. The reduction in toxic hydrogen cyanide (HCN) generated during thermal decomposition of polyurethane pattern was achieved by increasing either oxidant level or residence time in heated zone. Thermal degradation kinetics of the pattern materials were examined with a thermogravimetric analysis and activation energies were determined by Kissinger and Flynn-Wall-Ozawa methods.

Facing Up to Death

ERIC Educational Resources Information Center

Ross, Elizabeth Kubler

1972-01-01

Doctor urges that Americans accept death as a part of life and suggests ways of helping dying patients and their families face reality calmly, with peace. Dying children and their siblings, as well as children's feelings about relatives' deaths, are also discussed. (PD)

Legal bans on pro-suicide web sites: an early retrospective from Australia.

PubMed

Pirkis, Jane; Neal, Luke; Dare, Andrew; Blood, R Warwick; Studdert, David

2009-04-01

There are worldwide concerns that pro-suicide web sites may trigger suicidal behaviors among vulnerable individuals. In 2006, Australia became the first country to criminalize such sites, sparking heated debate. Concerns were expressed that the law casts the criminal net too widely; inappropriately interferes with the autonomy of those who wish to die; and has jurisdictional limitations, with off-shore web sites remaining largely immune. Conversely, proponents point out that the law may limit access to domestic pro-suicide web sites, raise awareness of Internet-related suicide, mobilize community efforts to combat it, and serve as a powerful expression of societal norms about the promotion of suicidal behavior.

Laser Hot Wire Process: A Novel Process for Near-Net Shape Fabrication for High-Throughput Applications

NASA Astrophysics Data System (ADS)

Kottman, Michael; Zhang, Shenjia; McGuffin-Cawley, James; Denney, Paul; Narayanan, Badri K.

2015-03-01

The laser hot wire process has gained considerable interest for additive manufacturing applications, leveraging its high deposition rate, low dilution, thermal stability, and general metallurgical control including the ability to introduce and preserve desired meta-stable phases. Recent advancements in closed-loop process control and laser technology have increased productivity, process stability, and control of deposit metallurgy. The laser hot wire process has shown success in several applications: repairing and rejuvenating casting dies, depositing a variety of alloys including abrasion wear-resistant overlays with solid and tubular wires, and producing low-dilution (<5%) nickel alloy overlays for corrosion applications. The feasibility of fabricating titanium buildups is being assessed for aerospace applications.

A High Resolution Study of Black Sea Circulation and Hypothetical Oil Spills

NASA Astrophysics Data System (ADS)

Dietrich, D. E.; Bowman, M. J.; Korotenko, K. A.

2008-12-01

A 1/24 deg resolution adaptation of the DieCAST ocean model simulates a realistically intense Rim Current and ubiquitous mesoscale coastal anticyclonic eddies that result from anticyclonic vorticity generation by laterally differential bottom drag forces that are amplified near Black Sea coastal headlands. Climatological and synoptic surface forcings are compared. The effects of vertical momentum transfer by known (by Synop region fishermen, as reported by Ballard National Geographic article) big amplitude internal waves are parameterized by big vertical viscosity. Sensitivity to vertical viscosity is shown. Results of simulated hypothetical oil spills are shown. A simple method to nowcast/forecast the Black Sea currents is described and early results are shown.

Lightweight Mg-based composites with thermodynamically stable interfaces by in-situ combustion synthesis

NASA Astrophysics Data System (ADS)

Jo, Ilguk

Lightweight Mg-based composites have been produced by in-situ combustion synthesis of the Al-Ti-C reaction system. The characteristics of the in-situ composites were investigated in terms of phase evolution and interfacial stability using various analysis techniques. The structural analysis results showed that full conversion of the Al-Ti-C reactants into spherical TiC reinforcements with sizes around 1mum was achieved by the combustion reaction. In-situ formed TiC had less oxygen and higher Al contents at the interface than ex-situ formed TiC; these clean interfaces with an Al layer on the reinforcements were shown to yield interfacial stability. For these reasons, the in-situ composites exhibited higher theoretical densities and also good mechanical properties compared with ex-situ produced composites. The interfacial characteristics of molten Mg with the Al-Ti-C reactants and the commercial TiC+Al substrates were evaluated using an infiltration technique under an argon atmosphere. Infiltration length increased with time at temperature, yielding activation energies (Ea) for each system. The value of Ea for the Al-Ti-C system (307.31kJ/mol) is lower than that for the other system (350.84kJ/mol); the high Ea value indicates that the infiltration is not a simple viscosity-controlled phenomenon but involves a chemical reaction. Formation of the Al3Ti phase was observed from the crystal structural analysis of the infiltrated area; thus, existence of reaction promoting the wetting of Mg. The phase evolution, reaction mechanism and kinetics of the Al-Ti-C reaction were studied using DSC and HT-XRD. It was confirmed that, along with the melting of Al, there was formation of Al3Ti by reaction between Al and Ti. A detailed structural analysis indicates that, the reaction mechanism involves melting of Al followed by formation and growth of Al 3Ti, which then contacts the graphite powder and initiates the combustion reaction. The effect of important process parameters, such as the Al content and the reactant sizes, on the microstructure of the resulting in-situ composites is discussed. Feasibility and castability of the composites were investigated by high pressure die casting the composite preforms into automotive parts and durability tests were conducted on the cast parts.

Setup of a Parameterized FE Model for the Die Roll Prediction in Fine Blanking using Artificial Neural Networks

NASA Astrophysics Data System (ADS)

Stanke, J.; Trauth, D.; Feuerhack, A.; Klocke, F.

2017-09-01

Die roll is a morphological feature of fine blanked sheared edges. The die roll reduces the functional part of the sheared edge. To compensate for the die roll thicker sheet metal strips and secondary machining must be used. However, in order to avoid this, the influence of various fine blanking process parameters on the die roll has been experimentally and numerically studied, but there is still a lack of knowledge on the effects of some factors and especially factor interactions on the die roll. Recent changes in the field of artificial intelligence motivate the hybrid use of the finite element method and artificial neural networks to account for these non-considered parameters. Therefore, a set of simulations using a validated finite element model of fine blanking is firstly used to train an artificial neural network. Then the artificial neural network is trained with thousands of experimental trials. Thus, the objective of this contribution is to develop an artificial neural network that reliably predicts the die roll. Therefore, in this contribution, the setup of a fully parameterized 2D FE model is presented that will be used for batch training of an artificial neural network. The FE model enables an automatic variation of the edge radii of blank punch and die plate, the counter and blank holder force, the sheet metal thickness and part diameter, V-ring height and position, cutting velocity as well as material parameters covered by the Hensel-Spittel model for 16MnCr5 (1.7131, AISI/SAE 5115). The FE model is validated using experimental trails. The results of this contribution is a FE model suitable to perform 9.623 simulations and to pass the simulated die roll width and height automatically to an artificial neural network.

Replication of engine block cylinder bridge microstructure and mechanical properties with lab scale 319 Al alloy billet castings

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

Lombardi, A., E-mail: a2lombar@ryerson.ca; D'Elia, F.; Ravindran, C.

2014-01-15

In recent years, aluminum alloy gasoline engine blocks have in large part successfully replaced nodular cast iron engine blocks, resulting in improved vehicle fuel efficiency. However, because of the inadequate wear resistance properties of hypoeutectic Al–Si alloys, gray iron cylinder liners are required. These liners cause the development of large tensile residual stress along the cylinder bores and necessitate the maximization of mechanical properties in this region to prevent premature engine failure. The aim of this study was to replicate the engine cylinder bridge microstructure and mechanical properties following TSR treatment (which removes the sand binder to enable easy castingmore » retrieval) using lab scale billet castings of the same alloy composition with varying cooling rates. Comparisons in microstructure between the engine block and the billet castings were carried out using optical and scanning electron microscopy, while mechanical properties were assessed using tensile testing. The results suggest that the microstructure at the top and middle of the engine block cylinder bridge was successfully replicated by the billet castings. However, the microstructure at the bottom of the cylinder was not completely replicated due to variations in secondary phase morphology and distribution. The successful replication of engine block microstructure will enable the future optimization of heat treatment parameters. - Highlights: • A method to replicate engine block microstructure was developed. • Billet castings will allow cost effective optimization of heat treatment process. • The replication of microstructure in the cylinder region was mostly successful. • Porosity was more clustered in the billet castings compared to the engine block. • Mechanical properties were lower in billet castings due to porosity and inclusions.« less

Phosphorylation of Heat Shock Protein 27 is Increased by Cast Immobilization and by Serum-free Starvation in Skeletal Muscles

PubMed Central

Kim, Mee-Young; Lee, Jeong-Uk; Kim, Ju-Hyun; Lee, Lim-Kyu; Park, Byoung-Sun; Yang, Seung-Min; Jeon, Hye-Joo; Lee, Won-Deok; Noh, Ji-Woong; Kwak, Taek-Yong; Jang, Sung-Ho; Lee, Tae-Hyun; Kim, Ju-Young; Kim, Bokyung; Kim, Junghwan

2014-01-01

[Purpose] Cast immobilization- and cell starvation-induced loss of muscle mass are closely associated with a dramatic reduction in the structural muscle proteins. Heat shock proteins are molecular chaperones that are constitutively expressed in several eukaryotic cells and have been shown to protect against various stressors. However, the changes in the phosphorylation of atrophy-related heat shock protein 27 (HSP27) are still poorly understood in skeletal muscles. In this study, we examine whether or not phosphorylation of HSP27 is changed in the skeletal muscles after cast immobilization and serum-free starvation with low glucose in a time-dependent manner. [Methods] We undertook a HSP27 expression and high-resolution differential proteomic analysis in skeletal muscles. Furthermore, we used western blotting to examine protein expression and phosphorylation of HSP27 in atrophied gastrocnemius muscle strips and L6 myoblasts. [Results] Cast immobilization and starvation significantly upregulated the phosphorylation of HSP27 in a time-dependent manner, respectively. [Conclusion] Our results suggest that cast immobilization- and serum-free starvation-induced atrophy may be in part related to changes in the phosphorylation of HSP27 in rat skeletal muscles. PMID:25540511

Inboard seal mounting

DOEpatents

Hayes, John R.

1983-01-01

A regenerator assembly for a gas turbine engine has a hot side seal assembly formed in part by a cast metal engine block having a seal recess formed therein that is configured to supportingly receive ceramic support blocks including an inboard face thereon having a regenerator seal face bonded thereto. A pressurized leaf seal is interposed between the ceramic support block and the cast metal engine block to bias the seal wear face into sealing engagement with a hot side surface of a rotary regenerator matrix.

Characterization of Novel Gel Casting System to Make Complex Shaped Aluminum Oxide (Al2O3) Parts

DTIC Science & Technology

2016-03-01

investigated including systems based on starch , gelatin, protein, and agarose. Generally, all systems are too expensive for high-volume casting.13 While gel...was determined by measuring the resistance force in uniaxial compression. Therefore, the specimen was considered gelled when the resistance force was...used to lower the indenter tip at a rate of 30 mm/min by a distance of 6 mm while measuring the maximum resistance force during the indentation. At the

Discussion of "Investigation of Oxide Bifilms in Investment Cast Superalloy IN100 Parts I and II"*

NASA Astrophysics Data System (ADS)

Campbell, John

2017-10-01

Fuchs and Kaplan carried out experiments in an attempt to ascertain whether oxide bifilms were present in a vacuum-cast Ni-base superalloy but concluded negatively. Although this author challenged their interpretation of their findings, both parties had overlooked the presence in the alloy of boron which is now known to inhibit bifilm formation. However, even though boron can help significantly, improved filling system designs remain important if other damaging entrainment defects are to be avoided.

Influence of Ultrasound Treatment on Cavitation Erosion Resistance of AlSi7 Alloy

PubMed Central

Pola, Annalisa; Montesano, Lorenzo; Tocci, Marialaura; La Vecchia, Giovina Marina

2017-01-01

Ultrasound treatment of liquid aluminum alloys is known to improve mechanical properties of castings. Aluminum foundry alloys are frequently used for production of parts that undergo severe cavitation erosion phenomena during service. In this paper, the effect of the ultrasound treatment on cavitation erosion resistance of AlSi7 alloy was assessed and compared to that of conventionally cast samples. Cavitation erosion tests were performed according to ASTM G32 standard on as-cast and heat treated castings. The response of the alloy in each condition was investigated by measuring the mass loss as a function of cavitation time and by analyzing the damaged surfaces by means of optical and scanning electron microscope. It was pointed out that the ultrasound treatment increases the cavitation erosion resistance of the alloy, as a consequence of the higher chemical and microstructural homogeneity, the finer grains and primary particles and the refined structure of the eutectic induced by the treatment itself. PMID:28772617

Influence of Ultrasound Treatment on Cavitation Erosion Resistance of AlSi7 Alloy.

PubMed

Pola, Annalisa; Montesano, Lorenzo; Tocci, Marialaura; La Vecchia, Giovina Marina

2017-03-03

Ultrasound treatment of liquid aluminum alloys is known to improve mechanical properties of castings. Aluminum foundry alloys are frequently used for production of parts that undergo severe cavitation erosion phenomena during service. In this paper, the effect of the ultrasound treatment on cavitation erosion resistance of AlSi7 alloy was assessed and compared to that of conventionally cast samples. Cavitation erosion tests were performed according to ASTM G32 standard on as-cast and heat treated castings. The response of the alloy in each condition was investigated by measuring the mass loss as a function of cavitation time and by analyzing the damaged surfaces by means of optical and scanning electron microscope. It was pointed out that the ultrasound treatment increases the cavitation erosion resistance of the alloy, as a consequence of the higher chemical and microstructural homogeneity, the finer grains and primary particles and the refined structure of the eutectic induced by the treatment itself.

Grindability of cast Ti-Hf alloys.

PubMed

Kikuchi, Masafumi; Takahashi, Masatoshi; Sato, Hideki; Okuno, Osamu; Nunn, Martha E; Okabe, Toru

2006-04-01

As part of our systematic studies characterizing the properties of titanium alloys, we investigated the grindability of a series of cast Ti-Hf alloys. Alloy buttons with hafnium concentrations up to 40 mass% were made using an argon-arc melting furnace. Each button was cast into a magnesia-based mold using a dental titanium casting machine; three specimens were made for each metal. Prior to testing, the hardened surface layer was removed. The specimens were ground at five different speeds for 1 min at 0.98 N using a carborundum wheel on an electric dental handpiece. Grindability was evaluated as the volume of metal removed per minute (grinding rate) and the volume ratio of metal removed compared to the wheel material lost (grinding ratio). The data were analyzed using ANOVA. A trend of increasing grindability was found with increasing amounts of hafnium, although there was no statistical difference in the grindability with increasing hafnium contents. We also found that hafnium may be used to harden or strengthen titanium without deteriorating the grindability.

"Split Cast Mounting: Review and New Technique".

PubMed

Gundawar, S M; Pande, Neelam A; Jaiswal, Priti; Radke, U M

2014-12-01

For the fabrication of a prosthesis, the Prosthodontist meticulously performs all the steps. The laboratory technician then make every effort/strives to perform the remaining lab procedures. However when the processed dentures are remounted on the articulator, some changes are seen. These changes may be divided into two categories: Pre-insertion and post-insertion changes, which deal with the physical properties of the materials involved (Parker, J Prosthet Dent 31:335-342, 1974). Split cast mounting is the method of mounting casts on the articulator. It is essentially a maxillary cast constructed in two parts with a horizontal division. The procedure allows for the verification of the accuracy of the initial mounting and the ease of removal and replacement of the cast. This provides a precise means of correcting the changes in occlusion occurring as a result of the processing technique (Nogueira et al., J Prosthet Dent 91:386-388, 2004). Instability of the split mounting has always been a problem to the Prosthodontist thereby limiting its use. There are various materials mentioned in the literature. The new technique by using Dowel pins and twill thread is very easy, cheaper and simple way to stabilize the split mounting. It is useful and easy in day to day laboratory procedures. The article presents different methods of split cast mounting and the new procedure using easily available materials in prosthetic laboratory.

Methods and Algorithms for Computer-aided Engineering of Die Tooling of Compressor Blades from Titanium Alloy

NASA Astrophysics Data System (ADS)

Khaimovich, A. I.; Khaimovich, I. N.

2018-01-01

The articles provides the calculation algorithms for blank design and die forming fitting to produce the compressor blades for aircraft engines. The design system proposed in the article allows generating drafts of trimming and reducing dies automatically, leading to significant reduction of work preparation time. The detailed analysis of the blade structural elements features was carried out, the taken limitations and technological solutions allowed to form generalized algorithms of forming parting stamp face over the entire circuit of the engraving for different configurations of die forgings. The author worked out the algorithms and programs to calculate three dimensional point locations describing the configuration of die cavity.

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.

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.

CAE Based Die Face Engineering Development to Contribute to the Revitalization of the Tool & Die Industry

NASA Astrophysics Data System (ADS)

Tang, Arthur; Lee, Wing C.; St. Pierre, Shawn; He, Jeanne; Liu, Kesu; Chen, Chin C.

2005-08-01

Over the past two decades, the Computer Aided Engineering (CAE) tools have emerged as one of the most important engineering tools in various industries, due to its flexibility and accuracy in prediction. Nowadays, CAE tools are widely used in the sheet metal forming industry to predict the forming feasibility of a wide variety of complex components, ranging from aerospace and automotive components to household products. As the demand of CAE based formability accelerates, the need for a robust and streamlined die face engineering tool becomes more crucial, especially in the early stage when the tooling layout is not available, but a product design decision must be made. Ability to generate blank, binder and addendum surfaces with an appropriate layout of Drawbead, Punch Opening Line, Trim Line are the primary features and functions of a CAE based die face engineering tool. Once the die face layout is ready, a formability study should be followed to verify the die face layout is adequate to produce a formable part. If successful, the established die face surface should be exported back to the CAD/CAM environment to speed up the tooling and manufacturing design process with confidence that this particular part is formable with this given die face. With a CAE tool as described above, the tool & die industry will be greatly impacted as the processes will enable the bypass of hardware try-out and shorten the overall vehicle production timing. The trend has shown that OEMs and first tiers will source to low cost producers in the world which will have a negative impact to the traditional tool & die makers in the developed countries. CAE based tool as described should be adopted, along with many other solutions, in order to maintain efficiency of producing high quality product and meeting time-to-market requirements. This paper will describe how a CAE based die face engineering (DFE) tool could be further developed to enable the traditional tool & die makers to meet the challenge ahead.

Reading Pornography

ERIC Educational Resources Information Center

Hardy, Simon

2004-01-01

Over the last 30 years academic discussion of pornography has been largely confined to questions about its social and psychological effects. The debate has been caste in black and white terms; partly because the stakes were political, as in the debate over porn amongst feminists, and partly because social scientists have sought to produce a hard,…

Reliability of capturing foot parameters using digital scanning and the neutral suspension casting technique

PubMed Central

2011-01-01

Background A clinical study was conducted to determine the intra and inter-rater reliability of digital scanning and the neutral suspension casting technique to measure six foot parameters. The neutral suspension casting technique is a commonly utilised method for obtaining a negative impression of the foot prior to orthotic fabrication. Digital scanning offers an alternative to the traditional plaster of Paris techniques. Methods Twenty one healthy participants volunteered to take part in the study. Six casts and six digital scans were obtained from each participant by two raters of differing clinical experience. The foot parameters chosen for investigation were cast length (mm), forefoot width (mm), rearfoot width (mm), medial arch height (mm), lateral arch height (mm) and forefoot to rearfoot alignment (degrees). Intraclass correlation coefficients (ICC) with 95% confidence intervals (CI) were calculated to determine the intra and inter-rater reliability. Measurement error was assessed through the calculation of the standard error of the measurement (SEM) and smallest real difference (SRD). Results ICC values for all foot parameters using digital scanning ranged between 0.81-0.99 for both intra and inter-rater reliability. For neutral suspension casting technique inter-rater reliability values ranged from 0.57-0.99 and intra-rater reliability values ranging from 0.36-0.99 for rater 1 and 0.49-0.99 for rater 2. Conclusions The findings of this study indicate that digital scanning is a reliable technique, irrespective of clinical experience, with reduced measurement variability in all foot parameters investigated when compared to neutral suspension casting. PMID:21375757

Friction stir welded AM50 and AZ31 Mg alloys: Microstructural evolution and improved corrosion resistance

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

Templeman, Yael

One of the major drawbacks of Mg alloys is poor weldability, caused by porosity formation during conventional fusion welding processes. Friction Stir Welding (FSW) is promising technique in this context since it is a solid state technique. Contradicting results were published in the literature regarding the FSWed Mg alloys joint's properties. Current research was performed in order to investigate the microstructure and corrosion properties of FSWed Mg alloys, studying representatives of two commercial families: wrought AZ31-H24 and die cast AM50. It was found that in both alloys recrystallization occurred during the FSW. In AM50 the mechanism of the recrystallization wasmore » continuous, manifested by dislocation rearrangement into sub grain boundaries. In AZ31 discontinuous recrystallization had occurred through grain boundaries migration - twins rotated with respect to the matrix, turning into low angle grain boundaries. Corrosion resistance has improved during the FSW in both alloys to different extents. In the AM50 alloy, the nugget exhibited significantly higher surface potential than the base metal mainly due to the higher Al concentration in the matrix of the nugget, resulting from the dissolution of Al-enrichment and β-Mg{sub 17}Al{sub 12} phase. In the AZ31 alloy, no change in Al concentration had occurred, and the surface potential measured in the nugget was only slightly higher than in the base metal. These results underline the appropriateness of the FSW for Mg alloys since during the conventional welding deterioration of the corrosion resistance occurs. - Highlights: • Following FSW, AZ31-H24 experienced discontinuous recrystallization. • In AZ31 grain boundaries migration occurred, thus twins rotated. • In die cast AM50 continuous recrystallization occurred during the FSW. • In AM50 - dislocations rearranged into sub grain boundaries. • Corrosion resistance has improved during the FSW in both alloys to different extent.« less

Evolution of A-Type Macrosegregation in Large Size Steel Ingot After Multistep Forging and Heat Treatment

NASA Astrophysics Data System (ADS)

Loucif, Abdelhalim; Ben Fredj, Emna; Harris, Nathan; Shahriari, Davood; Jahazi, Mohammad; Lapierre-Boire, Louis-Philippe

2018-03-01

A-type macrosegregation refers to the channel chemical heterogeneities that can be formed during solidification in large size steel ingots. In this research, a combination of experiment and simulation was used to study the influence of open die forging parameters on the evolution of A-type macrosegregation patterns during a multistep forging of a 40 metric ton (MT) cast, high-strength steel ingot. Macrosegregation patterns were determined experimentally by macroetch along the longitudinal axis of the forged and heat-treated ingot. Mass spectroscopy, on more than 900 samples, was used to determine the chemical composition map of the entire longitudinal sectioned surface. FORGE NxT 1.1 finite element modeling code was used to predict the effect of forging sequences on the morphology evolution of A-type macrosegregation patterns. For this purpose, grain flow variables were defined and implemented in a large scale finite element modeling code to describe oriented grains and A-type segregation patterns. Examination of the A-type macrosegregation showed four to five parallel continuous channels located nearly symmetrical to the axis of the forged ingot. In some regions, the A-type patterns became curved or obtained a wavy form in contrast to their straight shape in the as-cast state. Mass spectrometry analysis of the main alloying elements (C, Mn, Ni, Cr, Mo, Cu, P, and S) revealed that carbon, manganese, and chromium were the most segregated alloying elements in A-type macrosegregation patterns. The observed differences were analyzed using thermodynamic calculations, which indicated that changes in the chemical composition of the liquid metal can affect the primary solidification mode and the segregation intensity of the alloying elements. Finite element modeling simulation results showed very good agreement with the experimental observations, thereby allowing for the quantification of the influence of temperature and deformation on the evolution of the shape of the macrosegregation channels during the open die forging process.

Evolution of A-Type Macrosegregation in Large Size Steel Ingot After Multistep Forging and Heat Treatment

NASA Astrophysics Data System (ADS)

Loucif, Abdelhalim; Ben Fredj, Emna; Harris, Nathan; Shahriari, Davood; Jahazi, Mohammad; Lapierre-Boire, Louis-Philippe

2018-06-01

A-type macrosegregation refers to the channel chemical heterogeneities that can be formed during solidification in large size steel ingots. In this research, a combination of experiment and simulation was used to study the influence of open die forging parameters on the evolution of A-type macrosegregation patterns during a multistep forging of a 40 metric ton (MT) cast, high-strength steel ingot. Macrosegregation patterns were determined experimentally by macroetch along the longitudinal axis of the forged and heat-treated ingot. Mass spectroscopy, on more than 900 samples, was used to determine the chemical composition map of the entire longitudinal sectioned surface. FORGE NxT 1.1 finite element modeling code was used to predict the effect of forging sequences on the morphology evolution of A-type macrosegregation patterns. For this purpose, grain flow variables were defined and implemented in a large scale finite element modeling code to describe oriented grains and A-type segregation patterns. Examination of the A-type macrosegregation showed four to five parallel continuous channels located nearly symmetrical to the axis of the forged ingot. In some regions, the A-type patterns became curved or obtained a wavy form in contrast to their straight shape in the as-cast state. Mass spectrometry analysis of the main alloying elements (C, Mn, Ni, Cr, Mo, Cu, P, and S) revealed that carbon, manganese, and chromium were the most segregated alloying elements in A-type macrosegregation patterns. The observed differences were analyzed using thermodynamic calculations, which indicated that changes in the chemical composition of the liquid metal can affect the primary solidification mode and the segregation intensity of the alloying elements. Finite element modeling simulation results showed very good agreement with the experimental observations, thereby allowing for the quantification of the influence of temperature and deformation on the evolution of the shape of the macrosegregation channels during the open die forging process.

Wear Behavior and Mechanism of a Cr-Mo-V Cast Hot-Working Die Steel

NASA Astrophysics Data System (ADS)

Wei, M. X.; Wang, S. Q.; Zhao, Y. T.; Chen, K. M.; Cui, X. H.

2011-06-01

The wear behavior and mechanisms of a Cr-Mo-V cast hot-working die steel with three microstructures (tempered martensite, troostite, and sorbite) were studied systematically through the dry-sliding wear tests within a normal load range of 50 to 300 N and an ambient temperature range of 298 K to 673 K (25 °C to 400 °C) by a pin-on-disk high-temperature wear machine. Five different mechanisms were observed in the experiments, namely adhesive, abrasive, mild oxidative, oxidative, and extrusive wear; one or more of those mechanisms would be dominant within particular ranges of load and temperature. The transition of wear mechanisms depended on the formation of tribo-oxides, which was related closely to load and temperature, and their delamination, which was mainly influenced by the matrix. By increasing the load and ambient temperature, the protective effect of tribo-oxides first strengthened, then decreased, and in some cases disappeared. Under a load ranging 50 to 300 N at 298 K (25 °C) and a load of 50 N at 473 K (200 °C), adhesive wear was the dominant wear mechanism, and abrasive wear appeared simultaneously. The wear was of mild oxidative type under a load ranging 100 to 300 N at 473 K (200 °C) and a load ranging 50 to 150 N at 673 K (400 °C) for tempered martensite and tempered troostite as well as under a load of 100 N at 473 K (200 °C) and a load ranging 50 to 100 N at 673 K (400 °C) for tempered sorbite. At the load of 200 N or greater, or the temperatures above 673 K (400 °C), oxidative wear (beyond mild oxidative wear) prevailed. When the highest load of 300 N at 673 K (400 °C) was applied, extrusive wear started to dominate for the tempered sorbite.

Conditions of life and death of psychiatric patients in France during World War II: euthanasia or collateral casualties?

PubMed

Lemoine, Patrick; Stahl, Stephen M

2018-04-01

Between 1940 and 1944, an estimated 48,588 patients resident in French psychiatric hospitals died of starvation. Standard prisons, while facing similar problems, did not experience the same number of deaths by starvation, partly due to their ability to develop a black market for food and rations. Patients in psychiatric hospitals, on the other hand, were completely at the mercy of their doctors and the personnel in charge. At Hôpital du Vinatier, a psychiatric facility in Lyon, the mortality rate increased sharply from 1940 to 1944. In 1942, the worst year, 42% of patients died of hunger and exposure. In the end, more than 2,000 patients died at Vinatier. Was this due to a supposed lack of rations, or was it something more sinister? In Germany at the same time, tens of thousands of psychiatric patients died of purposeful starvation in psychiatric hospitals as part of the Nazi program of psychiatric euthanasia. Was the same thing occurring in Lyon?

Influence of die geometry and material selection on the behavior of protective die covers in closed-die forging

NASA Astrophysics Data System (ADS)

Yu, Yingyan; Rosenstock, Dirk; Wolfgarten, Martin; Hirt, Gerhard

2016-10-01

Due to the fact that tooling costs make up to 30% of total costs of the final forged part, the tool life is always one main research topic in closed-die forging [1]. To improve the wear resistance of forging dies, many methods like nitriding and deposition of ceramic layers have been used. However, all these methods will lose its effect after a certain time, then tool repair or exchange is needed, which requires additional time and costs. A new method, which applies an inexpensive and changeable sheet metal on the forging die to protect it from abrasive wear, was firstly proposed in [2]. According to the first investigation, the die cover is effective for decreasing thermal and mechanical loads, but there are still several challenges to overcome in this concept, like wrinkling and thinning of the die cover. Therefore, an experimental study using different geometries and die cover materials is presented within this work. The results indicate the existence of feasible application cases of this concept, since conditions are found under which a die cover made of 22MnB5 still keeps its original shape even after 7 forging cycles.

Device-packaging method and apparatus for optoelectronic circuits

DOEpatents

Zortman, William A.; Henry, Michael David; Jarecki, Jr., Robert L.

2017-04-25

An optoelectronic device package and a method for its fabrication are provided. The device package includes a lid die and an active die that is sealed or sealable to the lid die and in which one or more optical waveguides are integrally defined. The active die includes one or more active device regions, i.e. integral optoelectronic devices or etched cavities for placement of discrete optoelectronic devices. Optical waveguides terminate at active device regions so that they can be coupled to them. Slots are defined in peripheral parts of the active dies. At least some of the slots are aligned with the ends of integral optical waveguides so that optical fibers or optoelectronic devices inserted in the slots can optically couple to the waveguides.

Europium containing red light-emitting fibers made by electrohydrodynamic casting

NASA Astrophysics Data System (ADS)

Gan, Yong X.; Panahi, Niousha; Yu, Christina; Gan, Jeremy B.; Cheng, Wanli

2018-05-01

Red light-emitting polymeric micro- and nanofibers were made by electrohydrodynamic co-casting of two fluids. One fluid contains a 10 wt% concentration europium (III) complex dissolved in a dimethylformamide (DMF) solvent. The europium complex, an Eu3+ compound with the nominal formula of Eu(BA)3phen/PAN, consists of polyacrylonitrile (PAN), 1,10-phenanthroline (phen), and benzoic acid (BA). The other fluid consists of iron metal oxide nanoparticles dispersed in a solution containing 10 wt% polyacrylonitrile polymer in DMF solvent. The two fluids were electrohydrodynamically co-cast onto a soft tissue paper using a stainless steel coaxial nozzle. The intensity of the electric field used for the co-casting was 1.5 kV/cm. Scanning electron microscopic observation on the fibers obtained from the co-casting was made. The size of the fibers ranges from several hundreds of nanometers to several microns. Energy dispersive X-ray spectroscopic analysis of the fibers confirmed that the major elements included C, O, Fe, and Eu. The fluorescence of the two types of fibers was tested under the excitation of a UV light source. It was found that when the europium complex-containing solution was the sheath fluid and the iron-containing solution was the core, the prepared fibers showed red light-emitting behavior under ultraviolet light. Time-dependent fluorescence shows the two-stage decaying behavior. The first stage lasts about 2000 s and the intensity of fluorescence decreases linearly. The second stage reveals the slow decaying behavior and it lasts longer than 3 h. Based on the bi-exponential data fitting using a processing MATLAB code, the fluorescence-related constants were extracted. A bi-exponential formula was proposed to describe the time-dependent fluorescence behavior of the fiber made by the europium complex-containing solution as the sheath fluid. The decaying in the fluorescence shows two different stages. The first stage lasts about 2000 s and it is characterized by a fast decaying model. The intensity of fluorescence decreases linearly. The second stage has a slow decaying feature. It takes over 3 h for the fluorescence to die out completely. Bi-exponential data fitting shows that the time constant for the decay of fluorescence is about 10,000 s.

Damage Resistance of Titanium Aluminide Evaluated

NASA Technical Reports Server (NTRS)

Lerch, Bradley A.; Draper, Susan L.; Baaklini, George Y.; Pereira, J. Michael; Austin, Curt

2000-01-01

As part of the aviation safety goal to reduce the aircraft accident rate, NASA has undertaken studies to develop durable engine component materials. One of these materials, g-TiAl, has superior high-temperature material properties. Its low density provides improved specific strength and creep resistance in comparison to currently used titanium alloys. However, this intermetallic is inherently brittle, and long life durability is a potential problem. Of particular concern is the material s sensitivity to defects, which may form during the manufacturing process or in service. To determine the sensitivity of TiAl to defects, a team consisting of GE Aircraft Engines, Precision Cast Parts, and NASA was formed. The work at the NASA Glenn Research Center at Lewis Field has concentrated on the fatigue response to specimens containing defects. The overall objective of this work is to determine the influence of defects on the high cycle fatigue life of TiAl-simulated low-pressure turbine blades. Two types of defects have been introduced into the specimens: cracking from impact damage and casting porosity. For both types of defects, the cast-to-size fatigue specimens were fatigue tested at 650 C and 100 Hz until failure.

University Teaching across Cultures: Lessons from U.S. Fulbrighters in Southeast Asia and Their Colleagues in Thailand.

ERIC Educational Resources Information Center

George, Pamela

This book is an inquiry into university teaching across cultures and includes, in Part 1, a cast study of the nature of the university workplace in Thailand, and in Part 2, common instructional problems and solutions faced by Western professors teaching in the Southeast Asian context. Within Part 1, "The Nature of the University as a…

Comparative evaluation of the amount of gingival displacement produced by three different gingival retraction systems: An in vivo study.

PubMed

Chaudhari, Jignesh; Prajapati, Paranjay; Patel, Jayanti; Sethuraman, Rajesh; Naveen, Y G

2015-01-01

Tetrahydrozoline has been introduced as new gingival retraction agent but its clinical efficacy with widely used conventional retraction agents has not been tested. The study was designed to clinically evaluate efficacy of newer retraction agent tetrahydrozoline with two widely used retraction systems i.e., Expasyl retraction system and medicated retraction cords on basis of amount of gingival retraction. 30 subjects were selected according to inclusion and exclusion criteria. Maxillary Impressions were made with irreversible hydrocolloid for all subjects. Tray material was used for making the special tray. Latin Block Design was Used in the Study to avoid tissue fatigue. Retraction was done with aluminium chloride; Tetrahydrozoline and Expasyl according to Latin block design. Impressions were poured with die stone. Casts were retrieved and sections were made with die cutter. 3 mm thin slices were obtained. Each slice was used to measure the amount of retraction under stereomicroscope under 20x and images were transferred to image analyser. The amount of gingival retraction obtained by using aluminium chloride as gingival retraction agent was maximum (148238.33 μm(2)) compared to tetrahydrozoline (140737.87 μm(2)) and Expasyl (67784.90 μm(2)).

Laser Surface Modification of H13 Die Steel using Different Laser Spot Sizes

NASA Astrophysics Data System (ADS)

Aqida, S. N.; Naher, S.; Brabazon, D.

2011-05-01

This paper presents a laser surface modification process of AISI H13 tool steel using three sizes of laser spot with an aim to achieve reduced grain size and surface roughness. A Rofin DC-015 diffusion-cooled CO2 slab laser was used to process AISI H13 tool steel samples. Samples of 10 mm diameter were sectioned to 100 mm length in order to process a predefined circumferential area. The parameters selected for examination were laser peak power, overlap percentage and pulse repetition frequency (PRF). Metallographic study and image analysis were done to measure the grain size and the modified surface roughness was measured using two-dimensional surface profilometer. From metallographic study, the smallest grain sizes measured by laser modified surface were between 0.51 μm and 2.54 μm. The minimum surface roughness, Ra, recorded was 3.0 μm. This surface roughness of the modified die steel is similar to the surface quality of cast products. The grain size correlation with hardness followed the findings correlate with Hall-Petch relationship. The potential found for increase in surface hardness represents an important method to sustain tooling life.

An invitation to die: initiators of sociality in a social amoeba become selfish spores

PubMed Central

Kuzdzal-Fick, Jennie J.; Queller, David C.; Strassmann, Joan E.

2010-01-01

Greater size and strength are common attributes of contest winners. Even in social insects with high cooperation, the right to reproduce falls to the well-fed queens rather than to poorly fed workers. In Dictyostelium discoideum, formerly solitary amoebae aggregate when faced with starvation, and some cells die to form a stalk which others ride up to reach a better location to sporulate. The first cells to starve have lower energy reserves than those that starve later, and previous studies have shown that the better-fed cells in a mix tend to form disproportionately more reproductive spores. Therefore, one might expect that the first cells to starve and initiate the social stage should act altruistically and form disproportionately more of the sterile stalk, thereby enticing other better-fed cells into joining the aggregate. This would resemble caste determination in social insects, where altruistic workers are typically fed less than reproductive queens. However, we show that the opposite result holds: the first cells to starve become reproductive spores, presumably by gearing up for competition and outcompeting late starvers to become prespore first. These findings pose the interesting question of why others would join selfish organizers. PMID:20504816

Silicon-based Porous Ceramics via Freeze Casting of Preceramic Polymers

NASA Astrophysics Data System (ADS)

Naviroj, Maninpat

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

Influence of Alloy Composition on Cast Cracking and Heat Resistance of Mg-Al-Ca Cast Alloy

NASA Astrophysics Data System (ADS)

Kato, Hajime; Kawabata, Hiroyuki; Inoue, Shuji; Kondo, Masaaki

Magnesium alloys are important materials since they can be used to significantly reduce the weight of automobiles, but their application has been limited thus far. One possible way to extend the usage of magnesium alloys is applying them to peripheral parts of the engine that are large, have complicated shapes, and are exposed to high temperatures under the loaded condition. However, heat-resistant magnesium alloys always have poor castability, since such alloys have a lot of intermetallic compounds with poor ductility.

Phase-field simulation of microstructure formation in technical castings - A self-consistent homoenthalpic approach to the micro-macro problem

NASA Astrophysics Data System (ADS)

Böttger, B.; Eiken, J.; Apel, M.

2009-10-01

Performing microstructure simulation of technical casting processes suffers from the strong interdependency between latent heat release due to local microstructure formation and heat diffusion on the macroscopic scale: local microstructure formation depends on the macroscopic heat fluxes and, in turn, the macroscopic temperature solution depends on the latent heat release, and therefore on the microstructure formation, in all parts of the casting. A self-consistent homoenthalpic approximation to this micro-macro problem is proposed, based on the assumption of a common enthalpy-temperature relation for the whole casting which is used for the description of latent heat production on the macroscale. This enthalpy-temperature relation is iteratively obtained by phase-field simulations on the microscale, thus taking into account the specific morphological impact on the latent heat production. This new approach is discussed and compared to other approximations for the coupling of the macroscopic heat flux to complex microstructure models. Simulations are performed for the binary alloy Al-3at%Cu, using a multiphase-field solidification model which is coupled to a thermodynamic database. Microstructure formation is simulated for several positions in a simple model plate casting, using a one-dimensional macroscopic temperature solver which can be directly coupled to the microscopic phase-field simulation tool.

Calpains mediate axonal cytoskeleton disintegration during Wallerian degeneration

PubMed Central

Ma, Marek; Ferguson, Toby A.; Schoch, Kathleen M.; Li, Jian; Qian, Yaping; Shofer, Frances S.; Saatman, Kathryn E.; Neumar, Robert W.

2013-01-01

In both the central nervous system (CNS) and peripheral nervous system (PNS), transected axons undergo Wallerian degeneration. Even though Augustus Waller first described this process after transection of axons in 1850, the molecular mechanisms may be shared, at least in part, by many human diseases. Early pathology includes failure of synaptic transmission, target denervation, and granular disintegration of the axonal cytoskeleton (GDC). The Ca2+-dependent proteases calpains have been implicated in GDC but causality has not been established. To test the hypothesis that calpains play a causal role in axonal and synaptic degeneration in vivo, we studied transgenic mice that express human calpastatin (hCAST), the endogenous calpain inhibitor, in optic and sciatic nerve axons. Five days after optic nerve transection and 48 hours after sciatic nerve transection, robust neurofilament proteolysis observed in wild-type controls was reduced in hCAST transgenic mice. Protection of the axonal cytoskeleton in sciatic nerves of hCAST mice was nearly complete 48 hours post-transection. In addition, hCAST expression preserved the morphological integrity of neuromuscular junctions. However, compound muscle action potential amplitudes after nerve transection were similar in wild-type and hCAST mice. These results, in total, provide direct evidence that calpains are responsible for the morphological degeneration of the axon and synapse during Wallerian degeneration. PMID:23542511

Effect of T6 heat treatment on the microstructural and mechanical properties of Al-Si-Cu-Mg alloys

NASA Astrophysics Data System (ADS)

Patel, Dhruv; Davda, Chintan; Solanki, P. S.; Keshvani, M. J.

2016-05-01

In this communication, it is aimed to optimize the conditions for T6 heat treatment of permanent die cast Al-Si-Cu-Mg alloys. Various solutionizing temperatures, aging treatments and soaking times were used to improve / modify the mechanical properties of presently studied alloys. Formation mechanism of the particles was understood by carrying out optical microscopy and energy dispersive X-ray (EDX) spectroscopy measurements. Spherical particles of alloys were studied for their microstructural properties using scanning electron microscopy (SEM). Microhardness test was performed to investigate their mechanical properties. Dependence of cluster formation and microhardness of the alloys on the adequate solutionizing temperature, aging treatment and soaking time has been discussed in detail.

Voltage Controller

NASA Technical Reports Server (NTRS)

1997-01-01

Power Efficiency Corporation, specifically formed to manufacture and develop products from NASA technology, has a license to a three-phase power factor controller originally developed by Frank Nola, an engineer at Marshall Space Flight Center. Power Efficiency and two major distributors, Performance Control and Edison Power Technologies, use the electronic control boards to assemble three different motor controllers: Power Commander, Performance Controller, and Energy Master. The company Power Factor Controller reduces excessive energy waste in AC induction motors. It is used in industries and applications where motors operate under variable loads, including elevators and escalators, machine tools, intake and exhaust fans, oil wells, conveyors, pumps, die casting, and compressors. Customer lists include companies such as May Department Stores, Caesars Atlantic City, Ford Motors, and American Axle.

Magnesium recycling in the United States in 1998

USGS Publications Warehouse

Kramer, Deborah A.

2002-01-01

As concern for the environment has grown in recent years, the importance of recycling has become more evident. The more materials that are recycled, the fewer natural resources will be consumed and the fewer waste products will end up in landfills, the water, and the air. As one of a series of reports on metals recycling, this report discusses the 1998 flow of magnesium in the United States from extraction through its uses with particular emphasis on recycling. In 1998, the recycling efficiency for magnesium was estimated to be 33 percent--almost 60 percent of the magnesium that was recycled came from new scrap, primarily waste from die-casting operations. The principal source of old scrap was recycled aluminum beverage cans.

Processing of Aluminum-Graphite Particulate Metal Matrix Composites by Advanced Shear Technology

NASA Astrophysics Data System (ADS)

Barekar, N.; Tzamtzis, S.; Dhindaw, B. K.; Patel, J.; Hari Babu, N.; Fan, Z.

2009-12-01

To extend the possibilities of using aluminum/graphite composites as structural materials, a novel process is developed. The conventional methods often produce agglomerated structures exhibiting lower strength and ductility. To overcome the cohesive force of the agglomerates, a melt conditioned high-pressure die casting (MC-HPDC) process innovatively adapts the well-established, high-shear dispersive mixing action of a twin screw mechanism. The distribution of particles and properties of composites are quantitatively evaluated. The adopted rheo process significantly improved the distribution of the reinforcement in the matrix with a strong interfacial bond between the two. A good combination of improved ultimate tensile strength (UTS) and tensile elongation (ɛ) is obtained compared with composites produced by conventional processes.

Microstructure and Porosity of Laser Welds in Cast Ti-6Al-4V with Addition of Boron

NASA Astrophysics Data System (ADS)

Tolvanen, Sakari; Pederson, Robert; Klement, Uta

2018-03-01

Addition of small amounts of boron to cast Ti-6Al-4V alloy has shown to render a finer microstructure and improved mechanical properties. For such an improved alloy to be widely applicable for large aerospace structural components, successful welding of such castings is essential. In the present work, the microstructure and porosity of laser welds in a standard grade cast Ti-6Al-4V alloy as well as two modified alloy versions with different boron concentrations have been investigated. Prior-β grain reconstruction revealed the prior-β grain structure in the weld zones. In fusion zones of the welds, boron was found to refine the grain size significantly and rendered narrow elongated grains. TiB particles in the prior-β grain boundaries in the cast base material restricted grain growth in the heat-affected zone. The TiB particles that existed in the as cast alloys decreased in size in the fusion zones of welds. The hardness in the weld zones was higher than in the base material and boron did not have a significant effect on hardness of the weld zones. The fusion zones were smaller in the boron-modified alloys as compared with Ti-6Al-4V without boron. Computed tomography X-ray investigations of the laser welds showed that pores in the FZ of the boron modified alloys were confined to the lower part of the welds, suggesting that boron addition influences melt pool flow.

New method for springback compensation for the stamping of sheet metal components

NASA Astrophysics Data System (ADS)

Birkert, A.; Hartmann, B.; Straub, M.

2017-09-01

The need for car body structures of higher strength and at the same time lower weight results in serious challenges for the stamping process. Especially the use of high strength steel and aluminium sheets is causing growing problems with regard to elastic springback. To produce accurate parts the stamping dies must be adjusted more or less by the amount of the springback in the opposite direction. For this purpose well-known software solutions use the Displacement Adjustment Method or algorithms which are closely based on that method. A crucial issue of this method is that the generated die surfaces deviate from those of the target geometry with regard to surface area. A new Physical Compensation Method has been developed and validated which takes geometrical nonlinearity into account and creates compensated die geometries with equal-in-area die surfaces. In contrast to the standard mathematical/geometrical approach, the adjusted geometry is generated by a physical approach, which makes use of the virtual part stiffness. Hereby the target geometry is being deformed mechanically in a virtual process based on the springback simulation results by applying virtual forces in an additional elastic simulation. By doing so better part dimensions can be obtained in less tool optimization loops.

Understandings of death and dying for people of Chinese origin.

PubMed

Hsu, Chiung-yin; O'Connor, Margaret; Lee, Susan

2009-02-01

This article introduces the primary beliefs about ancestor worship, Taoism, Confucianism, Buddhism and traditional Chinese medicine that have influenced Chinese people for thousands of years, particularly in relation to death and dying. These cultures and traditions remain important for Chinese people wherever they live. Over a long period, Chinese people have integrated these philosophies and religions to form the basis of their culture and traditions. Although they agree that death is a natural part of the life span, a unique belief about death and dying has emerged among the Chinese from this integration. From this, the people find a significant definition of death and dying.

Stamping Die Making. 439-318/320.

ERIC Educational Resources Information Center

Yunke, P.; And Others

Each unit in this curriculum guide on stamping die making contains an introduction, objectives, materials required, lessons, space for notes, figures, and diagrams. There are 29 units in this guide, dealing with the following topics: EZ-MILL programming; EZ-MILL BATT; print of punch and EZ-MILL part programming; download to Computer Numerical…

CAD system of design and engineering provision of die forming of compressor blades for aircraft engines

NASA Astrophysics Data System (ADS)

Khaimovich, I. N.

2017-10-01

The articles provides the calculation algorithms for blank design and die forming fitting to produce the compressor blades for aircraft engines. The design system proposed in the article allows generating drafts of trimming and reducing dies automatically, leading to significant reduction of work preparation time. The detailed analysis of the blade structural elements features was carried out, the taken limitations and technological solutions allowed forming generalized algorithms of forming parting stamp face over the entire circuit of the engraving for different configurations of die forgings. The author worked out the algorithms and programs to calculate three dimensional point locations describing the configuration of die cavity. As a result the author obtained the generic mathematical model of final die block in the form of three-dimensional array of base points. This model is the base for creation of engineering documentation of technological equipment and means of its control.