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Sample records for investment casting process

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

    SciTech Connect

    Sabau, Adrian S

    2006-01-01

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

  2. Advanced investment cast processing for gamma titanium aluminide alloys

    SciTech Connect

    Larsen, D.; Govern, C.

    1995-12-31

    Investment casting of gamma titanium aluminide alloys has become the near-term process of choice for component manufacture. This is largely due to its near-net shape processing capabilities which allow cast gamma components to be manufactured at a lower cost when compared to wrought or powder methods. Many papers have been published discussing the effect of heat treatment on the microstructure of HIP processed samples. However, the relationship between casting parameters and resultant microstructures has not been widely discussed. An L9 DOE casting experiment was performed to examine mold preheat, furnace atmosphere, shell type and gating design parameters. It was determined that mold preheat had a very significant effect on as-cast and as-HIP processed microstructures. Mold preheats of 70 F and 750 F produced HIP Processed microstructures containing 80 to >90% equiaxed gamma grains and 2,100 F mold preheats produced structures containing 10--30% equiaxed gamma grains. The results of this experiment will be presented, including optical microstructures and microprobe analysis.

  3. Mineral processing techniques for recycling investment casting shell

    SciTech Connect

    Dahlin, Cheryl L.; Nilsen, David N.; Dahlin, David C.; Hunt, Alton H.; Collins, W. Keith

    2002-01-01

    The Albany Research Center of the U.S. Department of Energy used materials characterization and minerals beneficiation methods to separate and beneficially modify spent investment-mold components to identify recycling opportunities and minimize environmentally sensitive wastes. The physical and chemical characteristics of the shell materials were determined and used to guide bench-scale research to separate reusable components by mineral-beneficiation techniques. Successfully concentrated shell materials were evaluated for possible use in new markets.

  4. Friction Stir Processing of Investment-Cast Ti-6Al-4V: Microstructure and Properties

    NASA Astrophysics Data System (ADS)

    Pilchak, A. L.; Norfleet, D. M.; Juhas, M. C.; Williams, J. C.

    2008-07-01

    Investment-cast titanium components are becoming increasingly common in the aerospace industry due to the ability to produce large, complex, one-piece components that were previously fabricated by mechanically fastening multiple pieces together. The fabricated components are labor-intensive and the fastener holes are stress concentrators and prime sites for fatigue crack initiation. The castings are typically hot-isostatically-pressed (HIP) to close internal porosity, but have a coarse, fully lamellar structure that has low resistance to fatigue crack initiation. The as-cast + HIP material exhibited 1- to 1.5-mm prior β grains containing a fully lamellar α + β microstructure consistent with slow cooling from above the β transus. Friction stir processing (FSP) was used to locally modify the microstructure on the surface of an investment-cast Ti-6Al-4V plate. Friction stir processing converted the as-cast microstructure to fine (1- to 2-μm) equiaxed α grains. Using micropillars created with a dual-beam focused ion beam device, it was found that the fine-grained equiaxed structure has about a 12 pct higher compressive yield stress. In wrought products, higher strength conditions are more resistant to fatigue crack initiation, while the coarse lamellar microstructure in the base material has better fatigue crack growth resistance. In combination, these two microstructures can increase the fatigue life of titanium alloy castings by increasing the number of cycles prior to crack initiation while retaining the same low-crack growth rates of the colony microstructure in the remainder of the component. In the current study, high-cycle fatigue testing of investment-cast Ti-6Al-4V was performed on four-point bend specimens. Early results show that FSP can increase fatigue strength dramatically.

  5. Sand, die and investment cast parts via the SLS selective laser sintering process

    NASA Astrophysics Data System (ADS)

    van de Crommert, Simon; Seitz, Sandra; Esser, Klaus K.; McAlea, Kevin

    1997-09-01

    Complex three-dimensional parts can be manufactured directly from CAD data using rapid prototyping processes. SLS selective laser sintering is a rapid prototyping process developed at the University of Texas at Austin and commercialized by DTM Corporation. SLS parts are constructed layer by layer from powdered materials using laser energy to melt CAD specified cross sections. Polymer, metal, and ceramic powders are all potential candidate materials for this process. In this paper the fabrication of complex metal parts rapidly using the investment, die and sand casting technologies in conjunction with the selective laser sintering process are being explained and discussed. TrueForm and polycarbonate were used for investment casting, while RapidSteel metal mould inserts were used for the die casting trials. Two different SandForm materials, zircon and silica sand, are currently available for the direct production of sand moulds and cores. The flexible and versatile selective laser sintering process all these materials on one single sinterstation. Material can be changed fast and easily between two different builds.

  6. Effects of material variables and process parameters on properties of investment casting shells

    NASA Astrophysics Data System (ADS)

    Tumurugoti, Priyatham

    Manufacture of investment casting shells is a complex process. The choice of raw materials - refractory powders or grains, binders and additives - affects the properties of investment casting shells. In this study, different systems of shells were prepared, according to a design of experiments, with commercially available raw materials that differ in chemistry, particle size or particle size distribution. Shell strength was measured in green, fired and cooled, and hot conditions and the results were analyzed for strength -- material property relation. Various microstructures of polished cross sections of these shells were characterized using scanning electron microscope. It was determined that the amount of matrix holding the stucco grains was dominant factor affecting green strength. Fired and hot strengths were observed to vary depending on interactions between different phases of matrix and stucco. In addition to the material properties, control of shell building parameters is critical to achieve quality shells. Process parameters affect strength of the shell by providing a means to change the relative amounts of stucco, slurry and porosity. To study the microstructural variations, shells were prepared by varying process parameters like slurry viscosity and stucco size. Data from image analysis of different microstructures were correlated to their respective fired strengths. It was determined that the shells prepared from high viscosity slurry and fine stucco had the highest strength.

  7. Effects of process variables on the properties of YBa2Cu3O(7-x) ceramics formed by investment casting

    NASA Technical Reports Server (NTRS)

    Hooker, M. W.; Taylor, T. D.; Leigh, H. D.; Wise, S. A.; Buckley, J. D.; Vasquez, P.; Buck, G. M.; Hicks, L. P.

    1993-01-01

    An investment casting process has been developed to produce net-shape, superconducting ceramics. In this work, a factorial experiment was performed to determine the critical process parameters for producing cast YBa2Cu3O7 ceramics with optimum properties. An analysis of variance procedure indicated that the key variables in casting superconductive ceramics are the particle size distribution and sintering temperature. Additionally, the interactions between the sintering temperature and the other process parameters (e.g., particle size distribution and the use of silver dopants) were also found to influence the density, porosity, and critical current density of the fired ceramics.

  8. Effects of process variables on the properties of YBa2Cu3O(7-x) ceramics formed by investment casting

    NASA Technical Reports Server (NTRS)

    Hooker, M. W.; Taylor, T. D.; Leigh, H. D.; Wise, S. A.; Buckley, J. D.; Vasquez, P.; Buck, G. M.; Hicks, L. P.

    1993-01-01

    An investment casting process has been developed to produce net-shape, superconducting ceramics. In this work, a factorial experiment was performed to determine the critical process parameters for producing cast YBa2Cu3O7 ceramics with optimum properties. An analysis of variance procedure indicated that the key variables in casting superconductive ceramics are the particle size distribution and sintering temperature. Additionally, the interactions between the sintering temperature and the other process parameters (e.g., particle size distribution and the use of silver dopants) were also found to influence the density, porosity, and critical current density of the fired ceramics.

  9. Combination Of Investment And Centrifugal Casting

    NASA Technical Reports Server (NTRS)

    Creeger, Gordon A.

    1994-01-01

    Modifications, including incorporation of centrifugal casting, made in investment-casting process reducing scrap rate. Used to make first- and second-stage high-pressure-fuel-turbopump nozzles, containing vanes with thin trailing edges and other thin sections. Investment mold spun for short time while being filled, and stopped before solidification occurs. Centrifugal force drives molten metal into thin trailing edges, ensuring they are filled. With improved filling, preheat and pour temperatures reduced and solidification hastened so less hot tearing.

  10. Combination Of Investment And Centrifugal Casting

    NASA Technical Reports Server (NTRS)

    Creeger, Gordon A.

    1994-01-01

    Modifications, including incorporation of centrifugal casting, made in investment-casting process reducing scrap rate. Used to make first- and second-stage high-pressure-fuel-turbopump nozzles, containing vanes with thin trailing edges and other thin sections. Investment mold spun for short time while being filled, and stopped before solidification occurs. Centrifugal force drives molten metal into thin trailing edges, ensuring they are filled. With improved filling, preheat and pour temperatures reduced and solidification hastened so less hot tearing.

  11. Advanced Pattern Material for Investment Casting Applications

    SciTech Connect

    F. Douglas Neece Neil Chaudhry

    2006-02-08

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

  12. Effect of Friction Stir Processing on Fatigue Behavior of an Investment Cast Al-7Si-0.6 Mg Alloy

    SciTech Connect

    Jana, Saumyadeep; Mishra, Rajiv S.; Baumann, John B.; Grant, Glenn J.

    2010-02-01

    Cast aluminum alloys in general show poor fatigue performance due to presence of defects. Friction stir processing (FSP) can be used as a tool for enhancing mechanical properties of cast alloys by eliminating such defects. In the present study FSP led to a five times improvement in fatigue life of an investment cast Al-7Si-0.6Mg hypoeutectic alloy. The reason for such enhancement was linked to closure of casting porosity which acted as crack nucleation sites in the as-cast condition. Porosity acted as notches in the as-cast alloy and led to an order of magnitude higher crack growth rate. As FSP eliminated the porosity and refined Si particles, crack growth rate dropped due to the elimination of the notch effect together with increased crack path tortuosity. Finally, short crack behavior was noted in both cast and FSP specimens. The critical crack length where transition from short crack to long crack behavior took place is related to respective microstructural characteristic dimensions.

  13. Neutron radiography inspection of investment castings.

    PubMed

    Richards, W J; Barrett, J R; Springgate, M E; Shields, K C

    2004-10-01

    Investment casting, also known as the lost wax process, is a manufacturing method employed to produce near net shape metal articles. Traditionally, investment casting has been used to produce structural titanium castings for aero-engine applications with wall thickness less than 1 in (2.54 cm). Recently, airframe manufacturers have been exploring the use of titanium investment casting to replace components traditionally produced from forgings. Use of titanium investment castings for these applications reduces weight, cost, lead time, and part count. Recently, the investment casting process has been selected to produce fracture critical structural titanium airframe components. These airframe components have pushed the traditional inspection techniques to their physical limits due to cross sections on the order of 3 in (7.6 cm). To overcome these inspection limitations, a process incorporating neutron radiography (n-ray) has been developed. In this process, the facecoat of the investment casting mold material contains a cocalcined mixture of yttrium oxide and gadolinium oxide. The presence of the gadolinium oxide, allows for neutron radiographic imaging (and eventual removal and repair) of mold facecoat inclusions that remain within these thick cross sectional castings. Probability of detection (POD) studies have shown a 3 x improvement of detecting a 0.050 x 0.007 in2 (1.270 x 0.178 mm2) inclusion of this cocalcined material using n-ray techniques when compared to the POD using traditional X-ray techniques. Further, it has been shown that this n-ray compatible mold facecoat material produces titanium castings of equal metallurgical quality when compared to the traditional materials. Since investment castings can be very large and heavy, the neutron radiography facilities at the University of California, Davis McClellan Nuclear Radiation Center (UCD/MNRC) were used to develop the inspection techniques. The UCD/MNRC has very unique facilities that can handle large

  14. Gelcasting Alumina Cores for Investment Casting

    SciTech Connect

    Janney, M A; Klug, F J

    2001-01-01

    General Electric currently uses silica investment casting cores for making superalloy turbine blades. The silica core technology does not provide the degree of dimensional control needed for advanced turbine system manufacture. The sum of the various process variables in silica core manufacturing produces cores that have more variability than is allowed for in advanced, power-generation gas turbine airfoils.

  15. The effect of friction stir processing on the microstructure, mechanical properties and fracture behavior of investment cast titanium aluminum vanadium

    NASA Astrophysics Data System (ADS)

    Pilchak, Adam L.

    The use of investment cast titanium components is becoming increasingly common in the aerospace industry due to the ability to produce large, one-piece components with complex geometries that were previously fabricated by mechanically fastening or welding multiple smaller parts together. However, the coarse, fully lamellar microstructure typical of investment cast alpha + beta titanium alloys results in relatively poor fatigue strength compared to forged titanium products. As a result, investment castings are not considered for use in fatigue limited structures. In recent years, friction stir processing has emerged as a solid state metalworking technique capable of substantial microstructure refinement in aluminum and nickel-aluminum-bronze alloys. The purpose of the present study is to determine the feasibility of friction stir processing and assess its effect on the microstructure and mechanical properties of the most widely used alpha + beta titanium alloy, Ti-6Al-4V. Depending on processing parameters, including tool travel speed, rotation rate and geometry, the peak temperature in the stir zone was either above or below the beta transus. The resulting microstructures consisted of either ˜1 mum equiaxed a grains, ˜25 mum prior beta grains containing a colony alpha + beta microstructure or a combination of 1 mum equiaxed alpha and fine, acicular alpha + beta. The changes in microstructure were characterized with scanning and transmission electron microscopy and electron backscatter diffraction. The texture in the stir zone was nearly random for all processing conditions, however, several components of ideal simple shear textures were observed in both the hexagonal close packed alpha and the body centered cubic beta phases which provided insight into the operative grain refinement mechanisms. Due to the relatively small volume of material affected by friction stir processing, conventionally sized test specimens were unable to be machined from the stir zone

  16. WinMod: An expert advisor for investment casting

    SciTech Connect

    Bivens, H.P.; Williamson, G.A. Jr.; Luger, G.F.; Erdmann, R.G.; Maguire, M.C.; Baldwin, M.D.; Anderson, D.J.

    1998-04-01

    Investment casting is an important method for fabricating a variety of high quality components in mechanical systems. Cast components, unfortunately, have a large design and gate/runner build time associated with their fabrication. In addition, casting engineers often require many years of actual experience in order to consistently pour high quality castings. Since 1989, Sandia National Laboratories has been investigating casting technology and software that will reduce the time overhead involved in producing quality casts. Several companies in the casting industry have teamed up with Sandia to form the FASTCAST Consortium. One result of this research and the formation of the FASTCAST consortium is the creation of the WinMod software, an expert casting advisor that supports the decision making process of the casting engineer through visualization and advice to help eliminate possible casting defects.

  17. Fiber reinforcement of investment cast parts

    SciTech Connect

    Nolte, M.; Neussl, E.; Schaedlich-Stubenrauch, J.; Sahm, P.R.

    1993-12-31

    For 3 years now the Foundry-Institute (Giesserei-Institut) of the Aachen Institute of Technology has worked on the development of a new, low-cost production process for longfiber-reinforced light alloy components. The process baseline is oriented on the precision casting process in its investment casting mode, also known as lost wax process. The investment casting process is well known as a typical near-net-shape process for the manufacture of high-quality cast components, predominantly for applications in the aerospace industry (structured components, turbine blades and parts etc.) and enjoys significant growth rates during the last decades. After preliminary studies on the modification of single process substeps R & D work concentrated on the final-shape production of Al-components (Al-alloys A356, A357, 201 etc.) reinforced with long ceramic fibers. Both SiC and Al{sub 2}O{sub 3}-based fibers of several producers were used. Main interest focuses on techniques for a selective reinforcement of main stress sections. Without using conventional sintered preforms the fibers are infiltrated with molten metal under a support pressure of less than 1 MPa. Combined with a new developed wax pattern technique test specimens with a nearly homogeneous fiber distribution were produced. In addition, even reactive matrix alloys did not lead to destructive interface reactions. In most cases sufficient bonding between fibers and matrix could be observed. Following to these positive tendencies a considerable improvement of mechanical properties could be measured for longfiber reinforced Al-alloys. Both tensile strength and elastic modulus could be increased up to 100% compared with the unreinforced matrix alloy. Latest work concentrated on the production of small representative components for potential applications.

  18. Effects of processing variables on the creep behavior of investment cast Ti-48Al-2Nb-2Cr

    SciTech Connect

    Keller, M.M.; Jones, P.E.; Porter, W.J. III; Eylon, D.

    1995-12-31

    Intermetallics based on ordered {gamma}-TiAl are being considered for the replacement of steels and nickel-based superalloys for high temperature aerospace and automotive applications. This study investigates the creep behavior of investment cast Ti-48Al-2Nb-2Cr with microstructures ranging from duplex to nearly lamellar. Constant load creep tests were conducted in air at temperatures of 650 C and 760 C and at stress levels of 104MPa, 155MPa, and 207MPa. The effects of cooling rates during casting, aluminum content, oxygen level, and microstructure on creep properties are discussed. The activation energy for creep and stress exponent are also reported.

  19. Physical Simulation of Investment Casting of Complex Shape Parts

    NASA Astrophysics Data System (ADS)

    Rahimian, Mehdi; Milenkovic, Srdjan; Maestro, Laura; De Azua, Aitor Eguidazu Ruiz; Sabirov, Ilchat

    2015-05-01

    Development of investment casting process has been a challenge for manufacturers of complex shape parts. Numerous experimental casting trials are typically carried out to determine the optimum casting parameters for fabrication of high-quality products. In this work, it is demonstrated that physical simulation of investment casting can successfully predict microstructure and hardness in as-cast complex shape parts. The physical simulation tool consists of a thermal model and melting/solidification experiments in thermo-mechanical simulator. The thermal model is employed to predict local cooling rate during solidification at each point of a casting. Melting/solidification experiments are carried out under controlled cooling rates estimated by the thermal model. Microstructural and mechanical characterization of the solidified specimens is performed; the obtained results predict the local microstructure and mechanical properties of the casting. This concept is applied to investment casting of complex shape nozzle guide vanes from Mar-M247 Ni-based superalloy. Experimental casting trials are performed and the outcomes of physical simulation tool are validated against experimental results. It is shown that phase composition, secondary dendrite arm spacing, grain size, γ/ γ' eutectic size and volume fraction, size and shape of carbide particles, and local microhardness can be predicted at each point of the casting via physical simulation.

  20. Some Investigations on Hardness of Investment Casting Process After Advancements in Shell Moulding for Reduction in Cycle Time

    NASA Astrophysics Data System (ADS)

    Singh, R.; Mahajan, V.

    2014-07-01

    In the present work surface hardness investigations have been made on acrylonitrile butadiene styrene (ABS) pattern based investment castings after advancements in shell moulding for replication of biomedical implants. For the present study, a hip joint, made of ABS material, was fabricated as a master pattern by fused deposition modelling (FDM). After preparation of master pattern, mold was prepared by deposition of primary (1°), secondary (2°) and tertiary (3°) coatings with the addition of nylon fibre (1-2 cm in length of 1.5D). This study outlines the surface hardness mechanism for cast component prepared from ABS master pattern after advancement in shell moulding. The results of study highlight that during shell production, fibre modified shells have a much reduced drain time. Further the results are supported by cooling rate and micro structure analysis of casting.

  1. Shrinkage Prediction for the Investment Casting of Stainless Steels

    SciTech Connect

    Sabau, Adrian S

    2007-01-01

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

  2. Investment cast AISI H13 tooling for automotive applications

    SciTech Connect

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

    1995-07-01

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

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

    SciTech Connect

    Sabau, Adrian S

    2005-09-01

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

  4. Rapid prototyping: A paradigm shift in investment casting

    SciTech Connect

    Atwood, C.L.; Maguire, M.C.; Baldwin, M.D.; Pardo, B.T.

    1996-09-01

    The quest for fabricating complex metal parts rapidly and with minimal cost has brought rapid prototyping (RP) processes to the forefront of the investment casting industry. Relatively recent advances in DTM Corporation`s selective laser sintering (SLS) and 3D Systems stereolithography (SL) processes have had a significant impact on the overall quality of patterns produced using these rapid prototyping processes. Sandia National Laboratories uses patterns generated from rapid prototyping processes to reduce the cycle time and cost of fabricating prototype and small lot production parts in support of a program called FASTCAST. The SLS process is used to fabricate patterns from materials such as investment casting wax, polycarbonate, and a new material called TrueForm PM{trademark}. With the timely introduction of each of these materials, the quality of patterns fabricated has improved. The development and implementation of SL QuickCast{trademark} software has enabled this process to produce highly accurate patterns for use in investment casting. This paper focuses on the successes with these new pattern materials and the infrastructure required to cast rapid prototyping patterns successfully. In addition, a brief overview of other applications of rapid prototyping at Sandia will be discussed.

  5. Efficient Runner Networks for Investment Castings

    SciTech Connect

    GIVLER,RICHARD C.; SAYLORS,DAVID B.

    2000-07-18

    We present a computational method that finds an efficient runner network for an investment casting, once the gate locations have been established. The method seeks to minimize a cost function that is based on total network volume. The runner segments are restricted to lie in the space not occupied by the part itself. The collection of algorithms has been coded in C and runner designs have been computed for several real parts, demonstrating substantial reductions in rigging volume.

  6. Effect of Friction Stir Processing on Microstructure and Tensile Properties of an Investment Cast Al-7Si-0.6Mg Alloy

    SciTech Connect

    Jana, Saumyadeep; Mishra, Rajiv S.; Baumann, John B.; Grant, Glenn J.

    2010-10-01

    Friction stir processing (FSP) is emerging as a promising tool for microstructural modification. The present study assesses the effects of FSP on the microstructure and mechanical properties of an investment cast Al-7Si-Mg alloy. FSP eliminates porosity and significantly refines eutectic Si particles. The extent of particle refinement varied with changes in processing conditions. High tool rotation rate and low to intermediate tool traverse speed generated a higher volume fraction of finer particles. Tensile ductility changed significantly as a result of FSP, whereas UTS improved only marginally. Yield strength was similar in both cast and FSPed samples under various heat treated conditions, with the highest value obtained after a T6 heat treatment. Further, FSP caused significant grain refinement in the stir zone, subsequently transforming into very coarse grains as abnormal grain growth (AGG) occurred during solution treatment at high temperature.

  7. Face Coat Materials Through Sessile Drop and Investment Casting Methods

    NASA Astrophysics Data System (ADS)

    Cheng, Xu; Yuan, Chen; Blackburn, Stuart; Withey, Paul A.

    2014-06-01

    Investment casting is uniquely suited to the manufacture of Ti alloys for the production of near net-shape components, reducing material waste, and machining costs. Because of the high reactivity of titanium and its based alloy, the molds which are used in the investment casting process require high chemical inertness, which results in them being very costly and non-recyclable. In order to reduce the cost of these molds, traditionally using yttria as the face coat, two alternative molds are developed in this study with face coat materials of Y2O3-Al2O3 and Y2O3-Al2O3-ZrO2. The slurry properties and chemical inertness of the face coats were evaluated for viscosity, thermal expansion, friability, and phase development. The chemical inertness of these two molds were determined using both the sessile drop test and investment casting to identify the levels of interaction with a Ti-45Al-2Mn-2Nb-0.2B alloy. The results illustrated that the molds using Y2O3-Al2O3 and Y2O3-Al2O3-ZrO2 as the face coats both showed excellent sintering properties and chemical inertness when compared to the yttria face coat. They can consequently be used as two alternative face coats for the investment casting of TiAl alloys.

  8. Improving Metal Casting Process

    NASA Technical Reports Server (NTRS)

    1998-01-01

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

  9. Improving Metal Casting Process

    NASA Technical Reports Server (NTRS)

    1998-01-01

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

  10. Modeling and control of casting and welding processes

    SciTech Connect

    Kou, S.; Mehrabian, R.

    1986-01-01

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

  11. Rapid mesh generation for finite element analysis of investment castings

    SciTech Connect

    Lober, R.R.; Bohnhoff, W.J.; Meyers, R.J.

    1992-11-01

    FASTCAST is a Sandia National Laboratories program to produce investment cast prototypical hardware faster by integrating experimental and computational technologies into the casting process. FASTCAST uses the finite element method to characterize the metal flow and solidification processes to reduce uncertainty in the mold design. For the casting process to benefit from finite element analysis, analysis results must be available in a very short time frame. By focusing on the bottleneck of finite element model creation, automated mesh generation can drastically reduce the time span between geometry definition (design) and accurate analysis results. The increased availability of analysis results will diminish the need for trial and error approaches to acquiring production worthy mold and gating systems for investment casting. The CUBIT meshing tool kit is being developed to address the need for rapid mesh generation. CUBIT is being designed to effectively automate the generation of quadrilateral and hexahedral elements. It is a solid-modeler based, two- and three-dimensional preprocessor that prepares solid models for finite element analysis. CUBIT contains several meshing algorithms including two- and three-dimensional mapping, two- and three-dimensional paving (patented), and a general two and one-half dimensional sweeper based upon the plastering algorithm. This paper describes progress in the development of the CUBIT meshing toolkit.

  12. Rapid mesh generation for finite element analysis of investment castings

    SciTech Connect

    Lober, R.R.; Bohnhoff, W.J.; Meyers, R.J.

    1992-01-01

    FASTCAST is a Sandia National Laboratories program to produce investment cast prototypical hardware faster by integrating experimental and computational technologies into the casting process. FASTCAST uses the finite element method to characterize the metal flow and solidification processes to reduce uncertainty in the mold design. For the casting process to benefit from finite element analysis, analysis results must be available in a very short time frame. By focusing on the bottleneck of finite element model creation, automated mesh generation can drastically reduce the time span between geometry definition (design) and accurate analysis results. The increased availability of analysis results will diminish the need for trial and error approaches to acquiring production worthy mold and gating systems for investment casting. The CUBIT meshing tool kit is being developed to address the need for rapid mesh generation. CUBIT is being designed to effectively automate the generation of quadrilateral and hexahedral elements. It is a solid-modeler based, two- and three-dimensional preprocessor that prepares solid models for finite element analysis. CUBIT contains several meshing algorithms including two- and three-dimensional mapping, two- and three-dimensional paving (patented), and a general two and one-half dimensional sweeper based upon the plastering algorithm. This paper describes progress in the development of the CUBIT meshing toolkit.

  13. FInal Report - Investment Casting Shell Cracking

    SciTech Connect

    Von Richards

    2003-12-01

    This project made a significant contribution to the understanding of the investment casting shell cracking problem. The effects of wax properties on the occurrence of shell cracking were demonstrated and can be measured. The properties measured include coefficient of thermal expansion, heating rate and crystallinity of the structure. The important features of production molds and materials properties have been indicated by case study analysis and fractography of low strength test bars. It was found that stress risers in shell cavity design were important and that typical critical flaws were either oversize particles or large pores just behind the prime coat. It was also found that the true effect of fugitive polymer fibers was not permeability increase, but rather a toughening mechanism due to crack deflection.

  14. Evaluation of the Inertness of Investment Casting Molds Using Both Sessile Drop and Centrifugal Casting Methods

    NASA Astrophysics Data System (ADS)

    Cheng, Xu; Yuan, Chen; Green, Nick; Withey, Paul

    2013-02-01

    The investment casting process is an economic production method for engineering components in TiAl-based alloys and offers the benefits of a near net-shaped component with a good surface finish. An investigation was undertaken to develop three new face coat systems based on yttria, but with better sintering properties. These face coat systems were mainly based on an yttria-alumina-zirconia system (Y2O3-0.5 wt pct Al2O3-0.5 wt pct ZrO2), an yttria-fluoride system (Y2O3-0.15 wt pct YF3), and an yttria-boride system (Y2O3-0.15 wt pct B2O3). After sintering, the chemical inertness of the face coat was first tested and analyzed using a sessile drop test through the metal wetting behavioral change for each face coat surface. Then, the interactions between the shell and metal were studied by centrifugal investment casting TiAl bars. Although the sintering aids in yttria can decrease the chemical inertness of the face coat, the thickness of the interaction layer in the casting was less than 10 μm; therefore, these face coats still can be possible face coat materials for investment casting TiAl alloys.

  15. Analysis of Different Inhibitors for Magnesium Investment Casting

    NASA Astrophysics Data System (ADS)

    Herrero-Dorca, N.; Sarriegi Etxeberria, H.; Hurtado, I.; Andres, U.; Rodriguez, P.; Arruebarrena, G.

    2012-01-01

    Investment casting of magnesium is a well suited process for the production of aeronautic and automotive components. But still, this process has not been properly developed. One reason for that are the reactions between the Mg melt and the ceramics of the mould that produce a non-desired oxide layer on the part surface. These reactions can be inhibited by the use of silica-free slurries with a higher stability than conventional ones. Another way is using inhibitors, chemical compounds based in fluorides that react with the melt, creating a protective surface layer in the casting. With the aim of developing a reaction-free process, alumina moulds with a stepped geometry have been constructed. These provide different interface conditions. Conventional SF6, non-conventional KBF4 and NaBF4 and environmentally friendly FK inhibitors have been tested on. As a result, KBF4 has been identified as the most suitable inhibitor for magnesium investment casting. Furthermore, the analysis of the cooling curve of different interfaces has provided essential information about the reaction mechanism of the inhibitors.

  16. 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.

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

    SciTech Connect

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

    2008-11-21

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

  18. Modeling the investment casting of a titanium crown.

    PubMed

    Atwood, R C; Lee, P D; Curtis, R V; Maijer, D M

    2007-01-01

    The objective of this study was to apply computational modeling tools to assist in the design of titanium dental castings. The tools developed should incorporate state-of-the-art micromodels to predict the depth to which the mechanical properties of the crown are affected by contamination from the mold. The model should also be validated by comparison of macro- and micro-defects found in a typical investment cast titanium tooth crown. Crowns were hand-waxed and investment cast in commercial purity grade 1 (CP-1) titanium by a commercial dental laboratory. The castings were analyzed using X-ray microtomography (XMT). Following sectioning, analysis continued with optical and scanning electron microscopy, and microhardness testing. An in-house cellular-automata solidification and finite-difference diffusion program was coupled with a commercial casting program to model the investment casting process. A three-dimensional (3D) digital image generated by X-ray tomography was used to generate an accurate geometric representation of a molar crown casting. Previously reported work was significantly expanded upon by including transport of dissolved oxygen and impurity sources upon the arbitrarily shaped surface of the crown, and improved coupling of micro- and macro-scale simulations. Macroscale modeling was found to be sufficient to accurately predict the location of the large internal porosity. These are shrinkage pores located in the thick sections of the cusp. The model was used to determine the influence of sprue design on the size and location of these pores. Combining microscale with macroscale modeling allowed the microstructure and depth of contamination to be predicted qualitatively. This combined model predicted a surprising result--the dissolution of silicon from the mold into the molten titanium is sufficient to depress the freezing point of the liquid metal such that the crown solidifies the subsurface. Solidification then progresses inwards and back out to the

  19. 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

  20. The effect of investment type on the fit of cast titanium crowns.

    PubMed

    Mori, T; Jean-Louis, M; Yabugami, M; Togaya, T

    1994-12-01

    In order to determine the best laboratory procedure for titanium crown casting, a set of thermal expansion measurements and casting experiments were carried out using a casting machine (argon arc, pressure difference type) and three different investments, two conventional SiO2 based investments and a new Al2O3/MgO based investment. The thermal expansion measurements involved a cycle of heating and cooling. The relatively low mould temperatures recommended (200 degrees C) or chosen (350 degrees C) for the conventional investments provided zero or negative mould expansion for the compensation of metal shrinkage. Crowns made from these investments exhibited heavy reaction with the mould, and the common cleaning method of sand blasting appeared to be essential. This cleaning process, however, was not adequate for the assessment of casting accuracy as the short sand blasting time (15 s) rapidly altered the fit of the crowns. The metal reacted little with the new investment and the best compensation (0.15 mm discrepancy) for the metal shrinkage, as assessed 'as cast', was achieved when the investment was heated to 950 degrees C and then cooled to the recommended mould temperature (600 degrees C).

  1. Thermal behaviour of casting investment during setting.

    PubMed

    Wakasa, K; Yamaki, M

    1995-05-01

    The aim of this study was to examine the thermal reactions of silica-sol liquids for mixing investment powders using differential thermal analysis (DTA) and also the setting behaviour of the mixed powders using differential scanning calorimetry (DSC). The silica-sol liquids showed the appearance of vapourization (around 100 degrees C as a peak temperature) and combustion (200-300 degrees C) in DTA measurement. Mixed silica-sol investment exhibited the setting behaviour with an exotherm in the DSC measurement representing that greater peak time, setting time and heat in mixed investment than with gypsum-bonded investment.

  2. Processing of IN-718 Lattice Block Castings

    NASA Technical Reports Server (NTRS)

    Hebsur, Mohan G.

    2002-01-01

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

  3. [Research on investing methods and mold cooling methods of the self-made investment for pure titanium castings].

    PubMed

    Zhao, Juan; Huang, Xu; Zhao, Yun-Feng; Xiao, Mao-Chun; Li, Yong

    2006-10-01

    To observe the influence of different investing methods and mold cooling methods on pure titanium castings invested in the self-made investment, and to provide theoretic base for the development for the investment. The influence of investing methods (one-step investing method and two-step investing method) on castability and crown fit of titanium castings were investigated, and the influence of cooling methods on reaction layers, mechanical properties and crown fit of titanium castings were investigated. Both the investing methods exhibited good castability, but only the titanium full crowns by one-step investing method showed clinically acceptable fit. Although the quenching group showed thinner reaction layer(100 microm), lower strength and similar elongation rate, the titanium castings by bench cooling showed clinically acceptable full crown fit with 115 microm thick reaction layer as cast. The one-step investing method and the bench cooling are recommended for the self-made investment.

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

    SciTech Connect

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

    1996-09-01

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

  5. Experimental measurement of investment shell properties and use of the data in casting simulation software

    SciTech Connect

    Browne, D.J.; Sayers, K.

    1995-12-31

    This paper describes the development of a systematic program of experimental measurement of relevant properties of mould materials, conducted with the express purpose of generating data for use in casting (filling and solidification) simulation software. In particular the thermophysical properties of the ceramic shell built up for the investment casting process are measured. These properties include specific heat capacity, thermal conductivity, gas permeability, density and surface emissivity. Much of the experimental measurements are taken as a function of temperature, up to the temperature at which moulds are typically fired or preheated. Typical results are presented. The data so generated is then used in a casting simulation model to simulate the investment casting of a prosthetic device. The results of the simulation are presented, and comparisons are made with measurements and observations from an experimental casting of the same part. In this way both the reliability of the data and the accuracy of the filling and solidification model are validated.

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

    SciTech Connect

    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 necessary 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

  7. Comparative analysis of constraints and caste differences in brain investment among social paper wasps

    PubMed Central

    O'Donnell, Sean; Clifford, Marie; Molina, Yamile

    2011-01-01

    We compared species mean data on the size of functionally distinct brain regions to test the relative rates at which investment in higher-order cognitive processing (mushroom body calyces) versus peripheral sensory processing (optic and antennal lobes) increased with increasing brain size. Subjects were eusocial paper wasps from queen and worker castes of 10 species from different genera. Relative investment in central processing tissue increased with brain size at a higher rate than peripheral structure investment, demonstrating that tissue devoted to higher-order cognitive processing is more constrained by brain size. This pattern held for raw data and for phylogenetically independent contrasts. These findings suggest that there is a minimum necessary investment in peripheral sensory processing brain tissue, with little to gain from additional investment. In contrast, increased brain size provides opportunities to invest in additional higher-order cognitive processing tissue. Reproductive castes differed within species in brain tissue investment, with higher central-to-peripheral brain tissue ratios in queens than in workers. Coupled with previous findings that paper wasp queen, but not worker, brain architecture corresponds to ecological and social variation, queen brain evolution appears to be most strongly shaped by cognitive demands, such as social interactions. These evolutionary patterns of neural investment echo findings in other animal lineages and have important implications, given that a greater investment in higher-order processing has been shown to increase the prevalence of complex and flexible behaviors across the animal kingdom. PMID:21482775

  8. The effect on cast post dimensions of casting investment and airborne particle abrasion.

    PubMed

    Hashem, Danya; German, Matthew J; Wassell, Robert W

    2011-09-01

    Cast posts can sometimes prove difficult to seat fully during fitting. This study compared two different liquid/water dilutions for phosphate bonded investment and the effect of controlled airborne particle abrasion on resulting post diameter. After measuring polymeric post patterns (n = 18), 3 groups were invested using concentrated solution and 3 groups using dilute solution. After casting they were weighed and remeasured then exposed to airborne particle abrasion. Both solutions produced oversized cast posts. Mean diameter reduction during airborne particle abrasion was 8 microm/10s taking an average of 41s to reach precast size. Where a post pattern fits tightly, airborne particle abrasion for 70s should reduce the casting sufficiently to accommodate the cement lute.

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

    SciTech Connect

    Nick Cannell; Adrian S. Sabau

    2005-09-30

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

  10. A new method for casting discrepancy: some results for a phosphate-bonded investment.

    PubMed

    Ho, E K; Darvell, B W

    1998-01-01

    An accurate and realistic casting discrepancy method applicable to base metal alloys has hitherto been lacking. The purpose of this study was to develop a method for determining casting discrepancy free of interference from oxide, slag and surface defects, working under realistic conditions. In addition, a variable was sought that could be used for calibrating the casting process to allow for local errors. A crown pattern was designed to incorporate circular V-grooves on the margin and the inside surface of the occlusal part for determination of the 'groove root diameter' (GRD) with a measuring microscope. Castings using a phosphate-bonded investment were made to test the effects of 'hygroscopic' expansion, burn-out temperature, powder/liquid ratio and groove location. The tested investment variables showed the expected effects, but the distortion between marginal and pulpal regions was clearly shown, as were interactions between some variables. 'Special liquid' proportion appears to be a good candidate variable for process calibration. The GRD method was shown to be sensitive and reproducible. It is also applicable to many other casting systems, and in particular to monitoring overall process discrepancy, i.e. from tooth preparation to casting, which is suggested as being the key issue.

  11. 3-Dimensional simulation of the grain formation in investment castings

    SciTech Connect

    Gandin, C.A.; Rappaz, M. ); Tintillier, R. . Dept. Materiaux et Procedes-Direction Technique)

    1994-03-01

    A 3-dimensional (3-D) probabilistic model which has been developed previously for the prediction of grain structure formation during solidification is applied to thin superalloy plates produced using the investment-casting process. This model considers the random nucleation and orientation of nuclei formed at the mold surface and in the bulk of the liquid, the growth kinetics of the dendrite tips, and the preferential growth directions of the dendrite trunks and arms. In the present study, the grains are assumed to nucleate at the surface of the mold only. The computed grain structures, as observed in 2-dimensional (2-D) sections made parallel to the mold surface, are compared with experimental micrographs. The grain densities are then deduced as a function of the distance from the mold surface for both the experiment and the simulation. It is shown that these values are in good agreement, thus, providing validation of the grain formation mechanisms built into the 3-D probabilistic model. Finally, this model is further extended to more complex geometries and the 3-D computed grain structure of an equiaxed turbine-blade airfoil is compared with the experimental transverse section micrograph.

  12. Investigation of Oxide Bifilms in Investment Cast Superalloy IN100: Part II. Characterization

    NASA Astrophysics Data System (ADS)

    Kaplan, Max A.; Fuchs, Gerhard E.

    2016-05-01

    Oxide bifilms are a proposed casting inclusion reported to have been observed in vacuum investment cast polycrystalline Ni-based superalloys. Ongoing research seeks to determine if current superalloy casting practices can result in the formation of oxide bifilms, and subsequently if it is possible to observe and characterize this phenomenon. The effect of casting atmosphere, turbulence, filtering, hot isostatic pressing, and heat treatment has been investigated to identify the critical parameters that have been reported to result in bifilm formation in Ni-based superalloy IN100. Scanning Auger microscopy (SAM), scanning electron microscopy (SEM), and high-resolution transmission electron microscopy (HR-TEM) were utilized to characterize samples from each casting condition. In situ ultrahigh vacuum Auger fractography did not indicate the presence of bifilms on the fracture behavior of IN100 in any processing condition. SAM analysis identified a sulfur-enriched monolayer on the surface of dendritic casting porosity, and identified heterogeneous Ti oxycarbide inclusions in air cast IN100. SEM analysis also indicated the presence of Ti oxycarbide inclusions in air cast IN100, and determined that these inclusion structures consist of fine blocky external M(Ti, Mo)C carbide enveloping an internal core of alumina. HR-TEM analysis indicated that none of the oxycarbide inclusion interfaces exist as discontinuous unbound interfaces, and that the internal alumina core is an ultra-fine polycrystalline structure.

  13. Investigation of Oxide Bifilms in Investment Cast Superalloy IN100: Part I. Mechanical Properties

    NASA Astrophysics Data System (ADS)

    Fuchs, Gerhard E.; Kaplan, Max A.

    2016-05-01

    Oxide bifilms are a proposed casting inclusion reported to have been observed in vacuum investment cast polycrystalline Ni-based superalloys. Ongoing research seeks to determine if current superalloy casting practices can result in the formation of oxide bifilms, and subsequently if it is possible to observe and characterize this phenomenon. The effects of casting atmosphere, turbulence, filtering, hot isostatic pressing (HIP), and heat treatment have been investigated to identify the critical parameters that have been reported to result in bifilm formation in Ni-based superalloys. Room temperature tensile and room temperature fatigue testing are used to identify the effects of each casting and processing parameter on casting defect formation and the resultant effects on mechanical properties. Characterization of mechanical test specimens seeks to identify the role of casting defects and microstructural features on the fracture mechanisms of the specimen conditions analyzed, and in particular, evidence of bifilm formation and the chemical composition(s) of oxide bifilms. Analyzed tensile and fatigue data did not indicate an influence of bifilms on the tensile or fatigue strength of vacuum processed IN100. Bifilms were not observed, via the characterization methods utilized, to be an active mechanism in tensile or fatigue fracture.

  14. Surface modification of investment cast-316L implants: microstructure effects.

    PubMed

    El-Hadad, Shimaa; Khalifa, Waleed; Nofal, Adel

    2015-03-01

    Artificial femur stem of 316L stainless steel was fabricated by investment casting using vacuum induction melting. Different surface treatments: mechanical polishing, thermal oxidation and immersion in alkaline solution were applied. Thicker hydroxyapatite (HAP) layer was formed in the furnace-oxidized samples as compared to the mechanically polished ones. The alkaline treatment enhanced the precipitation of HAP on the samples. It was also observed that the HAP precipitation responded differently to the different phases of the microstructure. The austenite phase was observed to have more homogeneous and smoother layer of HAP. In addition, the growth of HAP was sometimes favored on the austenite phase rather than on ferrite phase.

  15. The Effect of Thermal Cycling on the Surface Roughness of Dental Casting Investments.

    DTIC Science & Technology

    1991-05-01

    ceramometal alloys, cast into the various dental investment samples, was also evaluated. Finally, the roughness average measurement method was evaluated for...adaptability to dental casting investments. Ten epoxy resin dies were fabricated from the surface of six dental investment products after they were set...against a smooth reference surface. Ten additional epoxy resin dies were fabricated from the six dental investment samples after they were set

  16. Characterization of Bifilms and Oxide Inclusions in Investment Cast IN100

    NASA Astrophysics Data System (ADS)

    Kaplan, Max A.; Fuchs, G. E.

    Oxide bifilms are a proposed casting inclusion reported to have been observed in vacuum investment cast polycrystalline Ni-base superalloys. Ongoing research seeks to determine if current superalloy casting practices can result in the formation of oxide bifilms, and subsequently if it is possible to observe and characterize this phenomenon. The effect of casting atmosphere, turbulence, filtering, hot isostatic pressing (HIP), and heat treatment have been investigated to identify the critical parameters that can result in bifilm formation in Ni-based superalloy IN100. Tensile and fatigue testing is used to identify the effects of each casting and processing parameter on bifilm formation and the resultant effects on mechanical properties. Characterization of mechanical test specimens seeks to identify the role of bifilms in the fracture mechanics of the conditions utilized, as well as the prevalence of bifilm formation and the chemical composition(s) of oxide bifilms. The characterization methods used were scanning electron microscopy (SEM), energy dispersive x-ray spectroscopy (EDS), and Auger electron spectroscopy (AES). Across the range of process parameters investigated, bifilms were not indicated by mechanical testing or identified by the characterization methods employed. A nano-layer of sulfur has been identified on the surface of dendritic casting porosity and characterized by in-situ fractographic Auger analysis.

  17. Effect of Slurry Composition on Plate Weight in Ceramic Shell Investment Casting

    NASA Astrophysics Data System (ADS)

    Sidhu, Balwinder Singh; Kumar, Pradeep; Mishra, B. K.

    2008-08-01

    This paper deals with the study of the effect of primary slurry parameters on the plate weight (ceramic retention test) in ceramic shell investment casting process. Four controllable factors of the zircon flour and fused-silica powder based slurries were studied at three levels each by Taguchi’s parametric approach and single-response optimization of plate weight was conducted to identify the main factors controlling its stability. Variations in coating thickness with plate weight were calculated for each slurry and ceramic shell moulds were made on wax plate using primary slurry and coarse fused-silica sand as stucco. The Scanning Electronic Microscopy (SEM) technique has been used to study the surface morphology of zircon flour and fused silca powder particles as well as primary coating (shell surface). X-ray Diffraction (XRD) analysis was done to identify the various phases present in the ceramic slurry coating. Optical profilometer has been used to measure the surface roughness of the shells. The result reveals that the surface condition of shell can be improved by increasing the plate weight, corresponding to higher filler loading in the slurry. Confirmation experiments were conducted at an optimal condition showed that the surface quality of the ceramic shell mould were improved significantly. Castings were produced using Al-7%Si alloy in recommended parameters through ceramic shell investment casting process. Surface roughness of the produced casting were measured and presented in this paper.

  18. Effects of investment type and casting system on permeability and castability of CP titanium.

    PubMed

    Reza, Fazal; Takahashi, Hidekazu; Iwasaki, Naohiko; Tamaki, Yukimichi

    2010-08-01

    Several factors, such as casting systems and investment properties, are important to obtain a sound titanium casting. Although various casting systems and investments for titanium are commercially available, their effects on CP titanium castability are not clear. The purpose of this study was to determine permeability of investments and to evaluate the effects of investment type and casting system on titanium castability. Three investments for titanium (experimental gypsum-bonded investment, Selevest CB, and Speed Titan) and 4 titanium casting systems (Cyclarc, Ti-Cascom, Vulcan T, and Ticast Super R) were used. Permeability was measured using a flow meter and argon gas at 0.1, 0.2, and 0.3 MPa. Castability was calculated as the percentage of reproduced holes compared to a perforated wax pattern. Data for castability and permeability were analyzed separately with 2-way ANOVA and the Tukey HSD test (alpha=.05). The ANOVA for permeability and castability showed significant interaction (P<.001 and P=.004, respectively). Differences in permeability among the 3 investments increased with a higher gas pressure. Permeability of the experimental investment at each pressure level was significantly greater than that of the other investments, except for Speed Titan at 0.1 MPa (P<.05). The permeability of Selevest CB at each pressure level was significantly less than that of the other investments (P<.05). Cyclarc and Ti-Cascom specimens were not significantly different, in terms of castability, using the investments evaluated, but castability of Vulcan T and Ticast specimens varied significantly by the investment used (P<.05). Within the limitations of this study, investment type, pressure level, and their combinations influenced permeability. Castability of titanium was influenced by investment type, casting system, and their combinations. The investment with the highest permeability did not demonstrate the best result for castability. (c) 2010 The Editorial Council of the

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

    SciTech Connect

    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 were 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.

  20. 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.

  1. Characterization of oxide bifilms and nonmetallic inclusions in investment cast superalloy IN100

    NASA Astrophysics Data System (ADS)

    Kaplan, Max A.

    Oxide bifilms are a proposed casting inclusion reported to have been observed in vacuum investment cast polycrystalline Ni-base superalloys. This investigation seeks to determine if current superalloy casting methods can result in the formation of oxide bifilms, and subsequently if it is possible to observe and characterize this phenomenon. The effect of casting atmosphere, turbulence, filtering, HIP, and heat treatment have been investigated to identify the critical parameters that may result in bifilm formation in Ni-based superalloy IN100. Bifilms have been reported to impact mechanical behavior and fracture characteristics of cast superalloys, therefore tensile and fatigue testing was used in an effort to identify the effects of each casting and processing parameter on bifilm formation. Characterization of mechanical test specimens sought to identify the role of bifilms in the fracture mechanics of the conditions utilized, as well as the prevalence of bifilm formation and the chemical composition(s) of oxide bifilms. The characterization methods used were SEM, EDS, SAM, AES, STEM, BF-TEM, and HR-TEM. Tensile and fatigue test data did not indicate an influence of bifilms on the mechanical behavior of IN100, however there was a considerable impact due to the formation of Ti oxycarbide inclusions. Statistical analysis confirmed that vacuum and argon cast material under conditions expected to cause abundant bifilm formation exhibit no measurable debit to mechanical properties as compared to conditions anticipated to prevent/remediate bifilms. Bifilms were not identified during metallographic characterization or fractographic analysis of mechanical test specimens. In-situ ultrahigh vacuum Auger fractography also did not indicate the presence of bifilms in the fracture behavior of IN100 in any processing condition. However, a sulfur-enriched monolayer has been identified on the surface of dendritic casting porosity, as characterized by Auger analysis. Metallographic

  2. Gypsum-bonded investment and dental precision casting (I) two investments.

    PubMed

    Mori, Toshiko; Mcaloon, Janis; Aghajani, Farzaneh

    2003-09-01

    The present study compared the TE of two gypsum-bonded dental casting investments, the oldest K and more recent G. They had almost identical composition, 70% refractory (cristobalite) and 30% binder, but had different recommended water/powder ratios, 0.40 (K) and 0.33 (G). The average TE was significantly less (1.19%) in K than in G (1.45%); the volume decrease accompanied by the phase change of gypsum was more pronounced in the less dense K. When the dehydration conditions around gypsum are similar to those prevailing in wet calcinations methods, an expansion is likely to occur in the mold due to the formation of dental stone by recrystallization. This additional expansion has not been detected in ordinary laboratory measurement but can effectively increase the actual TE of an investment. The present study has proved the formation of dental stone by rapid heating of an investment. Specific laboratory techniques may have been supplementing low TE by this mechanism.

  3. Microscopy analysis of dental titanium casting investment materials

    SciTech Connect

    Mueller, H.J. )

    1989-09-01

    Scanning electron microscopy (SEM) analysis and qualitative energy dispersive x-ray microanalysis (EDS) of investment materials for dental titanium casting were performed. Two commercial investment materials, Ohara and Castmatic, and an experimental zirconia material were analyzed. The microstructural constituents and the unfired and fired structures were included. Larger refractory particles and matrix embedding smaller particles were observed with each material. Detection of aluminum, silicon, magnesium, zirconium and oxygen provided a basis to reason the presence of alumina (Al2O3), silica (SiO2), magnesia (MgO), and zirconia (ZrO2). Hence, Ohara contained quartz and an alumino-silicate, Castmatic contained magnesia and quartz and experimental zirconia contained zirconia and an alumino-silicate, taken to be kyanite, as components providing refractoriness and expansion. Even though unequivocal detection of phosphorous in the spectra for Ohara was not obtained (P K alpha = 2.013 keV; Zr L alpha = 2.042 keV), an emission peak at 2.0 keV was taken to be due to P and related, along with MgO, to bonding by magnesium phosphate. For Castmatic, unfired strength was thought to be due to calcium chloride and calcium silicate and fired strength to forsterite, (2MgO.SiO2). Detection of calcium and chlorine also suggested bonding of experimental zirconia via calcium chloride. Extensive microcracking occurred around refractory particles and through matrix in experimental zirconia which is likely to have resulted from the firing of kyanite to 1400 degrees C, to the monoclinic to tetragonal transformation of any unstabilized ZrO2, or to the thermal expansion mismatch between kyanite and matrix.

  4. FRICTION STIR MICROSTRUCTURAL MODIFICATION OF INVESTMENT CAST F357

    SciTech Connect

    Jana, s.; Mishra, Rajiv S.; Chou, H. N.; Herling, Darrell R.

    2007-02-09

    A hypoeutectic Al-Si alloy has been friction stir processed in this study using various run parameter combinations. Tensile test results indicate at least three times improvement in ductility value over as-cast T6 condition because of refinement in Si particle size. Si particle size and shape has been quantified and correlated with mechanical properties. Tool rotation rate seems to have the most significant effect on properties. Higher tool rotation rate resulted in more uniform and homogeneous microstructure though some anomaly is observed at very high tool rotation rate.

  5. Process development of thin strip steel casting

    SciTech Connect

    Sussman, R.C.; Williams, R.S.

    1990-12-01

    An important new frontier is being opened in steel processing with the emergence of thin strip casting. Casting steel directly to thin strip has enormous benefits in energy savings by potentially eliminating the need for hot reduction in a hot strip mill. This has been the driving force for numerous current research efforts into the direct strip casting of steel. The US Department of Energy initiated a program to evaluate the development of thin strip casting in the steel industry. In earlier phases of this program, planar flow casting on an experimental caster was studied by a team of engineers from Westinghouse Electric corporation and Armco Inc. A subsequent research program was designed as a fundamental and developmental study of both planar and melt overflow casting processes. This study was arranged as several separate and distinct tasks which were often completed by different teams of researchers. An early task was to design and build a water model to study fluid flow through different designs of planar flow casting nozzles. Another important task was mathematically modeling of melt overflow casting process. A mathematical solidification model for the formation of the strip in the melt overflow process was written. A study of the material and conditioning of casting substrates was made on the small wheel caster using the melt overflow casting process. This report discusses work on the development of thin steel casting.

  6. Effect of investment type and mold temperature on casting accuracy and titanium-ceramic bond.

    PubMed

    Leal, Mônica Barbosa; Pagnano, Valéria Oliveira; Bezzon, Osvaldo Luiz

    2013-01-01

    This study evaluated the casting accuracy of crown margins and metal-ceramic shear bond strength (SBS) of pure titanium injected into casting molds made using 2 investment types at 3 mold temperatures. Sixty crown (30-degree beveled finish line) and 60 cylinder (5mm diameter × 8mm high) patterns were divided into 6 groups (n=10), and cast using a phosphate-bonded investment (P) and a magnesium oxide-bonded investment (U), at 400°C (groups P400 and U400), 550°C (groups P550 and U550) and 700°C (groups P700 and U700) mold temperatures. Crown margins were recorded in impression material, the degree of marginal rounding was measured and margin length deficiencies (µm) were calculated. Titanium-ceramic specimens were prepared using Triceram ceramic (2mm high) and SBS was tested. Failure modes were assessed by optical microscopy. Data were subjected to two-way ANOVA and Tukey's HSD test (α=0.05). For casting accuracy, expressed by marginal deficiency (µm), investment U provided more accurate results (64 ± 11) than P (81 ± 23) (p<0.001). The increase in temperature resulted in different effects for the tested investments (p<0.001), as it provided better casting accuracy for U700 (55 ± 7) and worse for P700 (109 ± 18). Casting accuracy at 700°C (82 ± 31) was significantly different from 400°C (69 ± 9) and 550°C (68 ± 9) (p<0.05). For SBS, there was no significant differences among the groups for factors investment (p=0.062) and temperature (p=0.224), or for their interaction (p=0.149). Investment U provided better casting accuracy than investment P. The SBS was similar for all combinations of investments and temperatures.

  7. Effect of selected physical properties of waxes on investments and casting shrinkage.

    PubMed

    Ito, M; Yamagishi, T; Oshida, Y; Munoz, C A

    1996-02-01

    This study evaluated the relationship between flow characteristics, bending strength, and softening temperature of paraffin and dental inlay waxes to casting shrinkage when patterns were invested with a phosphate-bonded investment. This study found that the casting shrinkage decreased as the flow of the wax pattern increased. If a low flow wax is used or if there is a need for a thick pattern, the size of the casting ring should be increased. When wax patterns are formed for cast restorations, it is important to select the type of wax with the most desirable properties for the margin and the occlusal portions. Moreover, to accurately fabricate castings, it is necessary to understand the physical properties of the chosen waxes.

  8. The dependence of tensile ductility on investment casting parameters in gamma titanium aluminides

    SciTech Connect

    Raban, R.; Rishel, L.L.; Pollock, T.M.

    1999-07-01

    Plates of three gamma titanium aluminide alloys have been investment cast with a wide variety of casting conditions designed to influence cooling rates. These alloys include Ti-48Al-2Cr-2Nv, Ti-47Al-2Cr-2Nb+0.5at%B and Ti-45Al-2Cr-2Nb+0.9at%B. Cooling rates have been estimated with the use of thermal data from casting experiments, along with the UES ProCAST simulation package. Variations in cooling rate significantly influenced the microstructure and tensile properties of all three alloys.

  9. Effect of porosity on ductility variation in investment cast 17-4PH.

    SciTech Connect

    Wright, Robert D.; Kilgo, Alice C.; Grant, Richard P.; Crenshaw, Thomas B.; Susan, Donald Francis

    2005-02-01

    The stainless steel alloy 17-4PH contains a martensitic microstructure and second phase delta ({delta}) ferrite. Strengthening of 17-4PH is attributed to Cu-rich precipitates produced during age hardening treatments at 900-1150 F (H900-H1150). For wrought 17-4PH, the effects of heat treatment and microstructure on mechanical properties are well-documented [for example, Ref. 1]. Fewer studies are available on cast 17-4PH, although it has been a popular casting alloy for high strength applications where moderate corrosion resistance is needed. Microstructural features and defects particular to castings may have adverse effects on properties, especially when the alloy is heat treated to high strength. The objective of this work was to outline the effects of microstructural features specific to castings, such as shrinkage/solidification porosity, on the mechanical behavior of investment cast 17-4PH. Besides heat treatment effects, the results of metallography and SEM studies showed that the largest effect on mechanical properties is from shrinkage/solidification porosity. Figure 1a shows stress-strain curves obtained from samples machined from castings in the H925 condition. The strength levels were fairly similar but the ductility varied significantly. Figure 1b shows an example of porosity on a fracture surface from a room-temperature, quasi-static tensile test. The rounded features represent the surfaces of dendrites which did not fuse or only partially fused together during solidification. Some evidence of local areas of fracture is found on some dendrite surfaces. The shrinkage pores are due to inadequate backfilling of liquid metal and simultaneous solidification shrinkage during casting. A summary of percent elongation results is displayed in Figure 2a. It was found that higher amounts of porosity generally result in lower ductility. Note that the porosity content was measured on the fracture surfaces. The results are qualitatively similar to those found by

  10. Upscaling of the investment casting of the intermetallic alloy IC75

    NASA Astrophysics Data System (ADS)

    Hollad, Simon; Bührig-Polaczek, Andreas

    2010-10-01

    This research work is based on a specially developed SiO2-free shell mold system for the investment casting of NiAl alloys. Hitherto, this shell system has only been used for scientific work on small, laboratory scale samples made of IC75 alloy. The main focus of the research is to examine the feasibility of upscaling of the shell mold system for production scale samples. For this reason, 200 mm long dummy turbine blades were cast. Nondestructive analysis of the castings by visual examination of the blades’ surface quality, computed tomography scans of their internal structures and three-dimensional measurements showed very good results for the shell mold system. In particular, the good dimensional stability of the shell mold with average deviations of +0.3 mm and a local maximum deviation of -0.73 mm are excellent for a water-soluble shell mold system. The results of this work demonstrate that the investigated mold system is suitable for large samples and melt weights of up to 5 kg and is thus adaptable for the production process of NiAl components.

  11. Mold filling and dimensional accuracy of titanium castings in a spinel-based investment.

    PubMed

    Fischer, Jens; Ebinger, Andreas; Hägi, Tobias; Stawarczyk, Bogna; Wenger, Andreas; Keller, Egbert

    2009-11-01

    Aim of the study was to analyze the mold filling capacity and the dimensional accuracy of a spinel-based investment for titanium castings. Expansion of the investment in dependence of the preheating temperature was measured in a dilatometer. The degree of transformation of MgO and Al2O3 to spinel (MgAl2O4) was evaluated by means of X-ray powder diffraction. Mold filling capacity was assessed by casting a grid and calculating the percentage of completed segments. Dimensional accuracy was analyzed by casting a hollow cylinder and measuring the difference between the inner diameter of the resin pattern and the resulting titanium casting. Spinel formation starts at 819 degrees C. Diffraction patterns prove the formation of spinel from MgO and Al2O3. The amount of spinel increases with increasing preheating temperature. The final expansion of the investment at the end of the preheating cycle at 450 degrees C shows a linear correlation to the maximum preheating temperature. The degree of mold filling is reciprocal to the preheating temperature. The dimensional accuracy shows a linear correlation to the amount of spinel. Best dimensional accuracy was obtained at about 900 degrees C. After a preheating temperature of 884 degrees C, as recommended by the manufacturer, the cast specimens showed a slightly lower inner diameter as compared to the resin patterns. The results suggest that with the spinel investment analyzed an excellent accuracy of titanium castings may be obtained.

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

    SciTech Connect

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

    1995-11-01

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

  13. Neutron computed tomography investigation of the porosity on the titanium femoral knee investment casting

    NASA Astrophysics Data System (ADS)

    Prayoga, B. T.; Suyitno; Dharmastiti, R.; Akbar, F.; Juliani

    2017-02-01

    Rotational velocity in the centrifugal casting is one of the factors that affect to the porosity of the femoral knee cast. The objective of this research is to investigate the internal porosity of as-cast femoral knee prostheses. CP-titanium femoral knee was cast using vertical centrifugal investment casting. The three rotational velocities parameter utilized in the vertical centrifugal casting were 45, 55 and 65 rpm. Neutron computed tomography characterization was conducted to investigate the size, percentage, and location of pores. The maximum size of pores in casting with the rotational velocity of 45, 55, and 65 rpm are 14.78 mm3, 14.98 mm3, and, 14.65 mm3, respectively. The percentage of pores in the casting with the rotational velocity of 45, 55, and 65 rpm are 1.78%, 2.78% and, 1.78% respectively. The size and percentage of the pores for casting at the rotational velocity of 65 rpm are smaller than the size and percentage of the casting at 45 and 55 rpm.

  14. The Effects of Casting Porosity on the Tensile Behavior of Investment Cast 17-4PH Stainless Steel

    NASA Astrophysics Data System (ADS)

    Susan, D. F.; Crenshaw, T. B.; Gearhart, J. S.

    2015-08-01

    The effect of casting porosity on the mechanical behavior of investment cast 17-4PH stainless steel was studied as well as the effect of heat treatment on the alloy's sensitivity to casting defects. Interdendritic porosity, formed during solidification and shrinkage of the alloy, reduces the yield strength and ultimate tensile strength roughly in proportion to the reduction in load bearing cross-section. The effects of casting porosity on ductility (% strain, % reduction in area) are more severe, in agreement with research on other alloy systems. In this study, 10% porosity reduced the ductility of 17-4PH stainless steel by almost 80% for the high-strength H925 condition. Tensile testing at -10°C (263 K) further reduces the alloy ductility with and without pores present. In the lower strength H1100 condition, the ductility is higher than the H925 condition, as expected, and somewhat less sensitive to porosity. By measuring the area % porosity on the fracture surface of tensile specimens, the trend in failure strain versus area % porosity was obtained and analyzed using two methods: an empirical approach to determine an index of defect susceptibility with a logarithmic fit and an analytical approach based on the constitutive stress-strain behavior and critical strain concentration in the vicinity of the casting voids. The applicability of the second method depends on the amount of non-uniform strain (necking) and, as such, the softer H1100 material did not correlate well to the model. The behavior of 17-4PH was compared to previous work on cast Al alloys, Mg alloys, and other cast materials.

  15. Properties of experimental titanium cast investment mixing with water reducing agent solution.

    PubMed

    Zhang, Zutai; Ding, Ning; Tamaki, Yukimichi; Hotta, Yasuhiro; Han-Cheol, Cho; Miyazaki, Takashi

    2012-01-01

    This study aimed to develop a dental investment for titanium casting. ZrO(2) and Al(2)O(3) were selected as refractory materials to prepare three investments (Codes: A-C) according to the quantity of Zr. Al(2)O(3) cement was used as a binder at a ratio of 15%, they were mixed with special mixing liquid. B1 was used as a control mixed with water. Fundamental examinations were statistically evaluated. A casting test was performed with investment B. Fluidities, setting times, and green strengths showed no remarkable differences; however, they were significantly different from those of B1. Expansion values for A, B, C, and B1 at 850°C were 1.03%±0.08%, 1.96%±0.17%, 4.35%±0.23%, and 1.50%±0.28%, respectively. Castings were covered by only small amounts of mold materials. The hardness test showed no significant differences between castings from B and the ones from commercial investments. The experimental special mixing liquid effectively reduced the water/powder ratio and improved the strength and thermal expansion.

  16. A quality assessment of the casting process on magnetic keepers.

    PubMed

    Luk, Henry W K; Pow, Edmond H N; Dias, Andrew P L H

    2007-01-01

    The objective of this study was to qualitatively investigate the effect of the burn-out (mold) temperature, investment material, and casting alloy on the surface integrity of the Magfit EX keeper. Forty-two Magfit EX keepers were waxed-up, invested in five investment materials (Beauty-Cast, Cristobalite, CM-10, Cera-Fina, Castorit-super), and subjected to burn-out temperatures ranging from 450 to 700 degrees C at intervals of 50 degrees C. The keeper samples were then cast into copings with three alloys (Castwell, Protor 3, Optimum) under standard conditions. The keeper surfaces were then examined under a microscope, and the compositions were assessed by an X-ray micro-analyzer in a scanning electron microscope (SEM). A new keeper served as control. At a burn-out temperature of 550 degrees C, the keeper surface started to disintegrate. X-ray micro-analysis showed an increase in oxygen content with increasing temperature. At 700 degrees C, the keeper surface disintegrated, and the composition differed markedly from that of the new keeper. The keeper surfaces were intact with all investments except those with Beauty-Cast. The keeper surfaces were found to be damaged when the casting alloy was Optimum. Beauty-Cast investment with a burn-out temperature of 700 degrees C is unsuitable for casting the Magfit EX keeper-coping unit. Also, high fusing alloys are not recommended for casting Magfit EX keepers.

  17. Gating geometry studies of thin-walled 17-4PH investment castings

    SciTech Connect

    Maguire, M.C.; Zanner, F.J.

    1992-11-01

    The ability to design gating systems that reliably feed and support investment castings is often the result of ``cut-and-try`` methodology. Factors such as hot tearing, porosity, cold shuts, misruns, and shrink are defects often corrected by several empirical gating design iterations. Sandia National Laboratories is developing rules that aid in removing the uncertainty involved in the design of gating systems for investment castings. In this work, gating geometries used for filling of thin walled investment cast 17-4PH stainless steel flat plates were investigated. A full factorial experiment evaluating the influence of metal pour temperature, mold preheat temperature, and mold channel thickness were conducted for orientations that filled a horizontal flat plate from the edge. A single wedge gate geometry was used for the edge-gated configuration. Thermocouples placed along the top of the mold recorded metal front temperatures, and a real-time x-ray imaging system tracked the fluid flow behavior during filling of the casting. Data from these experiments were used to determine the terminal fill volumes and terminal fill times for each gate design.

  18. Gating geometry studies of thin-walled 17-4PH investment castings

    SciTech Connect

    Maguire, M.C.; Zanner, F.J.

    1992-01-01

    The ability to design gating systems that reliably feed and support investment castings is often the result of cut-and-try'' methodology. Factors such as hot tearing, porosity, cold shuts, misruns, and shrink are defects often corrected by several empirical gating design iterations. Sandia National Laboratories is developing rules that aid in removing the uncertainty involved in the design of gating systems for investment castings. In this work, gating geometries used for filling of thin walled investment cast 17-4PH stainless steel flat plates were investigated. A full factorial experiment evaluating the influence of metal pour temperature, mold preheat temperature, and mold channel thickness were conducted for orientations that filled a horizontal flat plate from the edge. A single wedge gate geometry was used for the edge-gated configuration. Thermocouples placed along the top of the mold recorded metal front temperatures, and a real-time x-ray imaging system tracked the fluid flow behavior during filling of the casting. Data from these experiments were used to determine the terminal fill volumes and terminal fill times for each gate design.

  19. [Development of dental quick casting with zircon-phosphoric acid investments].

    PubMed

    Fukumoto, R

    1990-03-01

    The application of zircon (ZrSiO4) that has high refractoriness, high thermal conductivity and a low coefficient of thermal expansion, to quick casting investment was studied. Various zircon powders and phosphoric acid solutions were tested with respect to the higher thermal shock resistance. The formulation and properties of zircon-phosphoric acid investment materials such as water/powder ratio, fluidity of slurry, setting time, setting expansion, thermal expansion, thermal analysis, green and fired compressive strength were measured. Formulation of zircon slurry for coating was zircon flower #600 30%, zircon flower #350 10%, and zircon sand CP 60%, and that for sanding was zircon flower #200. The mixing liquid was 15% phosphoric acid and liquid/powder ratio was 0.1. The slurry using phosphoric acid had good fluidity and good workability. The 24-hour green strength was 1 MPa, fired strength was 10 MPa, 24-hour setting expansion was -0.04% and the thermal expansion at 1000 degrees C was 0.31%. Immediately after coating with zircon slurry, the coating layer was dried, sintered and dewaxed by thermal shock. The thermal shock consisted of the following four-step manipulations. The first is hot air drying (50 degrees C, 5 minutes), the second is heat shock (900 degrees C, 3 seconds), the third is redrying (220 degrees C, 3 minutes) and the fourth is dewaxing (550 degrees C, 3 minutes). Small casting of pure titanium and K-metal could be done successfully by the quick casting method using the zircon-phosphoric acid investments. It was found that the total expansion of the secondary investments influenced the casting adapatability.

  20. The effect of coating patterns with spinel-based investment on the castability and porosity of titanium cast into three phosphate-bonded investments.

    PubMed

    Pieralini, Anelise R F; Benjamin, Camila M; Ribeiro, Ricardo Faria; Scaf, Gulnara; Adabo, Gelson Luis

    2010-10-01

    This study evaluated the effect of pattern coating with spinel-based investment Rematitan Ultra (RU) on the castability and internal porosity of commercially pure (CP) titanium invested into phosphate-bonded investments. The apparent porosity of the investment was also measured. Square patterns (15 × 15 × 0.3 mm(3)) were either coated with RU, or not and invested into the phosphate-bonded investments: Rematitan Plus (RP), Rema Exakt (RE), Castorit Super C (CA), and RU (control group). The castings were made in an Ar-arc vacuum-pressure machine. The castability area (mm(2) ) was measured by an image-analysis system (n = 10). For internal porosity, the casting (12 × 12 × 2 mm(3) ) was studied by the X-ray method, and the projected porous area percentage was measured by an image-analysis system (n = 10). The apparent porosity of the investment (n = 10) was measured in accordance with the ASTM C373-88 standard. Analysis of variance (One-way ANOVA) of castability was significant, and the Tukey test indicated that RU had the highest mean but the investing technique with coating increased the castability for all phosphate-bonded investments. The analysis of the internal porosity of the cast by the nonparametric test demonstrated that the RP, RE, and CA with coating and RP without coating did not differ from the control group (RU), while the CA and RE casts without coating were more porous. The one-way ANOVA of apparent porosity of the investment was significant, and the Tukey test showed that the means of RU (36.10%) and CA (37.22%) were higher than those of RP (25.91%) and RE (26.02%). Pattern coating with spinel-based material prior to phosphate-bonded investments can influence the castability and the internal porosity of CP Ti. © 2010 by The American College of Prosthodontists.

  1. Fabrication of low-cost, cementless femoral stem 316L stainless steel using investment casting technique.

    PubMed

    Baharuddin, Mohd Yusof; Salleh, Sh-Hussain; Suhasril, Andril Arafat; Zulkifly, Ahmad Hafiz; Lee, Muhammad Hisyam; Omar, Mohd Afian; Abd Kader, Ab Saman; Mohd Noor, Alias; A Harris, Arief Ruhullah; Abdul Majid, Norazman

    2014-07-01

    Total hip arthroplasty is a flourishing orthopedic surgery, generating billions of dollars of revenue. The cost associated with the fabrication of implants has been increasing year by year, and this phenomenon has burdened the patient with extra charges. Consequently, this study will focus on designing an accurate implant via implementing the reverse engineering of three-dimensional morphological study based on a particular population. By using finite element analysis, this study will assist to predict the outcome and could become a useful tool for preclinical testing of newly designed implants. A prototype is then fabricated using 316L stainless steel by applying investment casting techniques that reduce manufacturing cost without jeopardizing implant quality. The finite element analysis showed that the maximum von Mises stress was 66.88 MPa proximally with a safety factor of 2.39 against endosteal fracture, and micromotion was 4.73 μm, which promotes osseointegration. This method offers a fabrication process of cementless femoral stems with lower cost, subsequently helping patients, particularly those from nondeveloped countries.

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

    NASA Technical Reports Server (NTRS)

    Cooper, K. G.; Wells, D.

    2000-01-01

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

  3. Development of casting investment preventing blackening of noble metal alloys part 3. Effect of reducing agent addition on the strength and expansion of the investments.

    PubMed

    Meng, Yukun; Nakai, Akira; Ogura, Hideo

    2004-06-01

    Different reducing agents (B, Al, Si and Ti) were individually added to two gypsum-bonded investments to prepare investments preventing surface blackening of some noble cast alloys. The effect of different additive contents on green-body and burnout compressive strength, setting and thermal expansion of the investments were evaluated. The strength and expansion of the investments were changed by the additives. The compressive strength of Al-, Si- and Ti-added investments decreased with the increase of additive contents. The burnout strength of B-added investments significantly increased while green-body strength remained unchanged. The setting expansion of the B-added investments increased while those of the Al-, Si- and Ti-added investments decreased with the increase of additive contents. The thermal expansion of the Si- and Ti-added investments decreased, and that of the Al- and B-added investments remained unchanged. Further study is necessary to evaluate the effects of these additives on the accuracy of dental castings.

  4. Gypsum-bonded alumina dental investment for high-fusing casting.

    PubMed

    Yan, M; Takahashi, H

    1998-09-01

    In this study, we developed a new gypsum-bonded investment for high-fusing alloys. The investment was composed of gypsum as a binder and alumina as a refractory. Effects of type of alumina powder and gypsum content on characteristics of the gypsum-bonded alumina investment were investigated. Obtained characteristics of this experimental investment were as follows: fluidities ranged from 48.8 to 88.9 mm; setting times ranged from 21.2 to more than 120 minutes; setting expansions ranged from 0.4 to 1.3%; green strengths showed 0.5 to 4.5 MPa; fired strengths ranged from 0.2 to 1.7 MPa; thermal expansions after firing were -1.60 to 2.16%. Thermal expansion occurred because of the chemical reaction between Al2O3 and CaO decomposed from gypsum. These results suggest that this gypsum-bonded alumina investment with 20 or 25 mass% gypsum content possessed the fundamental properties for high-fusing alloy casting.

  5. Soda-lime glass as a binder in reusable experimental investment for dental castings.

    PubMed

    Yagi, Satoshi; Zhang, Zutai; Aida, Yoshiteru; Hotta, Yasuhiro; Tamaki, Yukimichi; Miyazaki, Takashi

    2011-01-01

    In this study, different glasses were investigated to improve reusable investments. Borosilicate glass (BSG) powder and soda-lime glass (SLG) powder were prepared by milling broken beakers and microscope slides, respectively, and used in experimental investments (I-BSG, I-SLG) by blending glass powder (10 wt%) with cristobalite (90 wt%). Some properties and casting fits were evaluated with commercial gypsum-bonded investment as the control. Both BSG and SLG were mainly composed of Si, but SLG had a large Ca content. The glass transition temperatures were approximately 800°C (BSG) and 700°C (SLG). Experimental investments with heating showed the significantly (p<0.05) higher expansion than that of the control. The compressive strength of I-SLG was higher than that of I-BSG, and increased with temperature. The MOD inlay obtained from I-SLG had a significantly smaller gap than that from I-BSG, and was comparable to the control. These results suggest SLG could be applied clinically as a reusable dental investment.

  6. Process for slip casting textured tubular structures

    SciTech Connect

    Steinlage, Greg A.; Trumble, Kevin P.; Bowman, Keith J.

    2002-01-01

    A process for centrifugal slip casting a textured hollow tube. A slip made up of a carrier fluid and a suspended powder is introduced into a porous mold which is rotated at a speed sufficient to create a centrifugal force that forces the slip radially outward toward the inner surface of the mold. The suspended powder, which is formed of particles having large dimensional aspect ratios such as particles of superconductive BSCCO, settles in a textured fashion radially outward toward the mold surface. The carrier fluid of the slip passes by capillary action radially outward around the settled particles and into the absorbent mold. A layer of mold release material is preferably centrifugally slip cast to cover the mold inner surface prior to the introduction of the BSCCO slip, and the mold release layer facilitates removal of the BSCCO greenbody from the mold without fracturing.

  7. Non-rigid Reconstruction of Casting Process with Temperature Feature

    NASA Astrophysics Data System (ADS)

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

    2017-09-01

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

  8. 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.

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

    SciTech Connect

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

    1995-07-01

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

  10. Acoustic emission signals from gypsum-bonded dental casting molds during thermal processing.

    PubMed

    Kim, K H; Asaoka, K; Yoshida, K

    1998-03-01

    To develop a suitable heating program for the investments which affect the casting accuracy/defects of prostheses, a probable microstructural change of the gypsum-bonded investments related to the transition of refractory particles during thermal processing was inspected by the measurement of acoustic emission (AE) signals. Gypsum-bonded cristobalite and quartz investment molds were used. AE measurements were carried out for the specimens in an electric furnace that was heated/cooled at a constant rate. For the heating process of the cristobalite investment, high AE activities were detected in the temperature range where the cristobalite was transformed. However, the AE signals detected were low for the second run of the heating and cooling processes. Even in the heating process, significant AE signals were not detected for the quartz investment. For cristobalite investment molds, micro-cracks are initiated and developed in relation to the transition of cristobalite particles in the mold. This leads to deterioration of the mechanical properties of the cristobalite investment at high temperatures (melt-pouring), and may affect the fitness of cast prostheses.

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

    NASA Technical Reports Server (NTRS)

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

    2006-01-01

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

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

    NASA Technical Reports Server (NTRS)

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

    2006-01-01

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

  13. Separate effects identification via casting process modeling for experimental measurement of U-Pu-Zr alloys

    NASA Astrophysics Data System (ADS)

    Crapps, J.; DeCroix, D. S.; Galloway, J. D.; Korzekwa, D. A.; Aikin, R.; Fielding, R.; Kennedy, R.; Unal, C.

    2013-11-01

    Computational simulations of gravity casting processes for metallic U-Pu-Zr nuclear fuel rods have been performed using a design-of-experiments technique to determine the fluid flow, liquid heat transfer, and solid heat transfer parameters which most strongly influence the process solidification speed and fuel rod porosity. The results are used to make recommendations for the best investment of experimental time and effort to measure process parameters.

  14. Effects of magnesia and potassium sulfate on gypsum-bonded alumina dental investment for high-fusing casting.

    PubMed

    Yan, M; Takahashi, H

    1998-12-01

    The purpose of this study was to improve the characteristics of gypsum-bonded alumina investments using magnesia and potassium sulfate as chemical additives. Magnesia content improved fluidity, delayed setting reaction, increased green strength, and decreased setting expansion, when mixed with distilled water. When the investment was mixed with potassium sulfate, the setting time and setting expansion were reduced, and the thermal expansion increased, however, the green strength decreased. Therefore, the investment with a small amount of magnesia mixed with potassium sulfate was considered a suitable composition, having adequate setting behavior, enough green strength and sufficient compensate expansion for casting.

  15. Numerical simulation of the solidification microstructure of a 17-4PH stainless steel investment casting and its experimental verification

    NASA Astrophysics Data System (ADS)

    Li, You Yun; Tsai, DeChang; Hwang, Weng Sing

    2008-06-01

    The purpose of this study is to develop a technique of numerically simulating the microstructure of 17-4PH (precipitation hardening) stainless steel during investment casting. A cellular automation (CA) algorithm was adopted to simulate the nucleation and grain growth. First a calibration casting was made, and then by comparing the microstructures of the calibration casting with those simulated using different kinetic growth coefficients (a2, a3) in CA, the most appropriate set of values for a2 and a3 would be obtained. Then, this set of values was applied to the microstructure simulation of a separate casting, where the casting was actually made. Through this approach, this study has arrived at a set of growth kinetic coefficients from the calibration casting: a2 is 2.9 × 10-5, a3 is 1.49 × 10-7, which is then used to predict the microstructure of the other test casting. Consequently, a good correlation has been found between the microstructure of actual 17-4PH casting and the simulation result.

  16. 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

  17. Numerical simulation and optimization of casting process for complex pump

    NASA Astrophysics Data System (ADS)

    Liu, Xueqin; Dong, Anping; Wang, Donghong; Lu, Yanling; Zhu, Guoliang

    2017-09-01

    The complex shape of the casting pump body has large complicated structure and uniform wall thickness, which easy give rise to casting defects. The numerical simulation software ProCAST is used to simulate the initial top gating process, after analysis of the material and structure characteristics of the high-pressure pump. The filling process was overall smooth, not there the water shortage phenomenon. But the circular shrinkage defects appear at the bottom of casting during solidification process. Then, the casting parameters were optimized and adding cold iron in the bottom. The shrinkage weight was reduced from 0.00167g to 0.0005g. The porosity volume was reduced from 1.39cm3 to 0.41cm3. The optimization scheme is simulated and actual experimented. The defect has been significantly improved.

  18. Cast Double Base Propellants: Process Mechanics

    DTIC Science & Technology

    1953-02-01

    thc rate of dilatation, of the casting powder and its .’ate of penetration by casting liquid, 2. 2. To measure the rate of dilatation of the...powders a)d fini.shed charges, 2.4. To dctcrminc the r,ate of solution of the casti)g owdcr in thc castino llquid, 2.5. To measturc the chrngo iu...O aad humidity cabiact ( sect a t 20OC. , 5 5 --c lat:v* hCum-’IitY) fo t ea,t 24 hours befo-re coiiencin-g the test. The gralcz L-u-o thc ):) mo,,sur

  19. MANUFACTURING PROCESS DEVELOPMENT FOR ROLLING CAST SLABS OF COLUMBIUM (CB-752) ALLOY.

    DTIC Science & Technology

    Slab castings of HAYNES alloy Nb-752 (Nb-10W-2.5Zr) were made by the centrifugal skull casting and the electron - beam melting and casting techniques...fabricability of slabs made either by the centrifugal skull casting process or by the electron - beam melting and casting process. The sheet produced in the

  20. CAST2D: A finite element computer code for casting process modeling

    SciTech Connect

    Shapiro, A.B.; Hallquist, J.O.

    1991-10-01

    CAST2D is a coupled thermal-stress finite element computer code for casting process modeling. This code can be used to predict the final shape and stress state of cast parts. CAST2D couples the heat transfer code TOPAZ2D and solid mechanics code NIKE2D. CAST2D has the following features in addition to all the features contained in the TOPAZ2D and NIKE2D codes: (1) a general purpose thermal-mechanical interface algorithm (i.e., slide line) that calculates the thermal contact resistance across the part-mold interface as a function of interface pressure and gap opening; (2) a new phase change algorithm, the delta function method, that is a robust method for materials undergoing isothermal phase change; (3) a constitutive model that transitions between fluid behavior and solid behavior, and accounts for material volume change on phase change; and (4) a modified plot file data base that allows plotting of thermal variables (e.g., temperature, heat flux) on the deformed geometry. Although the code is specialized for casting modeling, it can be used for other thermal stress problems (e.g., metal forming).

  1. Mould filling of Ag-Pd-Cu-Au and Ag-Zn-Sn-In alloy castings made using a rapidly prepared gypsum-bonded investment material.

    PubMed

    Shimizu, Hiroshi; Inoue, Shoko; Miyauchi, Hideaki; Watanabe, Kouichi; Takahashi, Yutaka

    2008-12-01

    Mandibular premolar-shaped wax patterns of full crowns with a marginal angle of 300 were prepared. Two semiprecious alloys were cast using a rapidly prepared gypsum-bonded investment material or a conventional gypsum-bonded investment. A precise impression was taken and cut into four segments. Scanning electron microscopy was used to evaluate the mould filling of each segment. The mould filling of the silver-palladium-copper-gold alloy was worse than that of the silver-zinc-tin-indium alloy. The mould filling of both alloys cast with the rapidly prepared gypsum-bonded investment material was superior to that using the conventional investment.

  2. Process improvement as an investment: Measuring its worth

    NASA Technical Reports Server (NTRS)

    Mcgarry, Frank; Jeletic, Kellyann

    1993-01-01

    This paper discusses return on investment (ROI) generated from software process improvement programs. It details the steps needed to compute ROI and compares these steps from the perspective of two process improvement approaches: the widely known Software Engineering Institute's capability maturity model and the approach employed by NASA's Software Engineering Laboratory (SEL). The paper then describes the specific investments made in the SEL over the past 18 years and discusses the improvements gained from this investment by the production organization in the SEL.

  3. Hanford's Simulated Low Activity Waste Cast Stone Processing

    SciTech Connect

    Kim, Young

    2013-08-20

    Cast Stone is undergoing evaluation as the supplemental treatment technology for Hanford’s (Washington) high activity waste (HAW) and low activity waste (LAW). This report will only cover the LAW Cast Stone. The programs used for this simulated Cast Stone were gradient density change, compressive strength, and salt waste form phase identification. Gradient density changes show a favorable outcome by showing uniformity even though it was hypothesized differently. Compressive strength exceeded the minimum strength required by Hanford and greater compressive strength increase seen between the uses of different salt solution The salt waste form phase is still an ongoing process as this time and could not be concluded.

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

    PubMed

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

    1990-07-01

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

  5. Development of a thin steel strip casting process. Final report

    SciTech Connect

    Williams, R.S.

    1994-04-01

    This is a comprehensive effort to develop direct strip casting to the point where a pilot scale program for casting carbon steel strip could be initiated. All important aspects of the technology were being investigated, however the program was terminated early due to a change in the business strategy of the primary contractor, Armco Inc. (focus to be directed at specialty steels, not low carbon steel). At termination, the project was on target on all milestones and under budget. Major part was casting of strip at the experiment casting facility. A new caster, capable of producing direct cast strip of up to 12 in. wide in heats of 1000 and 3000 lb, was used. A total of 81 1000-1200 lb heats were cast as well as one test heat of 3000 lb. Most produced strip of from 0.016 to 0.085 in. thick. Process reliability was excellent for short casting times; quality was generally poor from modern hot strip mill standards, but the practices necessary for good surface quality were identified.

  6. Effect of Annealing Temperature on Microstructure and Mechanical Properties of Hot Swaged cp-Ti Produced by Investment Casting

    NASA Astrophysics Data System (ADS)

    Ibrahim, Khaled M.; Mhaede, Mansour; Wagner, Lothar

    2012-01-01

    The purpose of this study is to evaluate the influence of hot swaging (SW) and annealing treatment on microstructure and mechanical properties of commercially pure titanium (grade 4) produced by investment casting. During SW at 700 °C, the diameter of the cast titanium bars was reduced from 25 to 8.5 mm in 14 steps. After SW, material was annealed for 1 h at 500, 700, or 870 °C. The as-cast samples showed a typical microstructure consisting of a variety of α-morphologies, while the hot swaged samples exhibited a kinked lamellar microstructure. Annealing at 500 °C did not significantly change this microstructure, while annealing at both 700 and 870 °C led to recrystallization and formation of equiaxed microstructures. The cast bars exhibited a typical hard α-layer in near-surface regions with maximum depth and maximum hardness of 720 μm and 660 HV0.5, respectively. Due to SW, the tensile strength of the as-cast material drastically increased from 605 to 895 MPa. Annealing at 500 °C decreased this tensile strength slightly from 895 to 865 MPa while annealing at 700 °C led to a further pronounced drop in tensile strength from 865 to 710 MPa. No additional decrease in tensile strength was observed by increasing the annealing temperature from 700 to 870 °C. The tensile ductility of the as-cast and hot swaged samples was approximately the same in the range of 0.05 to 0.11, while the annealed samples showed values in the range of 0.25 to 0.53. In addition, the as-cast and hot swaged samples revealed a brittle cleavage fracture surfaces. However, the annealed samples showed a transgranular ductile fracture with formation of dimples.

  7. Surface hardening of two cast irons by friction stir processing

    NASA Astrophysics Data System (ADS)

    Fujii, Hidetoshi; Yamaguchi, Yasufumi; Kikuchi, Toshifumi; Kiguchi, Shoji; Nogi, Kiyoshi

    2009-05-01

    The Friction Stir Processing (FSP) was applied to the surface hardening of cast irons. Flake graphite cast iron (FC300) and nodular graphite cast iron (FCD700) were used to investigate the validity of this method. The matrices of the FC300 and FC700 cast irons are pearlite. The rotary tool is a 25mm diameter cylindrical tool, and the travelling speed was varied between 50 and 150mm/min in order to control the heat input at the constant rotation speed of 900rpm. As a result, it has been clarified that a Vickers hardness of about 700HV is obtained for both cast irons. It is considered that a very fine martensite structure is formed because the FSP generates the heat very locally, and a very high cooling rate is constantly obtained. When a tool without an umbo (probe) is used, the domain in which graphite is crushed and striated is minimized. This leads to obtaining a much harder sample. The hardness change depends on the size of the martensite, which can be controlled by the process conditions, such as the tool traveling speed and the load. Based on these results, it was clarified that the FSP has many advantages for cast irons, such as a higher hardness and lower distortion. As a result, no post surface heat treatment and no post machining are required to obtain the required hardness, while these processes are generally required when using the traditional methods.

  8. Effect of wax melting range and investment liquid concentration on the accuracy of a three-quarter crown casting.

    PubMed

    Ito, Michio; Kuroiwa, Akihiro; Nagasawa, Sakae; Yoshida, Takamitsu; Yagasaki, Hiroshi; Oshida, Yoshiki

    2002-01-01

    Dental casting accuracy is influenced by the setting expansion of investment materials. Although setting expansion can help compensate for casting shrinkage, it cannot be fully realized under a confined wax pattern. Exactly how soft a wax pattern should be to ensure optimum setting expansion has not been determined. In this study, the relationship between wax characteristics and the casting accuracy of a three-quarter crown was investigated. Four different wax materials were used: paraffin 135 with a softening temperature of 37.5 degrees C (P38), paraffin 1080 with a softening temperature of 63.5 degrees C, Shofu Red with a softening temperature of 41.5 degrees C, and Shofu Hard with a softening temperature of 51 degrees C. Two mixtures of phosphate-bonded investment were prepared: one with 100% special liquid and another with 75% special liquid plus 25% distilled water. For both, the liquid/powder ratio was 16:100. A type IV gold alloy was cast into a three-quarter crown mold. The discrepancy at 6 locations (1 lingual, 1 mesial, 1 distal, and 3 facial) was measured with a traveling microscope. Five readings were collected. Means and standard deviations were calculated for all data. A 2-way analysis of variance followed by the Student-Newman-Keuls test for multiple comparisons was used to identify significant differences between groups at the 95% confidence level. For the gingival measurement sites (lingual, mesial, and distal), there was no significant difference in cast adaptation when Shofu Hard and paraffin 1080 waxes were used. However, the results with these 2 waxes were different than with Shofu Red and P38. For the 3 facial measurement sites, significantly different measurements were found for each wax; P38 demonstrated the best results. Casting shrinkage was smaller with the use of 100% special liquid. Within the limitations of this study, casting shrinkage was affected by the type of wax used and was sensitive to the site at which dimensional measurements

  9. Lightweight Concrete Produced Using a Two-Stage Casting Process

    PubMed Central

    Yoon, Jin Young; Kim, Jae Hong; Hwang, Yoon Yi; Shin, Dong Kyu

    2015-01-01

    The type of lightweight aggregate and its volume fraction in a mix determine the density of lightweight concrete. Minimizing the density obviously requires a higher volume fraction, but this usually causes aggregates segregation in a conventional mixing process. This paper proposes a two-stage casting process to produce a lightweight concrete. This process involves placing lightweight aggregates in a frame and then filling in the remaining interstitial voids with cementitious grout. The casting process results in the lowest density of lightweight concrete, which consequently has low compressive strength. The irregularly shaped aggregates compensate for the weak point in terms of strength while the round-shape aggregates provide a strength of 20 MPa. Therefore, the proposed casting process can be applied for manufacturing non-structural elements and structural composites requiring a very low density and a strength of at most 20 MPa. PMID:28788007

  10. Lightweight Concrete Produced Using a Two-Stage Casting Process.

    PubMed

    Yoon, Jin Young; Kim, Jae Hong; Hwang, Yoon Yi; Shin, Dong Kyu

    2015-03-25

    The type of lightweight aggregate and its volume fraction in a mix determine the density of lightweight concrete. Minimizing the density obviously requires a higher volume fraction, but this usually causes aggregates segregation in a conventional mixing process. This paper proposes a two-stage casting process to produce a lightweight concrete. This process involves placing lightweight aggregates in a frame and then filling in the remaining interstitial voids with cementitious grout. The casting process results in the lowest density of lightweight concrete, which consequently has low compressive strength. The irregularly shaped aggregates compensate for the weak point in terms of strength while the round-shape aggregates provide a strength of 20 MPa. Therefore, the proposed casting process can be applied for manufacturing non-structural elements and structural composites requiring a very low density and a strength of at most 20 MPa.

  11. Application of particle method to the casting process simulation

    NASA Astrophysics Data System (ADS)

    Hirata, N.; Zulaida, Y. M.; Anzai, K.

    2012-07-01

    Casting processes involve many significant phenomena such as fluid flow, solidification, and deformation, and it is known that casting defects are strongly influenced by the phenomena. However the phenomena complexly interacts each other and it is difficult to observe them directly because the temperature of the melt and other apparatus components are quite high, and they are generally opaque; therefore, a computer simulation is expected to serve a lot of benefits to consider what happens in the processes. Recently, a particle method, which is one of fully Lagrangian methods, has attracted considerable attention. The particle methods based on Lagrangian methods involving no calculation lattice have been developed rapidly because of their applicability to multi-physics problems. In this study, we combined the fluid flow, heat transfer and solidification simulation programs, and tried to simulate various casting processes such as continuous casting, centrifugal casting and ingot making. As a result of continuous casting simulation, the powder flow could be calculated as well as the melt flow, and the subsequent shape of interface between the melt and the powder was calculated. In the centrifugal casting simulation, the mold was smoothly modeled along the shape of the real mold, and the fluid flow and the rotating mold are simulated directly. As a result, the flow of the melt dragged by the rotating mold was calculated well. The eccentric rotation and the influence of Coriolis force were also reproduced directly and naturally. For ingot making simulation, a shrinkage formation behavior was calculated and the shape of the shrinkage agreed well with the experimental result.

  12. Engineered Cooling Process for High Strength Ductile Iron Castings

    NASA Astrophysics Data System (ADS)

    Lekakh, Simon N.; Mikhailov, Anthony; Kramer, Joseph

    Professor Stefanescu contributed fundamentally to the science of solidification and microstructural evolutions in ductile irons. In this article, the possibility of development of high strength ductile iron by applying an engineered cooling process after casting early shake out from the sand mold was explored. The structures in industrial ductile iron were experimentally simulated using a computer controlled heating/cooling device. CFD modeling was used for process simulation and an experimental bench scale system was developed. The process concept was experimentally verified by producing cast plates with 25 mm wall thickness. The tensile strength was increased from 550 MPa to 1000 MPa in as-cast condition without the need for alloying and heat treatment. The possible practical applications were discussed.

  13. Process to Continuously Melt, Refine and Cast High Quality Steel

    SciTech Connect

    2005-09-01

    The purpose of this project is to conduct research and development targeted at designing a revolutionary steelmaking process. This process will deliver high quality steel from scrap to the casting mold in one continuous process and will be safer, more productive, and less capital intensive to build and operate than conventional steelmaking. The new process will produce higher quality steel faster than traditional batch processes while consuming less energy and other resources.

  14. Porosity of dental phosphate-bonded investments after setting and heating processes.

    PubMed

    Asaoka, Kenzo; Bae, Ji-Young; Lee, Hae-Hyoung

    2012-01-01

    Porosities of set and burnout compacts of phosphate-bonded investments were determined. A gas pycnometer was used to measure the volumes, and hence the densities, of fine powders and porous compacts. Porosities of set and burnout compacts were then obtained from these data for as-received powders and dry set compacts by a numerical simulation method, subsequently leading on to the estimated compositions of conventional and rapid-heating investments used in this study. Excess water content in the hardening investment compact was evaluated as a function of setting time elapsed from the start of mixing. Porosities were about 24-32% for set compacts and 43% for burnout compacts, which well agreed with the numerically computed results. It was concluded that the functional composition of investment powder needed to achieve the optimal porosity as well as process parameters such as water-powder (W/P) ratio and keeping time of mixed investment casting slurry before heat treatment could be determined using the numerical simulation method developed in this study.

  15. 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.

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

    NASA Astrophysics Data System (ADS)

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

    2008-12-01

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

  17. Relationship between microstructure and ductility of investment cast ASTM F-75 implant alloy.

    PubMed

    Gómez, M; Mancha, H; Salinas, A; Rodríguez, J L; Escobedo, J; Castro, M; Méndez, M

    1997-02-01

    Hip replacement implants fabricated using the ASTM F-75 alloy sometimes fail in a sudden catastrophic way. In general, fractures start at microstructural defects subjected to stress-corrosion under chemical attack by body fluids. In this paper the results of a study on the effect of casting parameters on the microstructure of ASTM F-75 are presented. The preheating mold temperature and the liquid temperature were varied between 900 and 1000 degrees C, and 1410 and 1470 degrees C, respectively. Optimum static strength and ductility were obtained when shrinkage microporosity and the volume fraction of M23C6 "eutectic" carbides precipitated at grain boundaries were minimized by increasing the preheating mold temperature to 1000 degrees C and by using intermediate pouring temperatures of 1455 degrees C. Under these casting conditions, however, the solidification rates are low, leading to large grain sizes, which, in turn, reduce the strength of the material under dynamic loading conditions. The volume fraction of the M23C6 "blocky" carbides appears to be independent of the casting conditions; however, their size and spatial distributions determine the strength of the as-cast alloys.

  18. Characterization of Spray Lubricants for the Die Casting Process

    SciTech Connect

    Sabau, Adrian S

    2008-01-01

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

  19. Lab experiments on the innovative rapid thick strip casting process

    NASA Astrophysics Data System (ADS)

    Nagy, Richard; Senk, Dieter

    2012-05-01

    Rapid thick strip casting (RTSC) by Anton Hulek, Inventmetall®, is an innovative concept for the production of hot strips with a final as-cast thickness of about 25 mm before rolling. The innovation of the mechanism consists in a vertical mould performing a caterpillar motion. This moving mould has an unconventional parallelogram-shaped cross-section. The conventional rectangular shape is formed in the shaping machine, which is placed straight below the mould. Further elements of the technology are state-of-the-art. For the investigation of this new casting system theoretical calculations were complemented with practical experiments. The investigation focused mainly on two key aspects: the characteristics of the mould and the shaping process. For the practical analysis a static mould with three pairs of elements in laboratory scale was developed and commissioned by the Dept. of Ferrous Metallurgy @ RWTH Aachen University. The shaping experiments were carried out in model scale with two different materials and in variable boundary conditions. The results of these experiments delivered important mechanical as well as thermal informations about the casting system.

  20. Fabrication and characterization of cast magnesium matrix composites by vacuum stir casting process

    NASA Astrophysics Data System (ADS)

    Gui, Manchang; Li, Peiyong; Han, Jianmin

    2003-04-01

    A vacuum stir casting process is developed to produce SiCp reinforced cast magnesium matrix composites. This process can eliminate the entrapment of external gas onto melt and oxidation of magnesium during stirring synthesis. Two composites with Mg-Al9Zn and Mg-Zn5Zr alloys as matrices and 15 vol.% SiC particles as reinforcement are obtained. The microstructure and mechanical properties of the composites and the unreinforced alloys in as-cast and heat treatment conditions are analyzed and evaluated. In 15 vol.% SiCp reinforced Mg-Al9Zn alloy-based composite (Mg-Al9Zn/15SiCp), SiC particles distribute homogenously in the matrix and are well bonded with magnesium. In 15 vol.% SiCp reinforced Mg-Zn5Zr alloy-based composite (Mg-Zn5Zr/15SiCp), some agglomerations of SiC particles can be seen in the microstructure. In the same stirring process conditions, SiC reinforcement is more easily wetted by magnesium in the Mg-Al9Zn melt than in the Mg-Zn5Zr melt. The significant improvement in yield strength and elastic modulus for two composites has been achieved, especially for the Mg-Al9Zn/15SiCp composite in which yield strength and elastic modulus increase 112 and 33%, respectively, over the unreinforced alloy, and increase 24 and 21%, respectively, for the Mg-Zn5Zr/15SiCp composite. The strain-hardening behaviors of the two composites and their matrix alloys were analyzed based on the microstructure characteristics of the materials.

  1. Liquid Metal Processing and Casting Experiences at the U.S. Department of Energy's Albany Research Center

    SciTech Connect

    Jablonski, Paul D.; Turner, Paul C.

    2005-09-01

    In this paper we will discuss some of the early pioneering work as well as some of our more recent research. The Albany Research Center (ARC) has been involved with the melting and processing of metals since it was established in 1942. In the early days, hardly anything was known about melting refractory or reactive metals and as such, virtually everything had to be developed in-house. Besides the more common induction heated air-melt furnaces, ARC has built and/or utilized a wide variety of furnaces including vacuum arc remelt ingot and casting furnaces, cold wall induction furnaces, electric arc furnaces, cupola furnaces and reverberatory furnaces. The melt size of these furnaces range from several grams to a ton or more. We have used these furnaces to formulate custom alloys for wrought applications as well as for such casting techniques as spin casting, investment casting and lost foam casting among many. Two early spin-off industrializations were Wah Chang (wrought zirconium alloys for military and commercial nuclear applications) and Oremet (both wrought and cast Ti). Both of these companies are now part of the ATI Allegheny Ludlum Corporation.

  2. Process modelings and simulations of heavy castings and forgings

    NASA Astrophysics Data System (ADS)

    Li, Dianzhong; Sun, Mingyue; Wang, Pei; Kang, Xiuhong; Fu, Paixian; Li, Yiyi

    2013-05-01

    The Materials Process Modeling Division, IMR, CAS has been promoting for more than 10 years research activities on modeling and experimental studies on heavy castings and forgings. In this report, we highlight some selected achievements and impacts in this area: To satisfy domestic strategic requirements, such as nuclear and hydraulic power, marine projects and high speed rail, we have developed a number of casting and forging technologies, which combine advanced computing simulations, X-ray real time observation techniques and industrial-scaled trial experiments. These technologies have been successfully applied in various industrial areas and yielded a series of scientific and technological breakthroughs and innovation. Important examples of this strategic research include the hot-processing technologies of the Three Gorge water turbine runner, marine crankshaft manufacturers, backup rolls for hot rolling mills and the production of hundreds-ton steel ingot.

  3. Improvement to the marginal coping fit of commercially pure titanium cast in phosphate-bonded investment by using a simple pattern coating technique.

    PubMed

    Pieralini, Anelise Rodolfo Ferreira; Nogueira, Fabiane; Ribeiro, Ricardo Faria; Adabo, Gelson Luis

    2012-07-01

    Coatings of zirconite, Y(2)O(3) or ZrO(2) on wax patterns before investing in phosphate-bonded investments have been recommended to reduce the reaction layer in titanium castings, but they are not easily obtainable. Spinel-based investments are relatively stable with molten titanium and could be used as coatings to improve the quality of castings made with those investments. The purpose of this study was to evaluate the effect of pattern coating with a commercial spinel-based investment before investing in 1 of 3 phosphate-bonded inves tments on the marginal coping fit and surface roughness of commercially pure titanium castings. Ten square acrylic resin patterns (12 × 12 × 2 mm) per group were invested in the phosphate-bonded investments Rematitan Plus (RP), Rema Exakt (RE), and Castorit Super C (CA) with or without a coating of the spinel-based investment, Rematitan Ultra (RU). After casting, the specimens were cleaned and the surface roughness was measured with a profilometer. Copings for dental implants with conical abutment were invested, eliminated, and cast as previously described. The copings were cleaned and misfit was measured with a profile projector (n=10). For both tests, the difference between the mean value of RU only and each value of the phosphate-bonded investment was calculated, and the data were analyzed by 2-way ANOVA and Tukey's HSD test (α=.05). In addition, the investment roughness was measured in bar specimens (30 × 10 × 10 mm), and the data (n=10) were analyzed by 1-way ANOVA and Tukey's HSD post hoc test (α=.05). Two-way ANOVA for casting surface roughness was significant because of the investment, the coating technique, and the interaction between variables. One-way ANOVA was performed to prove the interaction term, and Tukey's post hoc test showed that RP with coating had the lowest mean, while RP had the highest. CA with coating was not different from RP with coating or CA without coating. RE with coating was similar to CA, while

  4. 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.

  5. Casting defects of Ti-6Al-4V alloy in vertical centrifugal casting processes with graphite molds

    NASA Astrophysics Data System (ADS)

    Jia, Limin; Xu, Daming; Li, Min; Guo, Jingjie; Fu, Hengzhi

    2012-02-01

    Numerical simulation and experimental investigation are utilized to analyze the casting defects of Ti-6Al-4V alloy formed under different vertical centrifugal casting conditions in graphite molds. Mold rotating rates of 0, 110 and 210 rpm are considered in experimental process. Results show that centrifugal forces have significant effects on the quantity of both macropores and microdefects (micropores, microcracks and inclusions). The relative amount of all macro- and micro-scopic casting defects decreases from 62.4 % to 24.8 % with the increasing of the centrifugal force, and the macropore quantity in stepped casting decreases exponentially with the increase of the gravitation coefficient. The relative proportions of both micropores and microcracks decrease with the mold-rotating rate increase, but the relative proportion of inclusions increases significantly. Besides this, the mold-filling sequence is proved to be an important factor in casting quality control.

  6. Vacuum forming of thermoplastic sheet results in low-cost investment casting patterns

    NASA Technical Reports Server (NTRS)

    Clarke, A. E., Jr.

    1964-01-01

    Vacuum forming of a sheet of thermoplastic material around a mandrel conforming to the shape of the finished object provides a pattern for an investment mold. The thickness of the metal part is determined by the thickness of the plastic pattern.

  7. Investigation on the Interface Characteristics of Al/Mg Bimetallic Castings Processed by Lost Foam Casting

    NASA Astrophysics Data System (ADS)

    Jiang, Wenming; Li, Guangyu; Fan, Zitian; Wang, Long; Liu, Fuchu

    2016-05-01

    The lost foam casting (LFC) process was used to prepare the A356 aluminum and AZ91D magnesium bimetallic castings, and the interface characteristics of the reaction layer between aluminum and magnesium obtained by the LFC process were investigated in the present work. The results indicate that a uniform and compact interface between the aluminum and magnesium was formed. The reaction layer of the interface with an average thickness of approximately 1000 μm was mainly composed of Al3Mg2 and Al12Mg17 intermetallic compounds, including the Al3Mg2 layer adjacent to the aluminum insert, the Al12Mg17 middle layer, and the Al12Mg17 + δ eutectic layer adjacent to the magnesium base. Meanwhile, the Mg2Si intermetallic compound was also detected in the reaction layer. An oxide film mainly containing C, O, and Mg elements generated at the interface between the aluminum and magnesium, due to the decomposed residue of the foam pattern, the oxidations of magnesium and aluminum alloys as well as the reaction between the magnesium melt and the aluminum insert. The microhardness tests show that the microhardnesses at the interface were obviously higher than those of the magnesium and aluminum base metals, and the Al3Mg2 layer at the interface had a high microhardness compared with the Al12Mg17 and Al12Mg17 + δ eutectic layers, especially the eutectic layer.

  8. Dimensional Accuracy of Castings Fabricated with Ring-less and Metal Ring Investment Systems for Implant Supported Fixed Dental Prosthesis: An In-vitro Comparative Study.

    PubMed

    Shah, Rakesh; Singh, J P; Kumar, Manjit; D'Souza, Dsj

    2011-01-01

    The ring-less investment system is in use for dental casting, although there was no adequate scientific data to support its use either for conventional fixed dental prosthesis or implant retained fixed dental prosthesis. An in-vitro study was undertaken to compare the vertical marginal accuracy of single full coverage metal restorations, between ring-less and metal ring investment techniques, using two different investment materials, for implant supported fixed dental prosthesis. Three groups were made of ten samples each. Group I consisted of metal ring with PCT® FlexVest (phosphate bonded investment material). Group II consisted of metal ring with Bellasun® investment material. Group III and the final group consisted of ring-less investment system and Bellasun® investment material. The wax patterns were prepared on a metal die, cast and finished. The cast restorations (samples) were again seated on the metal die and the accuracy of fit was evaluated by measuring the gap between the finish line on the die and the margins of the sample at four specific sites using a profile projector (Helios-350H, Microtecnica, LTF, Italy) having accuracy of 1µm. Mean marginal accuracy for Group-III was found to be the least (58.87 +17.87 µm) followed by Group-II (97.23 + 16.37 µm), and Group-I (109 + 7.55 µm). However, Group I showed the least variability among the readings (SD=7.55). Ring-less system of casting can be recommended for use in fabricating implant supported fixed dental restorations.

  9. Simulation and Experiment on Direct Continuous Casting Process of Lead Frame Copper Alloy

    NASA Astrophysics Data System (ADS)

    Guojie, Huang; Shuisheng, Xie; Lei, Cheng

    2010-06-01

    Direct Continuous Casting (D.C.C) is an important method in casting lead frame copper alloy. In this paper, numerical simulation is adopted to investigate the casting process in order to optimize the D.C.C technical parameters, such as the casting temperature, casting speed and cooling intensity. According to the numerical results, the reasonable parameters are that the casting temperature is between 1413 K˜1413 K, the casting speed is between 8 m/h˜10 m/h and the speed of cooling water is between 4.2 m/s˜4.6 m/s. And the depth of liquid-solid boundary is measured in different casting temperature and casting speed by experiments. The results show the actual measurements have a little deviation with the numerical simulation. The results of numerical simulation provide the significant reference to the actual experiments.

  10. Investment casting using multi-jet modelling patterns: the thermogravimetric analysis of visijet® SR200 UV curable acrylate plastic

    NASA Astrophysics Data System (ADS)

    Hafsa, M. N.; Ibrahim, M.; Sharif, S.

    2013-12-01

    Rapid Prototyping (RP) technology is actively studied to be implemented in Investment Casting (IC) process. Nowadays RP techniques are studied for their feasibility as IC master patterns, in terms of pattern collapsibility and drainage during burnout. The purpose of the study is to determine the characteristic of Visijet® SR200 acrylate material during burnout process. Traditional IC patterns made from wax have properties that limit their application in precision casting, especially for parts with thin geometries that readily break or deform when handled or dipped in the refractory slurry. Furthermore, it is not economical when producing a small number of parts. Non wax patterns fabricated for IC process, revealed ceramic shell cracking due to excessive thermal expansions, incomplete collapsibility of pattern during burnout, residual ash and poor surface finish. Thermogravimetric analysis (TGA) was used to measured the weight loss of acrylate material as the temperature was increased. TGA measured the change of material's mass as it is heated. It represents the decomposition temperature after being subjected to varying temperatures, as well as the amount of residual ash. In this experiment, the temperature range was from 20°C to 700°C with 5°C increment. Experiment results show the values of material's optimum reaction temperature and decomposing temperature of Visijet® SR200 acrylate. The percentages of remaining materials were also monitored throughout the process to obtain the amount of residual ash. All of the temperature values obtained is a resemblance for the actual burnout process and can be used as references.

  11. Porosity of dental gypsum-bonded investments in setting and heating process.

    PubMed

    Asaoka, Kenzo; Bae, Ji-Young; Lee, Hae-Hyoung

    2012-02-03

    The porosity of gypsum-bonded investments for set and heated compacts was measured and theoretically computed quantitatively, because porosity is an effective factor for determining the strength, setting/heating expansion, and permeability of compacts at casting. A helium gas pycnometer was used to measure the solid volume of fine powders, powder-water mixtures, and porous compacts. The compositions of the conventional cristobalite investment and rapid-heating type investment were estimated from the measured solid densities of the as-received powders and the set investments. The porosity and water content of the set investments were determined from the experimental data. Excess water content in the set investment was calculated in relation to the elapsed time from the start of mixing with water. The experimental porosities of the set and heated investments were about 40% for dry set >compacts and about 50% for fired compacts, which well agreed with the numerically computed estimations, respectively.

  12. Minimization of Macrosegregation in DC Cast Ingots Through Jet Processing

    NASA Astrophysics Data System (ADS)

    Wagstaff, Samuel R.; Allanore, Antoine

    2016-10-01

    With an increase in demand for aluminum alloys, industrial suppliers are seeking to increase the size and speed of casting processes. Unfortunately operating the existing Direct-Chill (DC) process in such conditions tends to enhance metallurgical defects. Perhaps the most recognized of these defects is macrosegregation, whose effects are permanent once the material is solidified. In order to facilitate the expansion of the DC process without increasing the presence of macrosegregation, a novel jet mixing method to distribute the liquid metal is presented. The governing equations for this process are derived and the operating parameters necessary to minimize the centerline macrosegregation are predicted. The results of commercial-scale tests are presented, validating the predictive equations and performance of this process.

  13. Processing effects in spray casting of steel strip

    NASA Astrophysics Data System (ADS)

    Annavarapu, S.; Apelian, D.; Lawley, A.

    1988-12-01

    Spray cast strip of AISI 1026 and M2 has been produced by the Osprey™ process under controlled conditions of deposition. Droplet flight distance was varied over the range 325 to 475 mm and strip was spray cast onto either planar or roller substrates of copper and steel. Substrate surface speed was in the range of 0.02 to 1 m/s, which produced strip of 0.025 to 0.0007 m thickness, respectively, with a width of 0.1 m. Surface condition, microstructure, and extent of porosity in the strip were characterized as a function of distance from top and bottom surfaces. The microstructure of the strip is comprised of three regions —a ‘chill zone’ at the bottom surface consisting of fine grains of ferrite and pearlite with numerous pores; a middle region containing equiaxed or columnar grains, Widmanstätten plates, and fine pores; and a top region made up of equiaxed grains comprising Widmanstätten plates and a few pores. Process variables of primary importance with respect to microstructural integrity and surface condition of the strip are substrate velocity, the surface condition of the substrate, flight distance, and the uniformity of droplet flux in the spray cone. Flight distance determines the amount of cooling of the droplets by the atomizing gas and, therefore, the average temperature of the spray incident on the substrate. Microstructure is determined by convective cooling of the spray, and, to a lesser extent, by the substrate velocity and temperature. The processing conditions required to spray cast strip with a homogeneous microstructure and uniform thickness/surface condition have been established.

  14. Heat treatment of investment cast PH 13-8 Mo stainless steel; Part 2: Isothermal aging kinetics

    SciTech Connect

    Robino, C.V.; Cieslak, M.J. . Physical and Joining Metallurgy Dept.); Hochanadel, P.W.; Edwards, G.R. . Dept. of Metallurgical and Materials Engineering)

    1994-04-01

    The hardening response of investment cast PH 13-8 Mo stainless steel has been evaluated by hardness measurements following aging in the temperature range normally specified for this alloy (510 C to 593 C). A new relationship between fraction transformed and hardness was developed, and analysis of the data in terms of the kinetics of precipitation, in a manner similar to that frequently applied to other precipitation-hardenable martensitic steels, yielded low time exponents and a low value for the apparent activation energy. The values of the time exponents were 0.49, 0.37, 0.56, and 0.53 at 510 C, 538 C, 566 C, and 593 C, respectively, and that for the apparent activation energy was 139 kJ/mole. As has been proposed for other maraging type steels, these estimates suggest that [beta]-NiAl precipitates along or near dislocations and that growth of the precipitates is dominated by dislocation pipe diffusion. However, these predictions were neither supported nor refuted by transmission electron microscopy (TEM) because of difficulties in imaging the [beta]-NiAl precipitates at the aging times and temperatures used. Further, analysis of the data using the formalism of Wert and Zener for the growth of precipitates with interfering diffusion fields indicated that the estimates of fraction transformed from hardness data are not fully appropriate for maraging type steels. Consideration of the nature of the Avrami analysis and the electron microscopy results suggests that other phenomena, including dislocation recovery and reversion of martensite to austenite, occur at rates sufficient to convolute the Avrami analysis. It is further suggested that these results cast doubt on the fundamental implications of previous analyses of precipitation kinetics in age-hardening martensitic steels.

  15. Effect of Solidification Behavior on Microstructures and Mechanical Properties of Ni-Cr-Fe Superalloy Investment Casting.

    PubMed

    Kang, Maodong; Wang, Jun; Gao, Haiyan; Han, Yanfeng; Wang, Guoxiang; He, Shuxian

    2017-03-01

    The effect of solidification behavior on the microstructures and mechanical properties of Ni-Cr-Fe superalloy investment casting is given. Metallographic and image analysis have been used to quantitatively examine the microstructures' evolution. For the parts with the thickness of 3 mm and 24 mm, the volume fraction and maximum equivalent radius of the Laves phase increases from 0.3% to 1.2%, from 11.7 μm to 23.4 μm, respectively. Meanwhile, the volume fraction and maximum equivalent radius of carbides increase from 0.3% to 0.5%, from 8.1 μm to 9.9 μm, respectively. In addition, the volume fraction of microporosity increases from 0.3% to 2.7%. As a result, the ultimate tensile strength is reduced from 1125.5 MPa to 820.9 MPa, the elongation from 13.3% to 7.7%, and the quality index from 1294.2 MPa to 954.0 MPa, respectively. A typical brittle fracture is observed on the tensile fracture. As the cooling rate decreases, the microstructures become coarser.

  16. Heat treatment of investment cast PH 13-8 Mo stainless steel: Part I. Mechanical properties and microstructure

    NASA Astrophysics Data System (ADS)

    Hochanadel, P. W.; Edwards, G. R.; Robino, C. V.; Cieslak, M. J.

    1994-04-01

    The microstructure of investment cast PH 13-8 Mo stainless steel heat-treated to various conditions was studied using light and electron microscopy, electron probe microanalysis, and Mössbauer spectroscopy. The mechanical properties were investigated by using uniaxial tensile testing, hardness testing, and Charpy impact testing. The Β-NiAl strengthening precipitates, though detectable by electron diffraction, were difficult to resolve by transmission electron microscopy (TEM) in specimens aged at low temperatures (566 °C and below). A high dislocation density was observed in the lath martensitic structure. The higher strength and lower ductility observed at low aging temperatures was attributed to both the high dislocation density and the precipitation of Β-NiAl. When samples were aged at high temperatures (> 566 °C), a lower dislocation density and a reverted austenite fraction on the order of 15 pct were observed. Spherical Β-NiAl precipitates were observed in the overaged condition. The decrease in strength and corresponding increase in ductility observed in samples aged at temperatures above 566 °C were attributed to the reverted austenite and recovery. Mechanical properties were improved when the homogenizing temperature and time were increased. Electron probe microanalysis quantified the increased homogeneity realized by increasing homogenizing temperature and time. Elimination of the refrigeration step, which normally follows the solution treatment, did not degrade the mechanical properties. Mössbauer spectroscopy showed only minor decreases in the fraction of retained austenite when refrigeration followed the solution treatment.

  17. Effect of Solidification Behavior on Microstructures and Mechanical Properties of Ni-Cr-Fe Superalloy Investment Casting

    PubMed Central

    Kang, Maodong; Wang, Jun; Gao, Haiyan; Han, Yanfeng; Wang, Guoxiang; He, Shuxian

    2017-01-01

    The effect of solidification behavior on the microstructures and mechanical properties of Ni-Cr-Fe superalloy investment casting is given. Metallographic and image analysis have been used to quantitatively examine the microstructures’ evolution. For the parts with the thickness of 3 mm and 24 mm, the volume fraction and maximum equivalent radius of the Laves phase increases from 0.3% to 1.2%, from 11.7 μm to 23.4 μm, respectively. Meanwhile, the volume fraction and maximum equivalent radius of carbides increase from 0.3% to 0.5%, from 8.1 μm to 9.9 μm, respectively. In addition, the volume fraction of microporosity increases from 0.3% to 2.7%. As a result, the ultimate tensile strength is reduced from 1125.5 MPa to 820.9 MPa, the elongation from 13.3% to 7.7%, and the quality index from 1294.2 MPa to 954.0 MPa, respectively. A typical brittle fracture is observed on the tensile fracture. As the cooling rate decreases, the microstructures become coarser. PMID:28772611

  18. Influence of Refiner in ZA-12 Alloys During Centrifugal Casting Process

    NASA Astrophysics Data System (ADS)

    Jyothi, P. N.; Shailesh, Rao A.; Jagath, M. C.; Channakeshavalu, K.

    2014-05-01

    The behavior of the molten melt plays a predominant role in determining the quality cast product. In continuous casting, addition of refiner 1% (Al+Ti+B2) onto the molten metal increases its mechanical properties as a result of the nucleation within the process. In this article, the effect of refiners in the centrifugal casting process was studied. Eutectic ZA-12 alloys were taken for our experiment and cast at various rotational speeds (400 rpm, 600 rpm, and 800 rpm) with and without the addition of refiners. Rather than increase in the solidification rate as in continuous casting, these refiners diminish the solidification rate, which in turn forms an irregular-shaped cast tube. The microstructure and hardness for the entire cast specimen were discussed finally.

  19. The effect of mold temperature on castability of CP Ti and Ti-6Al-4V castings into phosphate bonded investment materials.

    PubMed

    Oliveira, Pedro César Garcia; Adabo, Gelson Luis; Ribeiro, Ricardo Faria; Rocha, Sicknan Soares

    2006-12-01

    The aim of this study was to evaluate the castability of CP titanium and Ti-6Al-4V alloy castings into Rematitan Plus investment at three different mold temperatures. A nylon mesh pattern (20 mm with 64 squares and wire of 0.7 mm in diameter) was used for the castability testing. Initially, an image of the wax pattern was obtained by means of a digital camera and the total extension of filaments (mm) was then measured, using the Leica Qwin image analysis system. The mesh sprued was placed in the Rematitan Plus investment material and the castings were made in a Discovery Plasma machine at three different mold temperatures: 430 degrees C (control group), 480 degrees C or 530 degrees C. Ten castings were made for each temperature. The images of the castings were analyzed (Leica Qwin) and the castability index determined by the number of the completely cast segments as a percentage of the wax pattern. Data were analyzed by two-way ANOVA and Tukey's multiple comparison test (a = 0.05) using materials and temperatures as discriminating variables. The Ti-6Al-4V alloy (60.86%) presented a better castability index than CP Ti (48.44%) (p < 0.000001). For CP Ti, the temperature of 530 degrees C (23.96%) presented better castability than at other temperatures, 480 degrees C (14.66%) and 430 degrees C (12.54%), with no difference between them (p < 0.001). For Ti-6Al-4V alloy, there was a statistically significant difference among the three temperatures: 530 degrees C (28.36%) > 480 degrees C (19.66%) > 430 degrees C (15.97%) (p < 0.002). Within the limitations of this study, the increase in the mold temperature of the Rematitan Plus investment resulted in a better castability index for both materials, and Ti-6Al-4V presented a better castability index than CP Ti.

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

    NASA Astrophysics Data System (ADS)

    Tomita, Yoshihiro; Sumimoto, Haruyoshi

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

  1. Engineering scale demonstration of a prospective Cast Stone process

    SciTech Connect

    Cozzi, A.; Fowley, M.; Hansen, E.; Fox, K.; Miller, D.; Williams, M.

    2014-09-30

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

  2. Thermal casting process for the preparation of membranes

    DOEpatents

    Caneba, G.T.M.; Soong, D.S.

    1985-07-10

    Disclosed is a method for providing anisotropic polymer membrane from a binary polymer/solvent solution using a thermal inversion process. A homogeneous binary solution is cast onto a support and cooled in such a way as to provide a differential in cooling rate across the thickness of the resulting membrane sheet. Isotropic or anisotropic structures of selected porosities can be produced, depending on the initial concentration of polymer in the selected solvent and on the extent of the differential in cooling rate. This differential results in a corresponding gradation in pore size. The method may be modified to provide a working skin by applying a rapid, high-temperature pulse to redissolve a predetermined thickness of the membrane at one of its faces and then freezing the entire structure.

  3. Fast Docking on Graphics Processing Units via Ray-Casting

    PubMed Central

    Khar, Karen R.; Goldschmidt, Lukasz; Karanicolas, John

    2013-01-01

    Docking Approach using Ray Casting (DARC) is structure-based computational method for carrying out virtual screening by docking small-molecules into protein surface pockets. In a complementary study we find that DARC can be used to identify known inhibitors from large sets of decoy compounds, and can identify new compounds that are active in biochemical assays. Here, we describe our adaptation of DARC for use on Graphics Processing Units (GPUs), leading to a speedup of approximately 27-fold in typical-use cases over the corresponding calculations carried out using a CPU alone. This dramatic speedup of DARC will enable screening larger compound libraries, screening with more conformations of each compound, and including multiple receptor conformations when screening. We anticipate that all three of these enhanced approaches, which now become tractable, will lead to improved screening results. PMID:23976948

  4. The Effect of Thermomechanical Processing on Mechanical Properties of a Cast 6061 Aluminum Metal Matrix Composite

    DTIC Science & Technology

    1993-12-01

    Conference Proceedings, 1990 19. Lewandowski, J. J. et al., "Effects of Casting Conditions and Deformation Processing on A356 Aluminum and A356 -20 Vol...CAST 6061 ALUMINUM METAL MATRIX COMPOSITE by Werner Fletcher Hoyt December 1993 Thesis Advisor: Terry R. McNelley Approved for public release...Security Classification) THE EFFECT OF THERMOMECHANICAL PROCESSING ON MECHANICAL PROPERTIES OF A CAST 6061 ALUMINUM METAL MATRIX COMPOSITE 12. PERSONAL

  5. Heat treatment of investment cast PH 13-8 Mo stainless steel: Part II. Isothermal aging kinetics

    NASA Astrophysics Data System (ADS)

    Robino, C. V.; Cieslak, M. J.; Hochanadel, P. W.; Edwards, G. R.

    1994-04-01

    The hardening response of investment cast PH 13-8 Mo stainless steel has been evaluated by hardness measurements following aging in the temperature range normally specified for this alloy (510 °C to 593 °C). A new relationship between fraction transformed and hardness was developed, and analysis of the data in terms of the kinetics of precipitation, in a manner similar to that frequently applied to other precipitation-hardenable martensitic steels, yielded low time exponents and a low value for the apparent activation energy. The values of the time exponents were 0.49, 0.37, 0.56, and 0.53 at 510 °C, 538 °C, 566 °C, and 593 °C, respectively, and that for the apparent activation energy was 139 kJ/mole. As has been proposed for other maraging type steels, these estimates suggest that Β-NiAl precipitates along or near dislocations and that growth of the precipitates is dominated by dislocation pipe diffusion. However, these predictions were neither supported nor refuted by transmission electron microscopy (TEM) because of difficulties in imaging the Β-NiAl precipitates at the aging times and temperatures used. Further, analysis of the data using the formalism of Wert and Zener for the growth of precipitates with interfering diffusion fields indicated that the estimates of fraction transformed from hardness data are not fully appropriate for maraging type steels. Consideration of the nature of the Avrami analysis and the electron microscopy results suggests that other phenomena, including dislocation recovery and reversion of martensite to austenite, occur at rates sufficient to convolute the Avrami analysis. It is further suggested that these results cast doubt on the fundamental implications of previous analyses of precipitation kinetics in age-hardening martensitic steels. Although the Avrami analysis was found not to provide a tenable description of the precipitation kinetics, it does provide a reasonable methodology for portrayal of the hardening response

  6. Investigation of the beryllia ceramics molding process by the hot casting method

    NASA Astrophysics Data System (ADS)

    Zhapbasbaev, U. K.; Ramazanova, G. I.; Sattinova, Z. K.

    2013-03-01

    Results of mathematical simulation of the ceramics molding process by the hot casting method are presented. The mathematical model describes the motion of beryllia liquid thermoplastic slurry in a form-building cavity subject to solidification. Velocity and temperature profiles providing homogeneous properties of the beryllia ceramics in the process of molding by the hot casting method are obtained.

  7. Numerical simulation on austenitization of cast steel during heating process

    NASA Astrophysics Data System (ADS)

    Su, B.; Han, Z. Q.; Liu, B. C.; Zhao, Y. R.; Shen, B. Z.; Zhang, L. Z.

    2012-07-01

    A cellular automaton model has been developed to simulate the austenitization process of ASTM A216 WCA cast steel during heating process. The dissolution of pearlite and the transformation of ferrite into austenite were simulated. The calculation domain was divided into square cells, which are characterized by certain attributes that represent the status of each cell: pearlite (P), ferrite (α), austenite (γ) or γ /α interface. The dissolution of pearlite was described by nucleation and growth of austenite. A mixed-mode model in multicomponent system was employed to calculate the growth velocity of the γ /α interface. According to Burke and Turnbull's theory, austenite grain coarsening induced by γ /γ grain boundary migration was simulated. To validate the model, dilatometric and quenching experiments were carried out. The dilatometric experiment was conducted using a Gleeble1500D with a sample 8 mm in diameter. The temperature of the sample was measured using thermocouples welded on the sample surface. In the quenching experiments, steel samples were heated to different temperatures then dropped into a water tank immediately, and the microstructure of the samples was examined to determine the fraction of the austenite. The simulated results were compared with the experimental results and the capability of the model for quantitatively predicting the microstructure evolution of the steel in heating process was assessed.

  8. Software Analytical Instrument for Assessment of the Process of Casting Slabs

    NASA Astrophysics Data System (ADS)

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

    2010-06-01

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

  9. Report of Separate Effects Testing for Modeling of Metallic Fuel Casting Process

    SciTech Connect

    Crapps, Justin M.; Galloway, Jack D.; Decroix, David S.; Korzekwa, David A.; Aikin, Robert M. Jr.; Unal, Cetin; Fielding, R.; Kennedy, R

    2012-06-29

    In order to give guidance regarding the best investment of time and effort in experimental determination of parameters defining the casting process, a Flow-3D model of the casting process was used to investigate the most influential parameters regarding void fraction of the solidified rods and solidification speed for fluid flow parameters, liquid heat transfer parameters, and solid heat transfer parameters. Table 1 summarizes the most significant variables for each of the situations studied. A primary, secondary, and tertiary effect is provided for fluid flow parameters (impacts void fraction) and liquid heat transfer parameters (impacts solidification). In Table 1, the wetting angle represents the angle between the liquid and mold surface as pictured in Figure 1. The viscosity is the dynamic viscosity of the liquid and the surface tension is the property of the surface of a liquid that allows it to resist an external force. When only considering solid heat transfer properties, the variations from case to case were very small. Details on this conclusion are provided in the section considering solid heat transfer properties. The primary recommendation of the study is to measure the fluid flow parameters, specifically the wetting angle, surface tension, and dynamic viscosity, in order of importance, as well as the heat transfer parameters latent heat and specific heat of the liquid alloy. The wetting angle and surface tension can be measured simultaneously using the sessile drop method. It is unclear whether there is a temperature dependency in these properties. Thus measurements for all three parameters are requested at 1340, 1420, and 1500 degrees Celsius, which correspond to the minimum, middle, and maximum temperatures of the liquid alloy during the process. In addition, the heat transfer coefficient between the mold and liquid metal, the latent heat of transformation, and the specific heat of the liquid metal all have strong influences on solidification. These

  10. Analytical and numerical study of the pressure die casting processes

    NASA Astrophysics Data System (ADS)

    Lopez Rodriguez, Joaquin

    In pressure die casting, the most common defect in manufactured parts is porosity, one of the major causes of which is air entrapment in the molten metal during the injection process. Among other factors, the correct design of the gating and venting systems and an appropriate selection of the operating conditions during the injection phase can contribute to minimizing casting porosity. In the present work, a systematic study of the operating conditions and the characteristics of the injection and venting systems (plunger motion law, initial filling fraction, shot sleeve dimensions, dimension and location of the vents, atmospheric and vacuum venting conditions, etc.) that reduce air entrapment while keeping the injection filling time as low as possible is carried out. Limiting values of the initial filling fraction required for appropriate operating conditions are also determined for wide ranges of acceleration parameters and pouring hole locations. The flow of molten metal inside the injection chamber is analyzed using a two-dimensional finite-element model and a simpler model based on the shallow-water approximation. Two commonly used types of plunger movements are considered, for which results for wave profiles, the volume (area) of entrapped air in the injection chamber, and optimum values of the parameters characterizing the law of plunger motion are presented. A new law of plunger acceleration which would completely eliminate the air from the shot sleeve at the end of the slow phase of injection and minimizes the filling time is derived. The flow through venting systems is analyzed using an unsteady model for both atmospheric and vacuum venting conditions. The model is solved numerically using the method of characteristics. The numerical results of the model agree very well with the results of previous quasi-steady models for conditions for which unsteady effects are negligible, as could be expected. The results presented in this work show that, for broad

  11. Ecological stabilization of thickened wastewater sludge from CAST process.

    PubMed

    Cui, Y B; Wu, X H; Liu, Zh Sh; Liu, J Zh; Lin, Y Z

    2008-01-01

    Wastewater sludge ecological stabilization (WWSES) pilot scale experiments were conducted for thickening treatment and disposal of sludge which came from Cyclic Activated Sludge Technology (CAST) process. The study was performed over the periods from June to November 2005 and from May to November 2006, on a bed of 80 m2. The sludge loadings were stopped for the winter from December 2005 and resumed in May 2006. The results shows that dried sludge layer has higher permeation coefficients of 0.15-1.3 m/h. It is suggested that the percolate did not filtrate downwards evenly, part of percolate filtrates downwards along stems, roots and cracks existing in dried sludge which have lower flow resistance. The relationship of dried sludge thickness and operation time is in accord with quadratic equation under fluctuating sludge loadings. Linear regression equation can indicate dried sludge thickness variation under fixed sludge loading. In comparison with natural ones, coarse protein content of Phragmites australis roots in the system is twice as high, coarse fiber content of roots, coarse fat content of stems and leaf are obviously higher; and coarse protein content of Typha augustifolia in the system are obviously higher, while coarse fat and coarse fiber contents have no significant difference.

  12. Numerical simulation of the solidification processes of copper during vacuum continuous casting

    NASA Astrophysics Data System (ADS)

    Tsai, D. C.; Hwang, W. S.

    2012-03-01

    A numerical simulation method is used to analyze the microstructure evolution of 8-mm-diameter copper rods during the vacuum continuous casting (VCC) process. The macro-microscopic coupling method is adopted to develop a temperature field model and a microstructure prediction model. The effects of casting parameters, including casting speed, pouring temperature, cooling rate, and casting dimension on the location and shape of the solid-liquid (S/L) interface and solidified microstructure are considered. Simulation results show that the casting speed has a large effect on the position and shape of the S/L interface and grain morphology. With an increase of casting speed, the shape of the S/L interface changes from a planar shape into an elliptical shape or a narrow, pear shape, and the grain morphology indicates a change from axial growth to axial-radial growth or completely radial growth. The simulation predictions agree well with the microstructure observations of cast specimens. Further analysis of the effects of other casting parameters on the position and shape of the S/L interface reveals that the casting dimension has more influence on the position and shape of the S/L interface and grain morphology than do pouring temperature and cooling rate. The simulation results can be summarized to obtain a discriminant of shape factor (η), which defines the shape of the S/L interface and grain morphology.

  13. Numerical simulation of casting process to assist in defects reduction in complex steel tidal power component

    NASA Astrophysics Data System (ADS)

    Guo, E. J.; Zhao, S. C.; Wang, L. P.; Wu, T.; Xin, B. P.; Tan, J. J.; Jia, H. L.

    2016-03-01

    In order to reduce defects and improve casting quality, ProCAST software is performed to study the solidification process of discharge bowl. Simulated results of original casting process show that the hot tearing is serious at the intersection of blades and outer or inner rings. The shrinkage porosity appears at the bottom of discharge bowl and the transition area of wall thickness. Based on the formation mechanisms of the defects, the structure of chills attached on the outer surface of discharge bowl casting is optimized. The thickness of chills ranges from 25mm to 35mm. The positions of chills corresponded to the outer surface of the T-shaped parts. Compared to the original casting design (without chills), the hot tearing and shrinkage porosity of the discharge bowl are greatly improved with addition of chills.

  14. Development of a low cost permanent mold casting process for TiAl automotive valves

    SciTech Connect

    Jones, P.E.; Porter, W.J. III; Eylon, D.; Colvin, G.

    1995-12-31

    This paper reviews progress made in the development of a low cost permanent mold casting process for TiAl automotive valves. The issues studied include mold life, mold/metal reaction, shrinkage void control, dimensional control, and post casting processes. More than 800 Ti-47Al-2Nb-1.75 Cr (at%) valves were produced by gravity, centrifugal, and pressure assisted casting methods on a laboratory scale. Microstructures, tensile, creep, and fatigue properties of as-HIP and as-heat treated valves are described. Process scale up challenges identified in this work are also discussed.

  15. Multiphysics modeling of the steel continuous casting process

    NASA Astrophysics Data System (ADS)

    Hibbeler, Lance C.

    This work develops a macroscale, multiphysics model of the continuous casting of steel. The complete model accounts for the turbulent flow and nonuniform distribution of superheat in the molten steel, the elastic-viscoplastic thermal shrinkage of the solidifying shell, the heat transfer through the shell-mold interface with variable gap size, and the thermal distortion of the mold. These models are coupled together with carefully constructed boundary conditions with the aid of reduced-order models into a single tool to investigate behavior in the mold region, for practical applications such as predicting ideal tapers for a beam-blank mold. The thermal and mechanical behaviors of the mold are explored as part of the overall modeling effort, for funnel molds and for beam-blank molds. These models include high geometric detail and reveal temperature variations on the mold-shell interface that may be responsible for cracks in the shell. Specifically, the funnel mold has a column of mold bolts in the middle of the inside-curve region of the funnel that disturbs the uniformity of the hot face temperatures, which combined with the bending effect of the mold on the shell, can lead to longitudinal facial cracks. The shoulder region of the beam-blank mold shows a local hot spot that can be reduced with additional cooling in this region. The distorted shape of the funnel mold narrow face is validated with recent inclinometer measurements from an operating caster. The calculated hot face temperatures and distorted shapes of the mold are transferred into the multiphysics model of the solidifying shell. The boundary conditions for the first iteration of the multiphysics model come from reduced-order models of the process; one such model is derived in this work for mold heat transfer. The reduced-order model relies on the physics of the solution to the one-dimensional heat-conduction equation to maintain the relationships between inputs and outputs of the model. The geometric

  16. Manufacturing Methods for Process Effects on Aluminum Casting Allowables

    DTIC Science & Technology

    1985-03-01

    YS 5% elongation Hardness per ASTM E18 Minimum of HRB 70 Electrical conductivity Minimum of 31% TACS per MIL-STD-1537 In addition, each foundry was...Min ( ASTM E18 ) A357-T6: 90HRB Min A Solidification A357-T6 A357-T6 Rate - DAS Control DAS Evaluation Max DAS (A357 Only) Per Proposed Det. by...defined in ASTM B557. 3.8.2 Hardness of Castings: Castings, should have hardness of ERE 90 minimum determined in accordance with ASTM E18 , but

  17. Advances in multi-scale modeling of solidification and casting processes

    NASA Astrophysics Data System (ADS)

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

    2011-04-01

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

  18. PREFACE: MCWASP XIV: International Conference on Modelling of Casting, Welding and Advanced Solidification Processes

    NASA Astrophysics Data System (ADS)

    Yasuda, H.

    2015-06-01

    The current volume represents contributed papers of the proceedings of the 14th international conference on ''Modeling of Casting, Welding and Advanced Solidification Processes (MCWASP XIV)'', Yumebutai International Conference Center, Awaji island, Hyogo, Japan on 21 - 26 June, 2016. The first conference of the series 'Modeling of Casting, Welding and Advanced Solidification Processes (MCWASP)' was started up in 1980, and this is the 14th conference. The participants are more than 100 scientists from industry and academia, coming from 19 countries. In the conference, we have 5 invited, 70 oral and 31 poster presentations on different aspects of the modeling. The conference deals with various casting processes (Ingot / shape casting, continuous casting, direct chill casting and welding), fundamental phenomena (nucleation and growth, dendritic growth, eutectic growth, micro-, meso- and macrostructure formation and defect formation), coupling problems (electromagnetic interactions, application of ultrasonic wave), development of experimental / computational methods and so on. This volume presents the cutting-edge research in the modeling of casting, welding and solidification processes. I would like to thank MAGMA Giessereitechnologie GmbH, Germany and SCSK Corporation, Japan for supporting the publication of contributed papers. Hideyuki Yasuda Conference Chairman Department of Materials Science and Engineering, Kyoto University Japan

  19. Numerical simulation of the casting process of titanium tooth crowns and bridges.

    PubMed

    Wu, M; Augthun, M; Wagner, I; Sahm, P R; Spiekermann, H

    2001-06-01

    The objectives of this paper were to simulate the casting process of titanium tooth crowns and bridges; to predict and control porosity defect. A casting simulation software, MAGMASOFT, was used. The geometry of the crowns with fine details of the occlusal surface were digitized by means of laser measuring technique, then converted and read in the simulation software. Both mold filling and solidification were simulated, the shrinkage porosity was predicted by a "feeding criterion", and the gas pore sensitivity was studied based on the mold filling and solidification simulations. Two types of dental prostheses (a single-crown casting and a three-unit-bridge) with various sprue designs were numerically "poured", and only one optimal design for each prosthesis was recommended for real casting trial. With the numerically optimized design, real titanium dental prostheses (five replicas for each) were made on a centrifugal casting machine. All the castings endured radiographic examination, and no porosity was detected in the cast prostheses. It indicates that the numerical simulation is an efficient tool for dental casting design and porosity control.

  20. The microstructures of strip-cast low-carbon steels and their response to thermal processing

    NASA Astrophysics Data System (ADS)

    Shiang, L.-T.; Wray, P. J.

    1989-07-01

    The as-cast microstructure and its modification when subjected to heat treatment is examined for strip-cast low carbon steels. The local solidification rate in the twin-roll strip casting process is estimated to. be 590 to 850 °C/s, and the primary and secondary dendrite arm spacings are approximately 17 to 25 and 10 μm, respectively. The as-cast structure is predominantly Widmanstätten ferrite and, thereby, differs from the conventional hot-rolled sheet. It is suggested that the as-cast morphology is a result of the large initial austenite grain size and the cooling rate and is not a unique characteristic of rapid solidification of strip casting. By restricting the austenite grain size and cooling rate, polygonal ferrite morphology probably can be produced during strip casting. The response to heat treatment depends on the presence of aluminum; with a moderate amount of aluminum, the A1N precipitates in the as-cast structure inhibit the subsequent grain boundary movement and may affect the subsequent recrystallization behavior.

  1. Computational modeling of structure of metal matrix composite in centrifugal casting process

    SciTech Connect

    Zagorski, Roman

    2007-04-07

    The structure of alumina matrix composite reinforced with crystalline particles obtained during centrifugal casting process are studied. Several parameters of cast process like pouring temperature, temperature, rotating speed and size of casting mould which influent on structure of composite are examined. Segregation of crystalline particles depended on other factors such as: the gradient of density of the liquid matrix and reinforcement, thermal processes connected with solidifying of the cast, processes leading to changes in physical and structural properties of liquid composite are also investigated. All simulation are carried out by CFD program Fluent. Numerical simulations are performed using the FLUENT two-phase free surface (air and matrix) unsteady flow model (volume of fluid model - VOF) and discrete phase model (DPM)

  2. Evaluation of Interfacial Interactions Between Ti-6Al-4V and Mold Use Ti-Added Backup Coat in Investment Casting

    NASA Astrophysics Data System (ADS)

    Cheng, Xu; Chai, Lianjing; Wu, Guoqing; Wang, Hong; Nan, Hai

    2016-05-01

    In this article, the chemical inertness of shell using Ti-added mullite backup coat against molten Ti-6Al-4V (Ti64) alloy was investigated. The metal/shell interfacial microstructures and compositions were characterized using an optical microscope, scanning electron microscope, roughness tester, and X-ray diffractometer; the hardened layer thickness was evaluated using a microhardness tester. By adding titanium powder into the mullite backup coat, the alpha case and hardened layer thickness of the Ti64 castings were largely reduced with good surface finishing. Silicon ions, from the backup coat, penetrated into the alloy and coarsened the β lath at the metal/shell interfacial area. The Ti powder in the mullite backup coat oxidized and interacted with silica during mold firing and casting, which reduced the silicon and oxygen concentrations at the metal/shell interfacial area. The oxygen penetration depth is thicker than the alpha case layer thickness, and around 0.26 wt pct, oxygen can obviously coarsen the alpha lath at the metal/shell interfacial area during investment casting.

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

    NASA Technical Reports Server (NTRS)

    Frankhouser, W. L.

    1980-01-01

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

  4. 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.

  5. A Thermal Simulation Method for Solidification Process of Steel Slab in Continuous Casting

    NASA Astrophysics Data System (ADS)

    Zhong, Honggang; Chen, Xiangru; Han, Qingyou; Han, Ke; Zhai, Qijie

    2016-10-01

    Eighty years after the invention of continuous cast of steels, reproducibility from few mm3 samples in the laboratory to m3 product in plants is still a challenge. We have engineered a thermal simulation method to simulate the continuous casting process. The temperature gradient ( G L ) and dendritic growth rate ( v) of the slab were reproduced by controlling temperature and cooling intensity at hot and chill end, respectively, in our simulation samples. To verify that our samples can simulate the cast slab in continuous casting process, the heat transfer, solidification structure, and macrosegregation of the simulating sample were compared to those of a much larger continuous casting slab. The morphology of solid/liquid interface, solidified shell thickness, and dendritic growth rate were also investigated by in situ quenching the solidifying sample. Shell thickness ( δ) determined by our quenching experiment was related to solidification time ( τ) by equation: δ = 4.27 × τ 0.38. The results indicated that our method closely simulated the solidification process of continuous casting.

  6. A Statistics-Based Cracking Criterion of Resin-Bonded Silica Sand for Casting Process Simulation

    NASA Astrophysics Data System (ADS)

    Wang, Huimin; Lu, Yan; Ripplinger, Keith; Detwiler, Duane; Luo, Alan A.

    2017-02-01

    Cracking of sand molds/cores can result in many casting defects such as veining. A robust cracking criterion is needed in casting process simulation for predicting/controlling such defects. A cracking probability map, relating to fracture stress and effective volume, was proposed for resin-bonded silica sand based on Weibull statistics. Three-point bending test results of sand samples were used to generate the cracking map and set up a safety line for cracking criterion. Tensile test results confirmed the accuracy of the safety line for cracking prediction. A laboratory casting experiment was designed and carried out to predict cracking of a cup mold during aluminum casting. The stress-strain behavior and the effective volume of the cup molds were calculated using a finite element analysis code ProCAST®. Furthermore, an energy dispersive spectroscopy fractographic examination of the sand samples confirmed the binder cracking in resin-bonded silica sand.

  7. Coordinated microgrid investment and planning process considering the system operator

    DOE PAGES

    Armendáriz, M.; Heleno, M.; Cardoso, G.; ...

    2017-05-12

    Nowadays, a significant number of distribution systems are facing problems to accommodate more photovoltaic (PV) capacity, namely due to the overvoltages during the daylight periods. This has an impact on the private investments in distributed energy resources (DER), since it occurs exactly when the PV prices are becoming attractive, and the opportunity to an energy transition based on solar technologies is being wasted. In particular, this limitation of the networks is a barrier for larger consumers, such as commercial and public buildings, aiming at investing in PV capacity and start operating as microgrids connected to the MV network. To addressmore » this challenge, this paper presents a coordinated approach to the microgrid investment and planning problem, where the system operator and the microgrid owner collaborate to improve the voltage control capabilities of the distribution network, increasing the PV potential. The results prove that this collaboration has the benefit of increasing the value of the microgrid investments while improving the quality of service of the system and it should be considered in the future regulatory framework.« less

  8. Influence of the casting processing route on the corrosion behavior of dental alloys.

    PubMed

    Galo, Rodrigo; Rocha, Luis Augusto; Faria, Adriana Claudia; Silveira, Renata Rodrigues; Ribeiro, Ricardo Faria; de Mattos, Maria da Gloria Chiarello

    2014-12-01

    Casting in the presence of oxygen may result in an improvement of the corrosion performance of most alloys. However, the effect of corrosion on the casting without oxygen for dental materials remains unknown. The aim of this study was to investigate the influence of the casting technique and atmosphere (argon or oxygen) on the corrosion behavior response of six different dental casting alloys. The corrosion behavior was evaluated by electrochemical measurements performed in artificial saliva for the different alloys cast in two different conditions: arc melting in argon and oxygen-gas flame centrifugal casting. A slight decrease in open-circuit potential for most alloys was observed during immersion, meaning that the corrosion tendency of the materials increases due to the contact with the solution. Exceptions were the Co-based alloys prepared by plasma, and the Co-Cr-Mo and Ni-Cr-4Ti alloys processed by oxidized flame, in which an increase in potential was observed. The amount of metallic ions released into the artificial saliva solution during immersion was similar for all specimens. Considering the pitting potential, a parameter of high importance when considering the fluctuating conditions of the oral environment, Co-based alloys show the best performance in comparison with the Ni-based alloys, independent of the processing route.

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

    NASA Astrophysics Data System (ADS)

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

    2013-09-01

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

  10. The Influence of ZrO2 Concentration in an Yttria-Based Face Coat for Investment Casting a Ti-45Al-2Mn-2Nb-0.2TiB Alloy Using a Sessile Drop Method

    NASA Astrophysics Data System (ADS)

    Cheng, Xu; Yuan, Chen; Blackburn, Stuart; Withey, Paul A.

    2015-03-01

    Investment casting is widely used to cast near-net shape components, reducing material waste and process cost. Due to the high reactivity of titanium and its alloys, in order to reduce the interaction between the mold and molten titanium, very costly materials are used in the mold face coat. In order to reduce the material cost while maintaining the chemical inertness of the face coat, ZrO2 was added into an yttria-based face coat in different concentrations in this study. The face coat properties of the different systems were analyzed using dilatometry and XRD. The chemical inertness of the different face coat systems were tested using a sessile drop test using a Ti-45Al-2Mn-2Nb-0.2TiB alloy, and the interactions between the face coat and the alloy were analyzed by the interfacial microstructures, contact angle, and hardness changes. The results showed that small amounts of ZrO2 can be added into yttria without changing the chemical inertness of the face coat. High amounts of ZrO2 in the face coat can interact with TiAl alloy to form different interaction products. Meanwhile, both Y2O3 and ZrO2 filler materials were observed to dissolve in molten TiAl during the sessile drop test.

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

    NASA Astrophysics Data System (ADS)

    Jiang, Chengcan; Rui, Yannian

    2017-03-01

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

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

    NASA Astrophysics Data System (ADS)

    Jiang, Chengcan; Rui, Yannian

    2017-03-01

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

  13. 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.

  14. HANFORD CONTAINERIZED CAST STONE FACILITY TASK 1 PROCESS TESTING & DEVELOPMENT FINAL TEST REPORT

    SciTech Connect

    LOCKREM, L L

    2005-07-13

    Laboratory testing and technical evaluation activities on Containerized Cast Stone (CCS) were conducted under the Scope of Work (SOW) contained in CH2M HILL Hanford Group, Inc. (CHG) Contract No. 18548 (CHG 2003a). This report presents the results of testing and demonstration activities discussed in SOW Section 3.1, Task I--''Process Development Testing'', and described in greater detail in the ''Containerized Grout--Phase I Testing and Demonstration Plan'' (CHG, 2003b). CHG (2003b) divided the CCS testing and evaluation activities into six categories, as follows: (1) A short set of tests with simulant to select a preferred dry reagent formulation (DRF), determine allowable liquid addition levels, and confirm the Part 2 test matrix. (2) Waste form performance testing on cast stone made from the preferred DRF and a backup DRF, as selected in Part I, and using low activity waste (LAW) simulant. (3) Waste form performance testing on cast stone made from the preferred DRF using radioactive LAW. (4) Waste form validation testing on a selected nominal cast stone formulation using the preferred DRF and LAW simulant. (5) Engineering evaluations of explosive/toxic gas evolution, including hydrogen, from the cast stone product. (6) Technetium ''getter'' testing with cast stone made with LAW simulant and with radioactive LAW. In addition, nitrate leaching observations were drawn from nitrate leachability data obtained in the course of the Parts 2 and 3 waste form performance testing. The nitrate leachability index results are presented along with other data from the applicable activity categories.

  15. Solidification Microstructure of AISI M2 High Speed Steel Manufactured by the Horizontal Continuous Casting Process

    NASA Astrophysics Data System (ADS)

    Zhou, X. F.; Fang, F.; Jiang, J. Q.

    2011-01-01

    In the present work, AISI M2 high speed steel is produced by the horizontal continuous casting process. The difference of solidification microstructure in ingots by mould casting and continuous casting has been examined by means of scanning electron microscope (SEM), electron back-scatter diffraction (EBSD), transmission electron microscope (TEM) and high resolution electron microscope (HREM). The results show that the as-cast structure consists of iron matrix and networks of M2C eutectic carbides, which are greatly refined in the continuous casting ingot compared to the case of ingot by mould casting. Meanwhile, the morphology of M2C eutectic carbides changes from the plate-like shape into the fibrous one. Micro-twining and stacking faults are observed in the plate-like M2C, whereas they are rarely identified in the fibrous M2C. Based on the characteristic of morphology and microstructure, it is expected that the plate-like M2C is a faceted phase while the fibrous M2C is a non-faceted phase.

  16. Process for Producing a Cast Article from a Hypereutectic Aluminum-Silicon Alloy

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A. (Inventor); Chen, Po-Shou (Inventor)

    2003-01-01

    A process for making a cast article from an aluminum alloy includes first casting an article from an alloy having the following composition, in weight percent: Silicon (Si) 14.0-25.0, Copper (CU) 5.5-8.0, Iron (Fe) 0-0.8, Magnesium (Mg) 0.5-1.5, Nickel (Ni) 0.05-1.2, Manganese (Mn) 0-1.0, Titanium (Ti) 0.05-1.2, Zirconium (Zr) 0.12-1.2, Vanadium (V) 0.05-1.2, Zinc (Zn) 0-0.9, Phosphorus (P) 0.001-0.1, Aluminum, balance. In this alloy the ration of Si:Mg is 15-35, and the ratio of Cu:Mg is 4-15. After an article is cast from the alloy, the cast article is aged at a temperature within the range of 400 F to 500 F for a time period within the range of four to 16 hours. It has been found especially advantageous if the cast article is first exposed to a solutionizing step prior to the aging step. This solutionizing step is carried out by exposing the cast article to a temperature within the range of 875 F to 1025 F for a time period of fifteen minutes to four hours. It has also been found to be especially advantageous if the solutionizing step is followed directly with a quenching step, wherein the cast article is quenched in a quenching medium such as water at a temperature within the range of 120 F to 300 F. The resulting cast article is highly suitable in a number of high temperature applications, such as heavy-duty pistons for internal combustion engines.

  17. Process for Producing a Cast Article from a Hypereutectic Aluminum-Silicon Alloy

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A. (Inventor); Chen, Po-Shou (Inventor)

    2003-01-01

    A process for making a cast article from an aluminum alloy includes first casting an article from an alloy having the following composition, in weight percent: Silicon (Si) 14.0-25.0, Copper (CU) 5.5-8.0, Iron (Fe) 0-0.8, Magnesium (Mg) 0.5-1.5, Nickel (Ni) 0.05-1.2, Manganese (Mn) 0-1.0, Titanium (Ti) 0.05-1.2, Zirconium (Zr) 0.12-1.2, Vanadium (V) 0.05-1.2, Zinc (Zn) 0-0.9, Phosphorus (P) 0.001-0.1, Aluminum, balance. In this alloy the ration of Si:Mg is 15-35, and the ratio of Cu:Mg is 4-15. After an article is cast from the alloy, the cast article is aged at a temperature within the range of 400 F to 500 F for a time period within the range of four to 16 hours. It has been found especially advantageous if the cast article is first exposed to a solutionizing step prior to the aging step. This solutionizing step is carried out by exposing the cast article to a temperature within the range of 875 F to 1025 F for a time period of fifteen minutes to four hours. It has also been found to be especially advantageous if the solutionizing step is followed directly with a quenching step, wherein the cast article is quenched in a quenching medium such as water at a temperature within the range of 120 F to 300 F. The resulting cast article is highly suitable in a number of high temperature applications, such as heavy-duty pistons for internal combustion engines.

  18. A comprehensive evaluation of the toxicology of the "Deli" cast sheet process used in experimental cigarettes.

    PubMed

    Coggins, Christopher R E; Merski, Jerome A; Oldham, Michael J

    2013-01-01

    Manufacture of cigarettes results in tobacco by-products, some of which can be processed and added back to cigarettes. Such additions (known as reconstituted tobacco or reconstituted leaf) have been shown to reduce tar yields. A new process (termed "Deli" cast sheet) is a potential refinement of the reconstitution process. Compare toxicity of smoke from experimental cigarettes made with reconstituted leaf with that from cigarettes made with Deli cast sheet. Analytical chemistry, Salmonella mutagenicity and cytotoxicity assays were used to evaluate the composition biological activity of mainstream smoke from experimental cigarettes made with Deli cast sheet or with reconstituted leaf. The effect of different amounts of guar and propylene glycol in Deli cast sheet was also evaluated. Small increases in the amount of nitrogen oxides were found as a result of inclusion of the Deli cast sheet when compared with reconstituted leaf; no differences in cytotoxicity or mutagenicity were found. The Deli process neither significantly modified chemical composition of smoke nor affected its biological activity, as measured by the mutagenicity and cytotoxicity assays used here.

  19. 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.

  20. Influence of Process Parameters on the Microstructure and Casting Defects of a LPDC Engine Block

    NASA Astrophysics Data System (ADS)

    Timelli, Giulio; Caliari, Daniele

    The growing demand in the automotive industry for lighter vehicles has led to increasing use of Al-Si based alloys in the production of engine blocks. Low-pressure die casting (LPDC) is an enhanced process generally used for parts with premium requirements, therefore it is one of the most promising technologies for the production of engine blocks. This work is aimed to study the effects of Sr modification and holding pressure on the microstructure and casting defects of a low-pressure die cast A356 engine block. The microstructural scale, evaluated by secondary dendrite arm spacing, the amount of porosity and inclusions, and the morphology of eutectic Si particles were investigated by metallographic and image analysis. The results were correlated with the variation of input process variables such as holding pressure and Sr level. The measured amount of porosity is low, therefore confirming LPDC as a useful foundry process for the production of Al blocks for high performance engines.

  1. Microstructure of Haynes® 282® Superalloy after Vacuum Induction Melting and Investment Casting of Thin-Walled Components

    PubMed Central

    Matysiak, Hubert; Zagorska, Malgorzata; Andersson, Joel; Balkowiec, Alicja; Cygan, Rafal; Rasinski, Marcin; Pisarek, Marcin; Andrzejczuk, Mariusz; Kubiak, Krzysztof; Kurzydlowski, Krzysztof J.

    2013-01-01

    The aim of this work was to characterize the microstructure of the as-cast Haynes® 282® alloy. Observations and analyses were carried out using techniques such as X-ray diffraction (XRD), light microscopy (LM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray spectroscopy (EDS), wave length dispersive X-ray spectroscopy (WDS), auger electron spectroscopy (AES) and electron energy-loss spectrometry (EELS). The phases identified in the as-cast alloy include: γ (gamma matrix), γʹ (matrix strengthening phase), (TiMoCr)C (primary carbide), TiN (primary nitride), σ (sigma-TCP phase), (TiMo)2SC (carbosulphide) and a lamellar constituent consisting of molybdenum and chromium rich secondary carbide phase together with γ phase. Within the dendrites the γʹ appears mostly in the form of spherical, nanometric precipitates (74 nm), while coarser (113 nm) cubic γʹ precipitates are present in the interdendritic areas. Volume fraction content of the γʹ precipitates in the dendrites and interdendritic areas are 9.6% and 8.5%, respectively. Primary nitrides metallic nitrides (MN), are homogeneously dispersed in the as-cast microstructure, while primary carbides metallic carbides (MC), preferentially precipitate in interdendritic areas. Such preference is also observed in the case of globular σ phase. Lamellar constituents characterized as secondary carbides/γ phases were together with (TiMo)2SC phase always observed adjacent to σ phase precipitates. Crystallographic relations were established in-between the MC, σ, secondary carbides and γ/γʹ matrix. PMID:28788373

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

    SciTech Connect

    Sabau, Adrian S; Wu, Zhuoxi

    2007-02-01

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

  3. Sealing micropores in thin castings

    NASA Technical Reports Server (NTRS)

    Mersereau, G. A.; Nitzschke, G. O.; Ochs, H. L.; Sutch, F. S.

    1981-01-01

    Microscopic pores in thin-walled aluminum castings are sealed by impregnation pretreatment. Technique was developed for investment castings used in hermetically sealed chassic for electronic circuitry. Excessively high leakage rates were previously measured in some chassis.

  4. Development of low-temperature high-strength integral steel castings for offshore construction by casting process engineering

    NASA Astrophysics Data System (ADS)

    Lim, Sang-Sub; Mun, Jae-Chul; Kim, Tae-Won; Kang, Chung-Gil

    2014-12-01

    In casting steels for offshore construction, manufacturing integral casted structures to prevent fatigue cracks in the stress raisers is superior to using welded structures. Here, mold design and casting analysis were conducted for integral casting steel. The laminar flow of molten metal was analyzed and distributions of hot spots and porosities were studied. A prototype was subsequently produced, and air vents were designed to improve the surface defects caused by the release of gas. A radiographic test revealed no internal defects inside the casted steel. Evaluating the chemical and mechanical properties of specimens sampled from the product revealed that target values were quantitatively satisfied. To assess weldability in consideration of repair welding, the product was machined with grooves and welded, after which the mechanical properties of hardness as well as tensile, impact, and bending strengths were evaluated. No substantive differences were found in the mechanical properties before and after welding.

  5. Polymer-melt interactions during casting formation in the lost foam process

    SciTech Connect

    Shivkumar, S.; Yao, X.; Makhlouf, M.

    1995-07-01

    The lost foam casting process utilizes injection modeled polymeric foam patterns for the production of metallic components. Foamed polymer patterns of the desired shape are coated with a water-based refractory slurry, dried and embedded in unbonded sand. Molten metal is poured directly on the coated polymer. The polymer undergoes thermal degradation and is gradually replaced by the liquid metal to yield the casting after solidification. Expanded polystyrene (EPS) is the most common pattern material used in commercial practice. The use of EPS patterns with ferrous castings may result in the formation of carbonaceous defects in the casting. Consequently, polymethylmethacrylate (PMMA) and copolymers of EPS and PMMA have been developed for ferrous castings. The thermal degradation of the foamed pattern results in the formation of gaseous degradation products and of a partially depolymerized viscous residue. The fraction of viscous residue increased with temperature and is essentially constant above about 650 C. During the filling of EPS patterns, nearly 60% of the polymer is converted to the viscous residue and 40% is transformed to gaseous products. In the case of PMM, almost 60% of the polymer undergoing degradation at the metal front is transformed to gaseous products. The melt flow velocity during the filling of the mold generally increases with temperature.

  6. A high resolution finite volume method for efficient parallel simulation of casting processes on unstructured meshes

    SciTech Connect

    Kothe, D.B.; Turner, J.A.; Mosso, S.J.; Ferrell, R.C.

    1997-03-01

    We discuss selected aspects of a new parallel three-dimensional (3-D) computational tool for the unstructured mesh simulation of Los Alamos National Laboratory (LANL) casting processes. This tool, known as {bold Telluride}, draws upon on robust, high resolution finite volume solutions of metal alloy mass, momentum, and enthalpy conservation equations to model the filling, cooling, and solidification of LANL castings. We briefly describe the current {bold Telluride} physical models and solution methods, then detail our parallelization strategy as implemented with Fortran 90 (F90). This strategy has yielded straightforward and efficient parallelization on distributed and shared memory architectures, aided in large part by new parallel libraries {bold JTpack9O} for Krylov-subspace iterative solution methods and {bold PGSLib} for efficient gather/scatter operations. We illustrate our methodology and current capabilities with source code examples and parallel efficiency results for a LANL casting simulation.

  7. 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.

  8. Prototype casting fabrication by stereolithography

    SciTech Connect

    Cromwell, W.E.

    1990-11-01

    A new product development technology is emerging which could have a major impact on the investment casting industry. It's identified by several names, the most common of which is STEREOLITHOGRAPHY.'' This technology involves a three-dimensional printing process which will yield plastic parts (polymer models) from solid, surface, or wireframe CAD files. The concept links a CAD database to a process which guides a laser beam to solidify liquid photo-curable polymer into a programmed shaped. The process can produce models in far less time and at far less cost than can be done by other known (conventional) model producing methods. Parts that would normally require weeks or months to prototype with conventional processes can be produced in a matter of hours by Stereolithography. The Allied-Signal Inc., Kansas City Division, is engaged in a development project (funded by the Department of Energy) which is aimed at establishing this process as a practical, expedient, and cost-effective method fabricating prototype investment castings. The early phases of the project include procurement of a special designed test unit for several companies (Service Centers) involved in fabrication of models. These models are produced in various materials and used in experimental casting programs being conducted with four casting suppliers (two ferrous and two non-ferrous). This presentation will cover the objectives of the project and the results obtained up to this time. We will also briefly review future plans for the continuation of the project, until this new technology has been proven as a viable process for rapid development of investment castings.

  9. The Influence of Casting Conditions on the Microstructure of As-Cast U-10Mo Alloys: Characterization of the Casting Process Baseline

    SciTech Connect

    Nyberg, Eric A.; Joshi, Vineet V.; Lavender, Curt A.; Paxton, Dean M.; Burkes, Douglas

    2013-12-13

    Sections of eight plate castings of uranium alloyed with 10 wt% molybdenum (U-10Mo) were sent from Y-12 to the Pacific Northwest National Laboratory (PNNL) for microstructural characterization. This report summarizes the results from this study.

  10. Achieving High Strength and High Ductility in Friction Stir-Processed Cast Magnesium Alloy

    NASA Astrophysics Data System (ADS)

    Yuan, Wei; Panigrahi, Sushanta K.; Mishra, Rajiv S.

    2013-08-01

    Friction stir processing (FSP) is emerging as an effective tool for microstructural modification and property enhancement. As-cast AZ91 magnesium alloy was friction stir processed with one-pass and two-pass to examine the influence of processing conditions on microstructural evolution and corresponding mechanical properties. Grain refinement accompanied with development of strong basal texture was observed for both processing conditions. Ultrafine-grained (UFG) AZ91 was achieved under two-pass FSP with fine precipitates distributed on the grain boundary. The processed UFG AZ91 exhibited a high tensile strength of ~435 MPa (117 pct improvement) and tensile fracture elongation of ~23 pct. The promising combination of strength and ductility is attributed to the elimination of casting porosity, and high density of fine precipitates in an UFG structure with quite low dislocation density. The effects of grain size, precipitate, and texture on deformation behavior have been discussed.

  11. The GTAW of Ti-6Al-4V castings and its effect on microstructural and mechanical properties

    NASA Astrophysics Data System (ADS)

    Ault, James; Pillers, James; Veeck, Stewart

    2005-11-01

    The gas-tungsten arc welding of Ti-6Al-4V investment castings is an integral part of titanium casting processing due to the need to repair casting defects. It is speculated that the refined alpha/beta microstructure produced by faster solidification of the weld metal can affect the static and dynamic properties of the casting. This report examines the effects of weld repair on microstructure and mechanical properties.

  12. Biostratinomic processes for the development of mud-cast logs in Carboniferous and Holocene swamps

    SciTech Connect

    Gastaldo, R.A.; Demko, T.M.; Liu, Yuejin; Keefer, W.D.; Abston, S.L. )

    1989-08-01

    Prostrate trees are common features of fossil forest litters, and are frequently preserved as mud-casts. Specimens of Carboniferous mud-cast trees and a mud-filled incipient cast of a Holocene Taxodium have been investigated to determine the biostratinomic processes responsible for their formation. These processes are complex. Hollowing of tree trunks may take place during life or by degradation after death. Once the trunk has fallen, the hollow cavity is supported by surrounding wood and/or bark tissues and acts as a conduit for sediment-laden waters. Leaf litter may be preserved on bedding surfaces. The infilling sequence of horizontal, parallel bedded, fine-grained sediment is deposited from suspended load during multiple overbank flooding events. These results differ from experimentally produced pith casts in which the sediment grain size is of fine sand. In Holocene specimens, alluvial mud within the log may provide a substrate for infaunal invertebrates. No evidence of infaunal burrowing in Carboniferous analogues exists.

  13. Design and Processing of Bimetallic Aluminum Alloys by Sequential Casting Technique

    NASA Astrophysics Data System (ADS)

    Karun, Akhil S.; Hari, S.; Ebhota, Williams S.; Rajan, T. P. D.; Pillai, U. T. S.; Pai, B. C.

    2017-01-01

    Sequential casting is a facile and fairly new technique to produce functionally graded materials (FGMs) and components by controlled mold filling process. In the present investigation, functionally graded bimetallic aluminum alloys are produced by sequential gravity casting using A390-A319 and A390-A6061 alloy combinations. The control in pouring time between two melts has shown a significant effect on the quality and nature of interface bonding. The microstructure reveals good interface miscibility achieved through diffusion bonding between the alloys. A higher hardness of 160 BHN in the A390 region is obtained in both sequential cast systems, and a minimum value of 105 and 91 BHN is observed in the A319 and A6061 regions, respectively. The tensile and compression strength for A390-A319 are 337 and 490 MPa, whereas for A390-A6061, they are 364 and 401 MPa, respectively, which are significantly higher compared with the standard values of the base alloys, which confirms strong interface bonding. The A390 region shows higher wear resistance compared with other regions of the sequential cast system. The process described in this study is a potential and efficient approach to create good bonding between two different aluminum alloys to develop advanced functional and structural materials.

  14. The potential of centrifugal casting for the production of near net shape uranium parts

    SciTech Connect

    Robertson, E.

    1993-09-01

    This report was written to provide a detailed summary of a literature survey on the near net shape casting process of centrifugal casting. Centrifugal casting is one potential casting method which could satisfy the requirements of the LANL program titled Near Net Shape Casting of Uranium for Reduced Environmental, Safety and Health Impact. In this report, centrifugal casting techniques are reviewed and an assessment of the ability to achieve the near net shape and waste minimization goals of the LANL program by using these techniques is made. Based upon the literature reviewed, it is concluded that if properly modified for operation within a vacuum, vertical or horizontal centrifugation could be used to safely cast uranium for the production of hollow, cylindrical parts. However, for the production of components of geometries other than hollow tubes, vertical centrifugation could be combined with other casting methods such as semi-permanent mold or investment casting.

  15. Understanding how processing additives tune the nanoscale morphology of high efficiency organic photovoltaic blends: from casting solution to spun-cast thin film.

    SciTech Connect

    Shao, Ming; Keum, Jong Kahk; Kumar, Rajeev; Chen, Jihua; Browning, James F.; Das, Sanjib; Chen, Wei; Hou, Jianhui; Do, Changwoo; Littrell, Kenneth C.

    2014-11-12

    Adding a small amount of a processing additive to the casting solution of photoactive organic blends has been demonstrated to be an effective method for achieving improved power conversion efficiency (PCE) in organic photovoltaics (OPVs). However, an understanding of the nano-structural evolution occurring in the transformation from casting solution to thin photoactive films is still lacking. In this report, the effects of the processing additive diiodooctane (DIO) on the morphology of the established blend of PBDTTT-C-T polymer and the fullerene derivative PC71BM used for OPVs are investigated, starting in the casting solution and tracing the effects in spun-cast thin films by using neutron/X-ray scattering, neutron reflectometry, and other characterization techniques. The results reveal that DIO has no observable effect on the structures of PBDTTT-C-T and PC71BM in solution; however, in the spun-cast films, it significantly promotes their molecular ordering and phase segregation, resulting in improved PCE. Thermodynamic analysis based on Flory-Huggins theory provides a rationale for the effects of DIO on different characteristics of phase segregation due to changes in concentration resulting from evaporation of the solvent and additive during film formation. Such information may help improve the rational design of ternary blends to more consistently achieve improved PCE for OPVs.

  16. Wear analysis of A356 alloy cast through rheometal process

    NASA Astrophysics Data System (ADS)

    Gupta, Robin; Sharma, Ashok; Pandel, Upender; Ratke, Lorenz

    2017-04-01

    In present investigation, correlation between microstructure, mechanical properties and wear analysis for the non-heat-treated and heat-treated A356 was observed. The rheometal process changed the dendritic morphology into globular morphology which improved the mechanical properties and wear resistance of the alloy. Mechanical properties of non-heat-treated and heat-treated A356 alloy were studied. Wear tests for the non-heat-treated and heat-treated samples were performed. The SEM analysis was employed for microstructural feature of worn surfaces. The results showed that the rheometal process along with the use of baffles, addition of grain refiner and T5 heat treatment showed better mechanical properties and wear resistance of A356 alloy as compared to other processing conditions.

  17. Advances in aluminum casting technology

    SciTech Connect

    Tiryakioglu, M.; Campbell, J.

    1998-01-01

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

  18. Characterization of a grain size refinement process in cast uranium

    SciTech Connect

    Garlea, Elena; Bridges, R.; Garlea, Vasile O; Carpenter, D; Hemphill, M.; Morrell, J

    2012-01-01

    The refinementofcoarsegrainsincasturaniumcanleadtowrought-likeproperties.Inthisstudy,a bquenchedprocessiscoupledwithashock-loadingtechniqueand a-annealingtomanipulateuranium s grain sizeandtheresultingmicrostructureshavebeencharacterized.Neutronpowderdiffractionhas been usedtoevaluatetheresidualstrainaccumulatedfromthethermo-mechanicaltreatments.Optical microscopyandelectronbackscattering(EBSD)inscanningelectronmicroscopyhavebeenemployed to evaluatethegrainsizevariationandthenatureofdeformationmechanisms,respectively.Large strain anisotropyatthelatticelevelwasobservedonshock-loadedspecimens.Thefinalstressrelief annealingdidnoteliminatealltheresidualstrain.Slipandtwinningwereobservedopticallyonthe shockedspecimenswhileEBSDindicatesthatalthough{130},{172},and{112}deformationtwinswere identified,anunusualtypeoftwinning {176} /o5124 was foundtobedominant.Itisbelievedthat the magnitudeofenergyappliedfavoredtheoccurrenceofthe{176}twininthepolycrystalline uranium.Averagegrainsizeofcasturaniumunderwentasignificantreductionto 92 mm attheendof the process.Theoverallresultsindicatetheshock-loadingapproachasapromisingsteptoward controllingcasturaniumgrainsizeandthusitsmechanicalproperties.

  19. Process development for producing fine-grain casting in space

    NASA Technical Reports Server (NTRS)

    Gelles, S. H.; Malik, R. K.

    1975-01-01

    Assessment of grain growth kinetics at temperatures near the melting point and investigation into the use of potential nucleating agents in combination with the naturally occurring BeO led to the definition of critical low-g experiments which would help to determine whether one or both of these possibilities are valid and whether space processing would be able to yield fine grain ingot beryllium.

  20. Interaction analysis of the twin-roller strip-casting process and the implications for process control

    NASA Astrophysics Data System (ADS)

    Edwards, John B.; Cavazos, Alberto

    2005-06-01

    Twin-roller steel strip casting may offer advantages with respect to classic continuous-casting hot-rolling processes. Only a few studies have reported control aspects of this process, and, although successful, little attention has been given to the interactions between variables. In this study, the derivation of a 3 × 3 linearized multivariable model for process control purposes that has been proposed in previous investigations is presented. The model was simplified to a 2×2 plant. The process was found to be highly interactive and nonlinear, involving time delays. An analysis of interactions and their implications for process control is also presented. The multivariable model proposed was successfully used for multivariable control design in subsequent works.

  1. Physical Characterization of Cementitious Materials on Casting and Placing Process

    PubMed Central

    Yim, Hong Jae; Kim, Jae Hong

    2014-01-01

    Coagulation of cement particles is an inevitable phenomenon of fresh cement-based materials undergoing solidification. Coagulation can be classified into two types, reversible flocculation and irreversible coagulation, wherein microstructural change affects the rheological properties, including shear thinning and thixotropy, and the hydration process. This paper attempts to measure the mechanical property and the coagulation of cement particles according to the mix proportions of cement paste. Experimental setups were proposed for two different types of coagulations using a laser backscattering instrument. Volume fraction and size distribution of coagulated particles were obtained, and their variations were discussed. From the obtained results the microstructural buildup of freshly mixed cement pastes can be divided into three categories: permanent coagulation and strong and weak flocculation. PMID:28788606

  2. Numerical Simulation of Filling Process During Twin-Roll Strip Casting

    NASA Astrophysics Data System (ADS)

    Liu, Zhiyu; Wang, Bo; Zhang, Qinghua; Ma, Jie; Zhang, Jieyu

    2014-01-01

    The modeling and controlling of flow and solidification of melt metal in the filling process is important for obtaining the optimal pool level and the formation of the solidified metal layer on the surface of twin-rolls during the twin-roll strip casting. The proper delivery system and processing parameters plays a key role to control flow characteristics in the initial filling stage of the twin-roll strip casting process. In this paper, a commercial CFD software was employed to simulate the transient fluid flow, heat transfer, and solidifications behaviors during the pouring stage of twin-roll strip casting process using different delivery systems. A 3D model was set up to solve the coupled set of governing differential equations for mass, momentum, and energy balance. The transient free-surface problem was treated with the volume of fluid approach, a k-ɛ turbulence model was employed to handle the turbulence effect and an enthalpy method was used to predict phase change during solidification. The predicted results showed that a wedge-shaped delivery system might have a beneficial impact on the distribution of molten steel and solidification. The predicted surface profile agreed well with the measured values in water model.

  3. Surface modification of cast inconel 740 superalloy by heat-assisted friction stir processing

    NASA Astrophysics Data System (ADS)

    Kim, Jae-Yeon; Jung, Woo-Sang; Lee, Won-Sik; Byeon, Jai-Won

    2016-07-01

    Cast In740 Ni-based alloy with large grains generally show remarkable high temperature strength. However, this alloy is still have insufficient surface microstructure-dependent properties. In this study, for improvement of surface properties, surface modification of a cast In740 Ni-based superalloy was successfully performed by friction stir processing using a conventional two-horsepower milling machine and by additional heating to facilitate plastic flow of the hard alloy. Without using a high-power heavy stirring machine, a notable reduction in grain size of 2.9 μm was achieved and a corresponding 30% increase in Vickers hardness was observed. The microstructure in the stir zone was analyzed in terms of the grain size and precipitate distribution. The result of the potential dynamic polarization test and in-situ acoustic emission monitoring show that electrochemical corrosion resistance was improved by this surface modification process.

  4. [Orthogonal test analysis of compressive strength of porous hydroxylapatite prepared by gel-casting process].

    PubMed

    Han, Yanjun; Li, Musen; Lü, Yupeng; Song, Yunjing; Chen, Y; Low, H

    2004-10-01

    Porous hydroxylapatite (HA) has excellent osseous inductive ability. It has been prepared by gel-casting process, which is feasible and can make complex ceramic material. According to the result of orthogonal test based on the compressive strength, the order and the level of the factors, including monomer HA, initiator MBAM, catalyst APS and water, were dealt with. The effects of drying and sintering technique on the properties of porous hydroxylapatite were also researched. The results showed that the order of every factor in the gel-casting process is as follows, AM-APS, MBAM, H2O. Based on the determined level of each factor, the suitable slurry constituents and drying and sintering technologies were selected, and the porous hydroxylapatite with compressive strength of 6-7 MPa was produced.

  5. Structure-property-processing correlations in freeze-cast composite scaffolds.

    PubMed

    Hunger, Philipp M; Donius, Amalie E; Wegst, Ulrike G K

    2013-05-01

    Surprisingly few reports have been published, to date, on the structure-property-processing correlations observed in freeze-cast materials directionally solidified from polymer solutions, or ceramic or metal slurries. The studies that exist focus on properties of sintered ceramics, that is materials whose structure was altered by further processing. In this contribution, we report first results on correlations observed in alumina-chitosan-gelatin composites, which were chosen as a model system to test and compare the effect of particle size and processing parameters on their mechanical properties at a specific composition. Our study reveals that highly porous (>90%) hybrid materials can be manufactured by freeze casting, through the self-assembly of a polymer and a ceramic phase that occurs during directional solidification, without the need of additional processing steps such as sintering or infiltration. It further illustrates that the properties of freeze-cast hybrid materials can independently be tailored at two levels of their structural hierarchy, allowing for the simultaneous optimization of both mechanical and structural requirements. An increase in freezing rate resulted in decreases in lamellar spacing, cell wall thickness, pore aspect ratio and cross-sectional area, as well as increases in both Young's modulus and compressive yield strength. The mechanical properties of the composite scaffolds increased with an increasing particle size. The results show that both structure and mechanical properties of the freeze-cast composites can be custom-designed and that they are thus ideally suited for a large variety of applications that require high porosity at low or medium load-bearing capacity.

  6. Inspection of HF-modified cast pipes in hydro-processing units

    SciTech Connect

    Smith, N.; Shannon, B.; Singh, A.K.

    1997-09-01

    HF-Modified austenitic stainless steel cast piping is utilized in hydro-processing units. Ultrasonic examination of HF-Modified material is difficult due to it`s inherent material properties. This paper outlines the results of trials conducted on test samples containing artificial flaws in the form of EDM notches. Use of manually manipulated Time Of Flight Diffraction (TOFD) ultrasonics has demonstrated the effectiveness of the technique to detect and size ID connected notches.

  7. Urinary casts

    MedlinePlus

    ... Waxy casts; Casts in the urine; Fatty casts; Red blood cell casts; White blood cell casts ... a sign of many types of kidney diseases. Red blood cell casts mean there is a microscopic amount of ...

  8. 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

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

    NASA Astrophysics Data System (ADS)

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

    2012-02-01

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

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

    SciTech Connect

    Madhav Rao Gonvindaraju

    1999-10-18

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

  11. A Coupled Thermo-Mechanical Simulation on Squeeze Casting Solidification Process of Three-Dimensional Geometrically Complex Components

    NASA Astrophysics Data System (ADS)

    Tang, Jie; Han, Zhiqiang; Wang, Feifan; Sun, Jue; Xu, Shanxin

    A coupled thermo-mechanical simulation method for three-dimensional squeeze casting components has been developed. The simulation was achieved by using ANSYS Parametric Design Language (APDL). The effect of volume shrinkage due to cooling and solidification, the effect of pressure on the latent heat release, the mutual dependence of interfacial heat transfer and casting deformation, and materials behavior under elevated temperatures were taken into account in the simulation. A step-shaped trial casting was simulated, which demonstrates the ability of the method to simulate the pressure transmission and decline inside the casting as well as the distribution and evolution of the interfacial heat transfer coefficient. Finally, the method was applied to simulate the solidification of an automotive sub-frame component, based on which the squeeze casting process of the component was optimized.

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

    SciTech Connect

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

    2007-03-15

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

  13. Influence of Multiple Bionic Unit Coupling on Sliding Wear of Laser-Processed Gray Cast Iron

    NASA Astrophysics Data System (ADS)

    Zhang, Haifeng; Zhang, Peng; Sui, Qi; Zhao, Kai; Zhou, Hong; Ren, Luquan

    2017-04-01

    In this study, in effort to improve the sliding wear resistance of gray cast iron under wet lubrication conditions, specimens with different bionic units were manufactured and modified according to bionic theory. Inspired by the structure and appearance of biological wear-resistant skin, two kinds of bionic units were processed by laser on the specimen surfaces. We investigated the wear resistance properties of the samples via indentation method and then observed the wear surface morphology of specimens and the stress distributions. The results indicated that coupling the bionic units enhanced the wear resistance of the cast iron considerably compared to the other samples. We also determined the mechanism of wear resistance improvement according to the results.

  14. Thermo-Mechanical Behavior of the Continuous Casting Bloom in the Heavy Reduction Process

    NASA Astrophysics Data System (ADS)

    Ji, Cheng; Wu, Chen-hui; Zhu, Miao-yong

    2016-12-01

    A two-stage sequential heavy reduction (HR) method, in which the reduction amount was increased both before and after the solidification end, is presented to simultaneously improve the homogeneity and compactness of the continuous casting bloom. With bearing steel GCr15 chosen as the specific research steel, a three-dimensional thermal-mechanical finite element model was developed to simulate and analyze the thermal and mechanical behaviors of the continuous casting bloom during the HR process. In order to ensure the accuracy of the simulation, the constitutive model parameters were derived from the experimental results. The predicted temperature distribution and shell thickness were verified using a thermal infrared camera and nail shooting results, respectively. The real measured relationship between the HR pressure and amount were applied to verify the mechanical model. The explorative application results showed that the quality of the bloom center and compactness of rolled bars have both been significantly improved after the HR was applied.

  15. Influence of Multiple Bionic Unit Coupling on Sliding Wear of Laser-Processed Gray Cast Iron

    NASA Astrophysics Data System (ADS)

    Zhang, Haifeng; Zhang, Peng; Sui, Qi; Zhao, Kai; Zhou, Hong; Ren, Luquan

    2017-03-01

    In this study, in effort to improve the sliding wear resistance of gray cast iron under wet lubrication conditions, specimens with different bionic units were manufactured and modified according to bionic theory. Inspired by the structure and appearance of biological wear-resistant skin, two kinds of bionic units were processed by laser on the specimen surfaces. We investigated the wear resistance properties of the samples via indentation method and then observed the wear surface morphology of specimens and the stress distributions. The results indicated that coupling the bionic units enhanced the wear resistance of the cast iron considerably compared to the other samples. We also determined the mechanism of wear resistance improvement according to the results.

  16. Transient thermal model of the continuous single-wheel thin-strip casting process

    NASA Astrophysics Data System (ADS)

    Li, Guowei; Thomas, Brian G.

    1996-06-01

    A transient heat-transfer model (STRIP1D) has been developed to simulate the single-roll continuous strip-casting process. The model predicts temperature in the solidifying strip coupled with heat transfer in the rotating wheel, using an explicit finite difference procedure. The model has been calibrated using strip thickness data from a test caster at ARMCO Inc. (Middletown, OH) and verified with a range of other available measurements. The strip/wheel interface contact resistance and heat transfer were investigated in particular, and an empirical formula to calculate this heat-transfer coefficient as a function of contact time was obtained. Wheel temperature and final strip thickness are investigated as a function of casting speed, liquid steel pool depth, superheat, coatings on the wheel hot surface, strip detachment point, wheel wall thickness, and wheel material.

  17. Microstructural modification of as-cast Al-Si-Mg alloy by friction stir processing

    NASA Astrophysics Data System (ADS)

    Ma, Z. Y.; Sharma, S. R.; Mishra, R. S.

    2006-11-01

    Friction stir processing (FSP) has been applied to cast aluminum alloy A356 plates to enhance the mechanical properties through microstructural refinement and homogenization. The effect of tool geometry and FSP parameters on resultant microstructure and mechanical properties was investigated. The FSP broke up and dispersed the coarse acicular Si particles creating a uniform distribution of Si particles in the aluminum matrix with significant microstructural refinement. Further, FSP healed the casting porosity. These microstructural changes led to a significant improvement in both strength and ductility. Higher tool rotation rate was the most effective parameter to refine coarse Si particles, heal the casting porosity, and consequently increase strength. The effect of tool geometry was complicated and no systematic trend was observed. For a standard pin design, maximum strength was achieved at a tool rotation rate of 900 rpm and traverse speed of 203 mm/min. Post-FSP aging increased strength for materials processed at higher tool rotation rates of 700 to 1100 rpm, but exerted only a marginal effect on samples prepared at the lower rotation rate of 300 rpm. Two-pass FSP with 100 pct overlapping passes resulted in higher strength for both as-FSP and post-FSP aged conditions.

  18. Bond Strength of Multicomponent White Cast Iron Coatings Applied by HVOF Thermal Spray Process

    NASA Astrophysics Data System (ADS)

    Maranho, Ossimar; Rodrigues, Daniel; Boccalini, Mario; Sinatora, Amilton

    2009-12-01

    Multicomponent white cast iron is a new alloy that belongs to system Fe-C-Cr-W-Mo-V, and because of its excellent wear resistance it is used in the manufacture of hot rolling mills rolls. To date, this alloy has been processed by casting, powder metallurgy, and spray forming. The high-velocity oxyfuel process is now also considered for the manufacture of components with this alloy. The effects of substrate, preheating temperature, and coating thickness on bond strength of coatings have been determined. Substrates of AISI 1020 steel and of cast iron with preheating of 150 °C and at room temperature were used to apply coatings with 200 and 400 μm nominal thickness. The bond strength of coatings was measured with the pull-off test method and the failure mode by scanning electron microscopic analysis. Coatings with thickness of 200 μm and applied on substrates of AISI 1020 steel with preheating presented bond strength of 87 ± 4 MPa.

  19. Freeze casting of porous hydroxyapatite scaffolds. I. Processing and general microstructure.

    PubMed

    Fu, Qiang; Rahaman, Mohamed N; Dogan, Fatih; Bal, B Sonny

    2008-07-01

    Freeze casting of aqueous suspensions on a cold substrate was investigated as a method for preparing hydroxyapatite (HA) scaffolds with unidirectional porosity. In the present paper, we report on the ability to manipulate the microstructure of freeze-cast constructs by controlling the processing parameters. Constructs prepared from aqueous suspensions (5-20 volume percent particles) on a steel substrate at -20 degrees C had a lamellar-type microstructure, consisting of plate-like HA and unidirectional pores oriented in the direction of freezing. Sintering for 3 h at 1350 degrees C produced constructs with dense HA lamellas, porosity of approximately 50%, and inter-lamellar pore widths of 5-30 microm. The thickness of the HA lamellas decreased but the width of the pores increased with decreasing particle concentration. Decreasing the substrate temperature from -20 degrees C to -196 degrees C produced a finer lamellar microstructure. The use of water-glycerol mixtures (20 wt % glycerol) as the solvent in the suspension resulted in the production of finer pores (1-10 microm) and a larger number of dendritic growth connecting the HA lamellas. On the other hand, the use of water-dioxane mixtures (60 wt % dioxane) produced a cellular-type microstructure with larger pores (90-110 microm). The ability to produce a uniaxial microstructure and its manipulation by controlling the processing parameters indicate the potential of the present freeze casting route for the production of scaffolds for bone tissue engineering applications.

  20. 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).

  1. AMCC casting development. Volume 1: Executive Summary

    NASA Astrophysics Data System (ADS)

    1995-03-01

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

  2. The Computational Fluid Dynamic (CFD) Modeling of the Horizontal Single Belt Casting (HSBC) Processing of Al-Mg-Sc-Zr Alloy Strips

    NASA Astrophysics Data System (ADS)

    Ge, S.; Isac, M.; Guthrie, R. I. L.

    2015-10-01

    Al-Mg-Sc-Zr alloys have shown exceptional potential as structural materials for transportation applications. These alloys have proved to be good candidates to be processed as thin strips via the horizontal single belt casting (HSBC) process. The HSBC process is a near-net-shape casting technology, which involves casting molten metal directly into thin strips, close to the final product thickness, at higher cooling rates than conventional continuous casting and thin-slab casting processes. It offers an efficient, economical, and environmentally friendly approach to the production of metal strips. Fluid mechanics and associated heat transfer are important aspects of any casting process, and the novel HSBC process is no exception. Three-dimensional computational fluid dynamics simulations using ANSYS FLUENT 14.5 were performed, in order to assess the importance and effects of the various operational conditions of the HSBC process. This enabled process parameter optimization. Numerical predictions were validated against experimental casting results.

  3. High Wear Resistance of White Cast Iron Treated by Novel Process: Principle and Mechanism

    NASA Astrophysics Data System (ADS)

    Jia, Xiaoshuai; Zuo, Xunwei; Liu, Yu; Chen, Nailu; Rong, Yonghua

    2015-12-01

    Based on microstructure desired, a novel process is proposed to treat Fe-2.4C-12.0Cr (mass pct) white cast iron balls, that is, destabilizing heat treatment following multicycle quenching and sub-critical treatment (De-MQ-Sct) process, and such a complex process is simply performed by alternate water quenching and air cooling. For comparison, the white cast iron balls also were treated by conventional normalization (NOR) process and Oil-quenching process, respectively. The partitioning of carbon from martensite to retained austenite during De-MQ-Sct process promotes the interaction between carbide precipitation and martensitic transformation, while this interaction is a unique effect only produced by multicycle quenching linking destabilizing and sub-critical treatments, which leads to more and finer secondary carbides and more carbon-enriched austenite in De-MQ-Sct sample than those in NOR or Oil-quenching sample. The average hardness of 60 HRC and impact toughness of 12.6 J/cm2 are obtained in De-MQ-Sct white cast iron balls, which are much higher than those in NOR and Oil-quenching ones. The wear behaviours measured by pin-on-disk wear tests indicate that the weight loss of De-MQ-Sct sample is only about one third of the NOR sample and one half of the Oil-quenching sample. Microstructural characterization reveals that high wear resistance related to hardness and toughness of the De-MQ-Sct balls are mainly attributed to the considerable fine secondary carbides and stable carbon-enriched retained austenite.

  4. PREFACE: MCWASP XIII: International Conference on Modeling of Casting, Welding and Advanced Solidification Processes

    NASA Astrophysics Data System (ADS)

    Ludwig, Andreas

    2012-07-01

    Due to fast-paced development in computer technologies during the last three decades, computer-based process modeling has become an important tool for the improvement of existing process technologies and the development of new, innovative technologies. With the help of numerical process simulations, complex and costly experimental trials can now be reduced to a minimum. For metallurgical processes in particular, computer simulations are of outstanding importance, as the flow and solidification of molten alloys or the formation of microstructure and defects can hardly be observed experimentally. Corresponding computer simulations allow us inside views into the key process phenomena and so offer great potential for optimization. In 1980 the conference series 'Modeling of Casting, Welding and Advanced Solidification Processes (MCWASP)' was started up, and has now been continued by holding the 13th international conference on 'Modeling of Casting, Welding and Advanced Solidification Processes', MCWASP XIII, in Schladming, Austria, from June 17-22 2012. Around 200 scientists from industry and academia, coming from 20 countries around the globe attended 78 oral and 50 poster presentations on different aspects of solidification-related modeling topics. Besides process-related sessions such as (i) Ingot and Shape Casting, (ii) Continuous Casting and Direct Chill Casting, (iii) Directional Solidification and Zone Melting, (iv) Welding, and (v) Centrifugal Casting, a larger focus was put on (vi) Experimental Investigation and In-Situ Observations. In recent years, this topic has been significantly strengthened as advanced synchrotron technologies allow fantastic in-situ observations of phenomena happening inside small metallic samples. These observations will definitely serve as a benchmark for the modeling community. Further macroscopic aspects of advanced solidification science were tackled in the sessions (vii) Electromagnetic Coupling, (viii) Thermomechanics, (ix

  5. Structure and properties of polypropylene cast films: Polymer type and processing effects

    NASA Astrophysics Data System (ADS)

    Mileva, Daniela; Gahleitner, Markus; Gloger, Dietrich

    2016-05-01

    The influence of processing parameters in a cast film extrusion process of thin films of isotactic polypropylene homopolymer and random propylene-ethylene copolymer was analyzed. Variation of the chill roll temperature allowed changing the supercooling of the melt and thus the generation of different crystal polymorphs of iPP. Additional focus was placed on the effect of flow induced crystallization via changing the output rate of the line. The crystal structure and morphology of the materials were evaluated and correlated to selected optical and mechanical properties.

  6. 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.

  7. Study on Fabrication of AA4032/AA6069 Cladding Billet Using Direct Chill Casting Process

    NASA Astrophysics Data System (ADS)

    Han, Xing; Zhang, Haitao; Shao, Bo; Li, Lei; Liu, Xuan; Cui, Jianzhong

    2016-04-01

    AA4032/AA6069 cladding billet in size of φ130 mm/φ110 mm was prepared by the modified direct chill casting process, and the parametric effect on casting performance was investigated using numerical simulation. Microstructures, elements distribution, and mechanical properties of the bonding interface were examined. The results show that metallurgical bonding interface can be obtained with the optimal parameters: the casting speed of 130 to 140 mm/min, the internal liquid level height of 50 to 60 mm, and the contact height of 40 to 50 mm. The metallurgical bonding interface is free of any discontinuities due to the fact that the alloying elements diffused across the interface and formed Ni-containing phase. Tensile strength of the cladding billet reaches 225.3 MPa, and the fracture position was located in AA6069 side, suggesting that the interface bonding strength is higher than the strength of AA6069. The interfacial shearing strength is 159.3 MPa, indicating excellent metallurgical bonding.

  8. A study on atomic diffusion behaviours in an Al-Mg compound casting process

    SciTech Connect

    Liu, Yongning; Chen, Yiqing; Yang, Chunhui

    2015-08-15

    Al and Mg alloys are main lightweight alloys of research interest and they both have superb material properties, i.e., low density and high specific strength, etc. Being different from Al alloys, the corrosion of Mg alloys is much more difficult to control. Therefore to combine merits of these two lightweight alloys as a composite-like structure is an ideal solution through using Al alloys as a protective layer for Mg alloys. Compound casting is a realistic technique to manufacture such a bi-metal structure. In this study, a compound casting technique is employed to fabricate bi-layered samples using Al and Mg and then the samples are analysed using electron probe micro-analyzer (EPMA) to determine diffusion behaviours between Al and Mg. The diffusion mechanism and behaviours between Al and Mg are studied numerically at atomic scale using molecular dynamics (MD) and parametric studies are conducted to find out influences of ambient temperature and pressure on the diffusion behaviours between Al and Mg. The results obtained clearly show the effectiveness of the compound casting process to increase the diffusion between Al and Mg and thus create the Al-base protection layer for Mg.

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

    SciTech Connect

    Pol, Harshawardhan; Banik, Sourya; Azad, Lal Busher; Doshi, Pankaj; Lele, Ashish; Thete, Sumeet

    2015-05-22

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

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

    NASA Astrophysics Data System (ADS)

    Pol, Harshawardhan; Banik, Sourya; Azad, Lal Busher; Thete, Sumeet; Doshi, Pankaj; Lele, Ashish

    2015-05-01

    Extrusion film casting (EFC) is an important polymer processing technique that is used to produce several thousand tons of polymer films/coatings on an industrial scale. In this research, we are interested in understanding quantitatively how macromolecular chain architecture (for example long chain branching (LCB) or molecular weight distribution (MWD or PDI)) influences the necking and thickness distribution of extrusion cast films. We have used different polymer resins of linear and branched molecular architecture to produce extrusion cast films under controlled experimental conditions. The necking profiles of the films were imaged and the velocity profiles during EFC were monitored using particle tracking velocimetry (PTV) technique. Additionally, the temperature profiles were captured using an IR thermography and thickness profiles were calculated. The experimental results are compared with predictions of one-dimensional flow model of Silagy et al1 wherein the polymer resin rheology is modeled using molecular constitutive equations such as the Rolie-Poly (RP) and extended Pom Pom (XPP). We demonstrate that the 1-D flow model containing the molecular constitutive equations provides new insights into the role of macromolecular chain architecture on film necking.1D. Silagy, Y. Demay, and J-F. Agassant, Polym. Eng. Sci., 36, 2614 (1996).

  11. Evaluation of the Effects of Rotary Degassing Process Variables on the Quality of A357 Aluminum Alloy Castings

    NASA Astrophysics Data System (ADS)

    Mostafaei, M.; Ghobadi, M.; Eisaabadi B., Ghasem; Uludağ, Muhammet; Tiryakioğlu, Murat

    2016-12-01

    The effects of rotary degassing process variables on the melt and casting quality have been investigated using reduced pressure test results and quality index calculations from tensile data. The results showed that the effectiveness of the rotary degassing process of Al alloys is highly dependent on the combination of rotational speed and the gas flow rate, and that the wrong combination of these factors may result in no improvement or even degradation in quality of castings. For the first time, it has been found that the effectiveness of the pouring and filling system to produce high-quality castings can be characterized numerically. This new method of quantifying the casting system is introduced as a new quality improvement tool for materials and process engineers.

  12. Numerical Simulation and Optimization of Directional Solidification Process of Single Crystal Superalloy Casting

    PubMed Central

    Zhang, Hang; Xu, Qingyan; Liu, Baicheng

    2014-01-01

    The rapid development of numerical modeling techniques has led to more accurate results in modeling metal solidification processes. In this study, the cellular automaton-finite difference (CA-FD) method was used to simulate the directional solidification (DS) process of single crystal (SX) superalloy blade samples. Experiments were carried out to validate the simulation results. Meanwhile, an intelligent model based on fuzzy control theory was built to optimize the complicate DS process. Several key parameters, such as mushy zone width and temperature difference at the cast-mold interface, were recognized as the input variables. The input variables were functioned with the multivariable fuzzy rule to get the output adjustment of withdrawal rate (v) (a key technological parameter). The multivariable fuzzy rule was built, based on the structure feature of casting, such as the relationship between section area, and the delay time of the temperature change response by changing v, and the professional experience of the operator as well. Then, the fuzzy controlling model coupled with CA-FD method could be used to optimize v in real-time during the manufacturing process. The optimized process was proven to be more flexible and adaptive for a steady and stray-grain free DS process. PMID:28788535

  13. Effect of Cast Modification on Denture Base Adaptation Following Maxillary Complete Denture Processing.

    PubMed

    Sayed, Mohammed E; Porwal, Amit; Ehrenberg, David; Weiner, Saul

    2017-01-19

    To investigate the effect of cast modifications on denture base adaptation in coronal and sagittal projections following maxillary complete denture processing. A total of 60 edentulous maxillary casts (n = 10) were distributed among six groups. Group 1 was the control group with no modification, groups 2 through 6 included a butterfly postdam preparation, groups 3 and 4 also included a 10-mm wide/4-mm deep box with addition of four round holes in group 4, and groups 5 and 6 also included a 20-mm wide/4-mm deep box with addition of four round holes in group 6. The boxes were prepared at the mid-heel area of the casts. Two layers of baseplate wax (1 mm each) were used to standardize denture base thickness across the groups. A standard technique was used to replicate the denture tooth set-up, and standardized processing was done for all the groups. Following deflasking, casts with the dentures were sectioned in the coronal and sagittal directions. Microscopic pictures were taken at preselected points. Data were organized in tables, and statistical analyses were performed using repeated measure ANOVA, Tukey post hoc tests, and post hoc comparison tests set at 5% level of significance. Maximum gaps were measured at the mid-palatal area followed by nearby areas and the areas near ridge crests in both coronal and sagittal projections. The analyses revealed significant differences between the groups in coronal projection (1/2, 3/4, 5/6) and sagittal projection (1, 2, 3/4, 5/6) without significant differences within the pairs. The groups were ranked from the highest group 1 to the lowest group 6 relative to the gap means. Post hoc comparisons showed that points 1C and 2A had the highest gap means across the study groups. Within the limitations of this study, it can be extrapolated that the denture base adaptation can be effectively increased with the box preparation at the mid-heel aspect of the casts. Significant reduction of gaps was seen when the box size increased from

  14. Effect of Process Parameters on Abnormal Grain Growth during Friction Stir Processing of a Cast Al Alloy

    SciTech Connect

    Jana, Saumyadeep; Mishra, Rajiv S.; Baumann, John A.; Grant, Glenn J.

    2010-11-25

    The effects of process parameters and friction stir processing (FSP) run configurations on the stability of nugget microstructure at elevated temperatures were evaluated. Cast plates of an Al-7Si- 0.6Mg alloy were friction stir processed using a combination of tool rotation rates and tool traverse speeds. All single pass runs showed some extent of abnormal grain growth (AGG), whereas multi-pass runs were more resistant to AGG. Additionally, higher tool rpm was found to be beneficial for controlling AGG. These effects were analyzed by comparing the result of this work with other published results and AGG models.

  15. Effects of casting conditions and deformation processing on A356 aluminum and A356-20 vol. pct SiC composites

    NASA Technical Reports Server (NTRS)

    Rozak, G. A.; Lewandowski, J. J.; Wallace, J. F.; Altmisoglu, A.

    1992-01-01

    The effects of casting conditions and deformation processing on the mechanical properties of unreinforced A356 aluminum and A356-20 vol pct SiC composite were investigated by tensile properties in these compounds fabricated by either sand casting or squeeze casting techniques followed by hot working to 33, 50, 90, and 95 percent reductions. The evolution of the microstructure and values of tensile properties were evaluated for the cast materials in each of the hot worked conditions. It was found that, while the deformation processing of the sand-cast composite resulted in banding of the Al and SiC particles within the microstructure, such features were not observed in the squeeze-cast microstructure. The tensile strengths of the squeeze cast materials was found to be higher than those of the sand cast materials, for both the unreinforced and composite samples, while increased amounts of deformation were found to improve the ductility of the composite.

  16. Effects of casting conditions and deformation processing on A356 aluminum and A356-20 vol. pct SiC composites

    NASA Technical Reports Server (NTRS)

    Rozak, G. A.; Lewandowski, J. J.; Wallace, J. F.; Altmisoglu, A.

    1992-01-01

    The effects of casting conditions and deformation processing on the mechanical properties of unreinforced A356 aluminum and A356-20 vol pct SiC composite were investigated by tensile properties in these compounds fabricated by either sand casting or squeeze casting techniques followed by hot working to 33, 50, 90, and 95 percent reductions. The evolution of the microstructure and values of tensile properties were evaluated for the cast materials in each of the hot worked conditions. It was found that, while the deformation processing of the sand-cast composite resulted in banding of the Al and SiC particles within the microstructure, such features were not observed in the squeeze-cast microstructure. The tensile strengths of the squeeze cast materials was found to be higher than those of the sand cast materials, for both the unreinforced and composite samples, while increased amounts of deformation were found to improve the ductility of the composite.

  17. Evaluation of Centrifugal Casting Process Parameters for In Situ Fabricated Functionally Gradient Fe-TiC Composite

    NASA Astrophysics Data System (ADS)

    Rahimipour, Mohammad Reza; Sobhani, Manoochehr

    2013-10-01

    A gradient Fe-TiC composite was successfully produced via combination of in situ reaction with centrifugal casting techniques. Additionally, some of the effective parameters of the centrifugal casting process have been studied. Cast iron and ferrotitanium, which were used as raw materials, were melted using a high-frequency induction furnace coupled with centrifugal equipment. The microstructure and phase characterization of the fabricated composite was studied by scanning electron microscopy, optical microscopy, and X-ray diffraction. The results show that the production of a pearlite matrix composite reinforced by TiC particles is feasible. The distribution of TiC in the pearlitic matrix is completely uneven as a result of density difference between molten medium and TiC in the centrifugal casting process.

  18. Investment Casting of Columbium Alloys

    DTIC Science & Technology

    1975-10-01

    This work was performed by Rom Metals Corporation, Albany, Oregon 97321, under the technical supervision of Mr. Starley Lopata and Dr. Robert D. French...34laced" structure. GB’s. Little or nomatri dLess overall ppt= Possible breaking Very fine & broken ppt. Less GB ppt, Noziceable absence of GB ppt in

  19. 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)

  20. Study on Pot Forming of Induction Heater Type Rice Cookers by Forging Cast Process

    NASA Astrophysics Data System (ADS)

    Ohnishi, Masayuki; Yamaguchi, Mitsugi; Ohashi, Osamu

    This paper describes a study result on pot fabrication by the forging cast process of stainless steel with aluminum. Rice cooked with the new bowl-shaped pot for the induction heater type rice cookers is better tasting than rice cooked with the conventional cylindrical one, due to the achievement of better heat conduction and convection. The conventional pot is made of the clad sheet, consisting of stainless steel and aluminum. However, it is rather difficult to form a bowl shape from the clad sheet, primarily due to the problem of a material spring back. The fabrication of a new type of a pot was made possible by means of the adoption of a forging cast process instead of the clad sheet. In this process, iron powder is inserted between stainless steel and aluminum in order to alleviate the large difference on the coefficient of expansion between each material. It was made clear that the application of two kinds of iron particle, namely 10 μm size powder on the stainless steel side and 44 μm on the aluminum side, enables the joints to become strong enough. The joint strength of the new pot by this fabrication process was confirmed by the tests of the shear strength and the fatigue tests together with the stress analysis.

  1. Effects of Post-Fabrication Processing on the Tensile Properties of Centrifugally Cast SiC Particulate Reinforced Aluminum Composites

    DTIC Science & Technology

    1993-09-01

    number) A centrifugally cast A356 aluminum -matrix composite reinforced with silicon carbide (SiC) particles was themo-mechanically processed by rolling and...Advisor Alan G. Fox, Second Reader Matthewn Department of Mechanical Engineering ii ABSTRACT A centrifugally cast A356 aluminum -matrix composite...used in this research, was commercial grade A356 Aluminum alloy. The material was supplied by Naval Surface Warefare Center, White Oak. The material

  2. EBSD Study on Grain Boundary and Microtexture Evolutions During Friction Stir Processing of A413 Cast Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Shamanian, Morteza; Mostaan, Hossein; Safari, Mehdi; Szpunar, Jerzy A.

    2016-07-01

    The as-cast Al alloys contain heterogeneous distributions of non-deforming particles due to non-equilibrium solidification effects. Therefore, these alloys have poor tribological and mechanical behaviors. It is well known that using friction stir processing (FSP), very fine microstructure is created in the as-cast Al alloys, while their wear resistance can be improved. In this research work, FSP is used to locally refine a surface layer of the coarse as-cast microstructure of cast A413 Al alloy. The main objective of this study is to investigate the effect of FSP on microstructure and microtexture evolutions in A413 cast Al alloy. The grain boundary character distribution, grain structure, and microtexture evolutions in as-cast and friction stir processed A413 Al alloy are analyzed by electron back scatter diffraction technique. It is found that with the FSP, the fraction of low ∑boundary such as ∑3, 7, and 9 are increased. The obtained results show that there are no deformation texture components in the structure of friction stir processed samples. However, some of the main recrystallization texture components such as BR and cubeND are formed during FSP which indicate the occurrence of dynamic recrystallization phenomenon due to the severe plastic deformation induced by the rotation of tool.

  3. Study on Venture Capital Investment Risk Avoiding Base on Option Pricing in Agricultural Production and Processing Enterprises

    NASA Astrophysics Data System (ADS)

    Zhang, Xubo

    This paper uses the approaches and models of option theory to analyze two-stage venture capital investment in agricultural production and processing enterprises decision-making under uncertainty. Mathematics expressions of this two-stage venture capital investment decision-making are presented. An option value model about two-stage venture capital investment decision-making base on options pricing theory under the uncertainty is presented. Get the solution of option pricing model which we present.

  4. Mechanical Strength and Failure Characteristics of Cast Mg-9 pctAl-1 pctZn Alloys Produced by a Heated-Mold Continuous Casting Process: Tensile Properties

    NASA Astrophysics Data System (ADS)

    Okayasu, Mitsuhiro; Takeuchi, Shuhei; Ohfuji, Hiroaki

    2014-11-01

    The mechanical properties and failure characteristics of a cast Mg alloy (AZ91: Mg-Al8.9-Zn0.6-Mn0.2) produced by a heated-mold continuous casting process (HMC) are investigated. In a modification of the original HMC process, the cooling of the liquid alloy by direct water spray is carried out in an atmosphere of high-purity argon gas. The HMC-AZ91 alloy exhibits excellent mechanical properties (high strength and high ductility) that are about twice as high as those for the same alloy produced by conventional gravity casting. The increased material strength and ductility of the HMC sample are attributed to nanoscale and microscale microstructural characteristics. The fine grains and tiny spherical eutectic structures ( e.g., Mg17Al12 and Al6Mn) distributed randomly in the matrix of the HMC alloy result in resistance to dislocation movement, leading to high tensile strength. Basal slip on (0001) planes in the relatively organized crystal orientation of the HMC alloy, as well as grain boundary sliding through tiny spherical eutectic structures, results in high ductility. Details of the failure mechanism under static loading in the HMC alloy are also discussed using failure models.

  5. Numerical Simulation of Infiltration and Solidification Processes for Squeeze Cast Al Composites with Parametric Study

    NASA Astrophysics Data System (ADS)

    Jung, C. K.; Jang, J. H.; Han, K. S.

    2008-11-01

    An axisymmetric finite element (FE) model is developed for the process of squeeze casting the metal-matrix composites (MMCs). The flow in the mold, the infiltration into the porous preform, and the solidification of the molten metal are studied numerically. The saturated porous flow model is adopted to simulate metal infiltration into the fibrous preform. To track the fluid front during the mold filling and infiltration, the level-set method is used. The enthalpy method is used to deal with transient heat transfer, including phase changes. Also, a simple preform deformation model is used to predict the permeability change caused by preform compression during infiltration. A numerical model representing the experiment setup is proposed. The infiltration and cooling behaviors during a process were calculated using pure aluminum as the matrix and a Saffil fiber preform. To validate the assumptions used in the numerical model, a series of infiltration experiments was carried out. The infiltration kinetics and the preform deformation were studied at different inlet pressures and at different preheat temperatures of the aluminum and the mold. A comparison with the experimental data shows that the developed FE program successfully predicts the actual squeeze casting process.

  6. Quantitative examination of carbide and sulphide precipitates in chemically complex steels processed by direct strip casting

    SciTech Connect

    Dorin, Thomas; Wood, Kathleen; Taylor, Adam; Hodgson, Peter; Stanford, Nicole

    2016-02-15

    A high strength low alloy steel composition has been melted and processed by two different routes: simulated direct strip casting and slow cooled ingot casting. The microstructures were examined with scanning and transmission electron microscopy, atom probe tomography and small angle neutron scattering (SANS). The formation of cementite (Fe{sub 3}C), manganese sulphides (MnS) and niobium carbo-nitrides (Nb(C,N)) was investigated in both casting conditions. The sulphides were found to be significantly refined by the higher cooling rate, and developed an average diameter of only 100 nm for the fast cooled sample, and a diameter too large to be measured with SANS in the slow cooled condition (> 1.1 μm). Slow cooling resulted in the development of classical Nb(C,N) precipitation, with an average diameter of 7.2 nm. However, after rapid cooling both the SANS and atom probe tomography data indicated that the Nb was retained in the matrix as a random solid solution. There was also some evidence that O, N and S are also retained in solid solution in levels not found during conventional processing. - Highlights: • The influence of cooling rate on microstructure is investigated in a HSLA steel. • SANS, TEM and APT are used to characterise the sulphides and Nb(C,N) precipitates. • The slow cooling rate result in the formation of Nb(C,N) precipitates. • The fast cooling rate results in a microstructure supersaturated in Nb, C and N. • The sulphides are 100 nm in the fast cooled sample and > 1 μm in the slow cooled one.

  7. The development of ultrahigh strength low alloy cast steels with increased toughness

    NASA Astrophysics Data System (ADS)

    Lynch, Paul C.

    This work describes the initial work on the development of the next generation of ultrahigh strength low alloy (UHSLA) cast steels. These UHSLA cast steels have both ultrahigh strength levels and good impact toughness. The influence of heat treatment, secondary processing using hot isostatic processing (HIP), and chemical composition on the microstructure and properties of UHSLA cast steels have been evaluated. The extent of microsegregation reduction expected during the heat treatment of UHSLA cast steels has also been estimated by diffusion modeling. This new family of UHSLA cast steels is similar in composition and properties to UHSLA wrought steels. However, the heat treatment and secondary processing of the UHSLA cast steels is used to develop microstructures and properties typically developed through thermomechanical processing and heat treatment for wrought UHSLA steels. Two martensitic UHSLA steels, 4340+ (silicon modified 4340) and ES-1 were investigated for this study. For the 4340+ alloy, heat treatment variables evaluated include homogenization temperature and time, tempering temperature, and austempering temperature and time. For the ES-1 alloy, heat treatment variables evaluated include homogenization temperature and time, austenization temperature, cryogenic treatment, and tempering temperature. The effect of high temperature hot isostatic processing (HIP) on the 4340+ and ES- 1 alloys was also investigated. Tensile properties, charpy v-notch impact toughness (CVN), microstructures, and fractographs have all been characterized after heat treatment. The effects of HIP on microporosity reduction in the ES-1 alloy were also investigated. The experiments carried out on the investment cast 4340+ alloy have shown that increasing the homogenization temperature can increase CVN without changing the ultimate tensile strength (UTS) or yield strength (YS) of the cast material. By replacing the homogenization step in the conventional heat treatment process with

  8. Low-investment carbonization process for coals makes liquid, gas and boiler fuel

    SciTech Connect

    Rammler, R.W.

    1981-11-09

    The advantages of carbonization are that it requires low investment compared with other liquefaction routes, and that the hydrogen requirement per ton of liquid product is low. The route should be considered only for tar-rich coals and where there is a market for the char produced. The Lurgi-Ruhrgas process, which has been used commercially for some years, is described. The development of large combined coal liquefaction and power plant is discussed.

  9. Colloidal processing, tape casting and sintering of PLZT for development of piezoceramic/polymer interlayered composites

    NASA Astrophysics Data System (ADS)

    Feng, Jian-Huei

    Piezoceramic/polymer composites possess many advantages as compared to single-phase piezoceramics. One typical form of the composites is the interlayered structure, where the main requirement is to obtain thin, flat and dense ceramic sheets. Tape casting is a reliable process for producing such high-quality sheets. The colloidal processing of tape casting slurries is a critical step to achieve uniform ceramic bodies. Lanthanum-modified lead zirconate titanate (PLZT) was selected for making piezoceramic sheets due to its superior piezoelectric properties. The quality of green tapes depends mainly on the solvents and organic additives of tape casting slurries. The effects of xylenes/ethanol solvent mixtures on non-aqueous slurries were first investigated. Well-dispersed colloidal suspensions were obtained in xylenes-rich solvents with a minimum amount of menhaden fish oil as a dispersant. Adsorption of dispersant and PLZT solids content of unfired tapes are strongly affected by the solvent(s) utilized. Furthermore, when selecting solvent mixtures, one needs to consider other additives, such as binder that can affect the viscosity of slurries. Aqueous tape casting was performed using a polyelectrolyte dispersant, poly(vinyl alcohol) (PVA) binders and various plasticizers. Zeta potential, conductivity and viscosity of PLZT suspensions containing dispersant were characterized. The effects of plasticizers and binders on properties of unfired tapes were also investigated. The tapes made from low molecular weight plasticizers showed higher plasticity. Glycerol was shown to be the most effective plasticizer for PVA. Strong hydrogen bonding in high hydrolysis PVA led to high strength and high bulk density of green tapes, but also caused deformation of the tapes after drying. There are many challenges for sintering PLZT tapes due to volatilization of PbO component at high temperatures and fragility of thin tapes. By using the proper setter powders and the sandwich method

  10. Fabrication of TiO2/PU Superhydrophobic Film by Nanoparticle Assisted Cast Micromolding Process.

    PubMed

    Li, Jie; Zheng, Jianyong; Zhang, Jing; Feng, Jie

    2016-06-01

    Lotus-like surfaces have attracted great attentions in recent years for their wide applications in water repellency, anti-fog and self-cleaning. This paper introduced a novel process, nanoparticle assisted cast micromolding, to create polymer film with superhydrophobic surface. Briefly, waterborne polyurethane (WPU) sol and nano TiO2/WPU sol were each cast onto the featured surfaces of the poly(dimethylsiloxane) (PDMS) stamps replicated from fresh lotus leaves. After being dried and peeled off from the stamps, PU and TiO2/WPU replica films were created respectively. To the former, only high hydrophobic property was observed with static water contact angle (WCA) at 142.5 degrees. While to the later, superhydrophobic property was obtained with WCA more than 150 degrees and slide angle less than 3 degrees. Scanning electron microscopy (SEM) imaging showed that the PU replica film only had the micro-papillas and the TiO2/PU replica film not only had micro papillas but also had a large number of nano structures distributed on and between the micro-papillas. Such nano and micro hierarchical structures were very similar with those on the natural lotus leaf surface, thus was the main reason for causing superhydrophobic property. Although an elastic PDMS stamp from lotus leaf was used in herein process, hard molds may also be used in theory. This study supplied an alternative technique for large scale production of polymeric films with superhydrophobic.

  11. The mechanical response of a uranium-nobium alloy: a comparison of cast versus wrought processing

    SciTech Connect

    Cady, Carl M; Gray, George T., III; Cerreta, Ellen K; Aikin, Robert M; Chen, Shuh - Rong; Trujillo, Carl P; Lopez, Mike F; Korzekwa, Deniece R; Kelly, Ann M

    2009-02-13

    A rigorous experimentation and validation program is being undertaken to create constitutive models that elucidate the fundamental mechanisms controlling plasticity in uranium-6 wt.% niobium alloys (U-6Nb). The first, 'wrought', material produced by processing a cast ingot I'ia forging and forming into plate was studied. The second material investigated is a direct cast U-6Nb alloy. The purpose of the investigation is to detennine the principal differences, or more importantly, similarities, between the two materials due to processing. It is well known that parameters like grain size, impurity size and chemistry affect the deformation and failure characteristics of materials. Metallography conducted on these materials revealed that the microstructures are quite different. Characterization techniques like tension, compression, and shear were performed to find the principal differences between the materials as a function of stress state. Dynamic characterization using a split Hopkinson pressure bar in conjunction with Taylor impact testing was conducted to derive and thereafter validate constitutive material models. The Mechanical Threshold Strength Model is shown to accurately capture the constitutive response of these materials and Taylor cylinder tests are used to provide a robust way to verify and validate the constitutive model predictions of deformation by comparing finite element simulations with the experimental results. The primary differences between the materials will be described and predictions about material behavior will be made.

  12. Coupled turbulent flow, heat, and solute transport in continuous casting processes

    NASA Astrophysics Data System (ADS)

    Aboutalebi, M. Reza; Hasan, M.; Guthrie, R. I. L.

    1995-08-01

    A fully coupled fluid flow, heat, and solute transport model was developed to analyze turbulent flow, solidification, and evolution of macrosegregation in a continuous billet caster. Transport equations of total mass, momentum, energy, and species for a binary iron-carbon alloy system were solved using a continuum model, wherein the equations are valid for the solid, liquid, and mushy zones in the casting. A modified version of the low-Reynolds number k-ɛ model was adopted to incorporate turbulence effects on transport processes in the system. A control-volume-based finite-difference procedure was employed to solve the conservation equations associated with appropriate boundary conditions. Because of high nonlinearity in the system of equations, a number of techniques were used to accelerate the convergence process. The effects of the parameters such as casting speed, steel grade, nozzle configuration on flow pattern, solidification profile, and carbon segregation were investigated. From the computed flow pattern, the trajectory of inclusion particles, as well as the density distribution of the particles, was calculated. Some of the computed results were compared with available experimental measurements, and reasonable agreements were obtained.

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

    SciTech Connect

    Zhang, X.

    1997-12-31

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

  14. Numerical modelling of evaporation in a ceramic layer in the tape casting process

    SciTech Connect

    Jabbari, M.; Hattel, J. H.; Jambhekar, V. A.; Helmig, R.

    2016-06-08

    Evaporation of water from a ceramic layer is a key phenomenon in the drying process for the manufacturing of tape cast ceramics. This process contains mass, momentum and energy exchange between the porous medium and the free–flow region. In order to analyze such interaction processes, a Representative Elementary Volume (REV)–scale model concept is presented for coupling non–isothermal multi–phase compositional porous–media flow and single–phase compositional laminar free–flow. The preliminary results show the typical expected evaporation behaviour from a porous medium initially saturated with water, and its transport to the free–flow region according to the existent results from the literature.

  15. Processing, microstructure, and mechanical behavior of cast magnesium metal matrix composites

    NASA Astrophysics Data System (ADS)

    Luo, A.

    1995-09-01

    Magnesium metal matrix composites (MMCs) have been receiving attention in recent years as an attractive choice for aerospace and automotive applications because of their low density and superior specific properties. This article presents a liquid mixing and casting process that can be used to produce SiC particulate-reinforced magnesium metal matrix composites via conventional foundry processes. Microstructural features, such as SiC particle distribution, grain refinement, and particle/matrix interfacial reactions of the cast magnesium matrix composites, are investigated, and the effects of solidification-process parameters and matrix alloys (pure Mg and Mg-9 pct Al-1 pct Zn alloy AZ91) on the microstructure are established. The results of this work suggest that in the solidification processing of MMCs, it is important to optimize the process parameters both to avoid excessive interfacial reactions and simultaneously achieve wetting, so that a good particle distribution and interfacial bonding are obtained. The tensile properties, strain hardening, and fracture behavior of the AZ91/SiC composites are also studied and the results are compared with those of the unreinforced AZ91 alloy. The strengthening mechanisms for AZ91/SiC composite, based on the proposed SiC particle/matrix interaction during deformation, are used to explain the increased yield strength and elastic modulus of the composite over the magnesium matrix alloy. The low ductility found in the composites is due to the early appearance of localized damages, such as particle cracking, matrix cracking, and occasionally interface debonding, in the fracture process of the composite.

  16. A fast and efficient adaptive parallel ray tracing based model for thermally coupled surface radiation in casting and heat treatment processes

    NASA Astrophysics Data System (ADS)

    Fainberg, J.; Schaefer, W.

    2015-06-01

    A new algorithm for heat exchange between thermally coupled diffusely radiating interfaces is presented, which can be applied for closed and half open transparent radiating cavities. Interfaces between opaque and transparent materials are automatically detected and subdivided into elementary radiation surfaces named tiles. Contrary to the classical view factor method, the fixed unit sphere area subdivision oriented along the normal tile direction is projected onto the surrounding radiation mesh and not vice versa. Then, the total incident radiating flux of the receiver is approximated as a direct sum of radiation intensities of representative “senders” with the same weight factor. A hierarchical scheme for the space angle subdivision is selected in order to minimize the total memory and the computational demands during thermal calculations. Direct visibility is tested by means of a voxel-based ray tracing method accelerated by means of the anisotropic Chebyshev distance method, which reuses the computational grid as a Chebyshev one. The ray tracing algorithm is fully parallelized using MPI and takes advantage of the balanced distribution of all available tiles among all CPU's. This approach allows tracing of each particular ray without any communication. The algorithm has been implemented in a commercial casting process simulation software. The accuracy and computational performance of the new radiation model for heat treatment, investment and ingot casting applications is illustrated using industrial examples.

  17. Development of Cast Alumina-forming Austenitic Stainless Steel Alloys for use in High Temperature Process Environments

    SciTech Connect

    Muralidharan, Govindarajan; Yamamoto, Yukinori; Brady, Michael P; Pint, Bruce A; Pankiw, Roman; Voke, Don

    2015-01-01

    There is significant interest in the development of alumina-forming, creep resistant alloys for use in various industrial process environments. It is expected that these alloys can be fabricated into components for use in these environments through centrifugal casting and welding. Based on the successful earlier studies on the development of wrought versions of Alumina-Forming Austenitic (AFA) alloys, new alloy compositions have been developed for cast products. These alloys achieve good high-temperature oxidation resistance due to the formation of protective Al2O3 scales while multiple second-phase precipitation strengthening contributes to excellent creep resistance. This work will summarize the results on the development and properties of a centrifugally cast AFA alloy. This paper highlights the strength, oxidation resistance in air and water vapor containing environments, and creep properties in the as-cast condition over the temperature range of 750°C to 900°C in a centrifugally cast heat. Preliminary results for a laboratory cast AFA composition with good oxidation resistance at 1100°C are also presented.

  18. Aluminum-Silicon Alloy Having Improved Properties At Elevated Temperatures and Process for Producing Cast Articles Therefrom

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A. (Inventor); Chen, Po-Shou (Inventor)

    2002-01-01

    A process for making a cast article from an aluminum alloy includes first casting an article from an alloy having the following composition, in weight percent: Silicon 11.0-14.0, Copper 5.6-8.0, Iron 0-0.8, Magnesium 0.5-1.5, Nickel 0.05-0.9, Manganese 0-1.0, Titanium 0.05-1.2, Zirconium 0.12-1.2, Vanadium 0.05-1.2, Zinc 0.05-0.9, Strontium 0.001-0.1, Aluminum balance . In this alloy the ratio of silicon to magnesium is 10 to 25, and the ratio of copper to magnesium is 4 to 15. After an article is cast from the alloy, the cast article is aged at a temperature within the range of 400F to 500F for a time period within the range of four to 16 hours. It has been found especially advantageous if the cast article is first exposed to a solutionizing step prior to the aging step. This solutionizing step is carried out by exposing the cast article to a temperature within the range of 900F to 1000F for a time period of fifteen minutes to four hours. It has also been found to be especially advantageous if the solutionizing step is followed directly with a quenching step, wherein the cast article is quenched in a quenching medium such as water at a temperature within the range of 120F to 300F. The resulting cast article is suitable in a number of high temperature applications, such as heavy-duty pistons for internal combustion engines.

  19. In-situ real time monitoring of the polymerization in gel-cast ceramic processes

    SciTech Connect

    Ahuja, S.; Dieckman, S.L.; Bostrom, G.A.; Waterfield, L.G.; Raptis, A.C.; Omatete, O.O.

    1996-08-01

    Gelcasting requires making a mixture of a slurry of ceramic powder in a solution of organic monomers and casting it in a mold. Gelcasting is different from injection molding in that it separates mold filling from setting during conversion of the ceramic slurry to a formed green part. In this work, NMR spectroscopy and imaging were used for in-situ monitoring of the gelation process and gelcasting of alumina. {sup 1}H NMR spectra and images are obtained during polymerization of a mixture of soluble reactive acrylamide monomers. Polymerization was initiated by adding an initiator and an accelerator to form long- chain, crosslinked polymers. Multidimensional NMR imaging was used for in-situ monitoring of the process and for verification of homogeneous polymerization. Comparison of the modeled intensities with acquired images shows a direction extraction of T{sub 1} data from the images.

  20. Effects of low-frequency electromagnetic field on the surface quality of 7050 aluminum alloy ingots during the hot-top casting process

    NASA Astrophysics Data System (ADS)

    Wang, Xiang-Jie; Cui, Jian-Zhong; Zuo, Yu-Bo; Zhao, Zhi-Hao; Zhang, Hai-Tao

    2011-04-01

    To improve the quality of 7050 aluminum alloy ingots, low-frequency electromagnetic (LFE) field was applied during the conventional hot-top casting process. Macrostructures and microstructures of the ingots by the conventional and LFE hot-top casting processes were studied. The experimental results show that when the LFE field is turn off during the hot-top casting process, cold folding appears, and the as-cast structure becomes very coarse. Additionally, the thickness of the shell zone is much thinner during the low-frequency electromagnetic hot-top casting process than that during the conventional hot-top casting process. Some reasons for low-frequency electromagnetic field improving the surface quality, refining the structure of the ingot, and minimizing the thickness of the shell zone have been studied.

  1. Machinability of Austempered Ductile Iron (ADI) Produced by Integrated Green Technology of Continuous Casting-Heat Treatment Processes

    SciTech Connect

    Meena, A.; El Mansori, M.; Ghidossi, P.

    2011-01-17

    This study presents the novel processing technique known as continuous casting-heat treatment processes to produce Austempered Ductile Iron (ADI) which is a new class of ductile iron. ADI is characterized by improved mechanical properties but has low machinability as compared to other cast irons and steel of similar strength. The novel technique is developed by the integration of casting (in die casting) and heat treatment processes in foundry to save cost energy and time. Specimens just after casting were austenitized at 930 deg. C for 90 min and then austempered in fluidized bed at 380 deg. C for 90 and 120 min. Hence, the effect of austempering time on the morphology of retained austenite and mechanical properties of the material were examined and compared with conventionally produced ADI. Drilling tests were then carried out to evaluate the machinability of ADI in terms of cutting forces, chip micro-hardness, chip morphology and surface roughness. The mechanical properties of ADI austempered for 120 min have found to be better as compare to the ADI austempered for 90 min.

  2. Structure-Property-Processing Correlations in Freeze-Cast Hybrid Scaffolds

    NASA Astrophysics Data System (ADS)

    Hunger, Philipp Malte

    Porous materials are highly sought after for applications ranging from catalyst carriers to tissue scaffolds. Most applications require clearly defined structural features and a specific mechanical performance. Therefore, it is essential to establish systematic structure-property-processing correlations to be able to tailor both structure and mechanical properties for a particular application. Because the introduction of porosity is detrimental to the mechanical performance of highly porous structures, it is necessary to generate a structure that allows for the mechanical properties to be maximized. One example for such a structure are honeycombs. In addition to the porosity and pore morphology, the scaffold's performance depends on the properties inherent to the material from which it is made. Polymeric foams possess high toughness but low stiffness, whereas ceramic foams possess high stiffness but low toughness. Natural composites like bone, antler and nacre have both high stiffness and high toughness. This unusual set of mechanical properties is thought to be intricately linked to the multi-level hierarchical composite structure present in these materials. Great potential for the fabrication of stiff, strong and tough porous scaffolds is thus seen in nacre-like composite materials with a hierarchical, honeycomb-like structure. Freeze casting is a method with which such hybrid materials can be made, adding the third dimension to nacre by forming a highly porous, hierarchical bulk material, with dense, nacre-like cell walls. The nacre-like cell walls self-assemble during the directional freezing of a water-based ceramic-polymer slurry. Reported here are structure-property-processing correlations observed in these materials. They are unusual, because they are, like nacre, solely glued by a polymeric phase and not processed further by sintering. The results illustrate several pathways to control both structure and mechanical properties in freeze-cast composites and

  3. Numerical simulation of casting processes: coupled mould filling and solidification using VOF and enthalpy-porosity method

    NASA Astrophysics Data System (ADS)

    Richter, Ole; Turnow, Johann; Kornev, Nikolai; Hassel, Egon

    2016-12-01

    Within the scope of industrial casting applications a numerical model for the simultaneous mould filling and solidification process has been formulated, implemented in a finite volume code and successfully validated using analytical and experimental data. In order to account for the developing of free surface flow and the liquid/solid phase change, respectively, the volume-of-fluid and enthalpy-porosity method have been coupled under a volume averaging framework on a fixed Eulerian grid. The coupled method captures the basic physical effects of a combined mould filling and solidification process and provides a trustful method for comprehensive casting simulations.

  4. Numerical simulation of casting processes: coupled mould filling and solidification using VOF and enthalpy-porosity method

    NASA Astrophysics Data System (ADS)

    Richter, Ole; Turnow, Johann; Kornev, Nikolai; Hassel, Egon

    2017-06-01

    Within the scope of industrial casting applications a numerical model for the simultaneous mould filling and solidification process has been formulated, implemented in a finite volume code and successfully validated using analytical and experimental data. In order to account for the developing of free surface flow and the liquid/solid phase change, respectively, the volume-of-fluid and enthalpy-porosity method have been coupled under a volume averaging framework on a fixed Eulerian grid. The coupled method captures the basic physical effects of a combined mould filling and solidification process and provides a trustful method for comprehensive casting simulations.

  5. Analysis and Evaluation of Novel Al-Mg-Sc-Zr Aerospace Alloy Strip Produced Using the Horizontal Single Belt Casting (HSBC) Process

    NASA Astrophysics Data System (ADS)

    Ge, Sa; Celikin, Mert; Isac, Mihaiela; Guthrie, Roderick I. L.

    2015-04-01

    Horizontal single belt casting (HSBC) is a near net shape casting process in which molten metal is directly cast into thin strips, at high cooling rates (order of several 100 °C/s), with the potential for high volume, friction free, continuous production of metal strips. This casting process was used in the present work to produce strips of Al-Mg alloys in the AA5000 series, with additions of Sc and Zr. Such aluminum alloys show exceptional potential as a structural material for transportation/aerospace applications. To demonstrate the suitability of the HSBC process to manufacture competitive strip products of Al-Mg-Sc-Zr, the mechanical properties and microstructures of the strips produced using the HSBC process were compared with conventionally cast products. The effects of annealing on the mechanical properties of the strip-cast Al-Mg-Sc-Zr alloys were also investigated.

  6. Processing and Microstructure Characteristics of As-Cast A356 Alloys Manufactured via Ultrasonic Cavitation during Solidification

    NASA Astrophysics Data System (ADS)

    Xuan, Yang; Jia, Shian; Nastac, Laurentiu

    2017-04-01

    Recent studies have showed that the microstructure and mechanical properties of A356 alloy can be significantly improved when ultrasonic cavitation and solidification processing is used. This is because during the fabrication of A356 castings, ultrasonic cavitation processing plays an important role in degassing and refining the as-cast microstructure. In the present study, A356 alloy and Al2O3/SiC nanoparticles are used as the matrix alloy and the reinforcements, respectively. Nanoparticles are injected into the molten alloy and dispersed by ultrasonic cavitation. Ultrasonic cavitation was also applied during solidification of these nanocomposites. The microstructure and nanoparticle distribution of the cast samples have been investigated in detail. The current experimental results indicated that ultrasonic cavitation during solidification will greatly improve the microstructure of the samples. Al2O3 and SiC nanoparticle reinforced nanocomposites have different nanoparticle distributions in the matrix.

  7. Thermal casting process for the preparation of anisotropic membranes and the resultant membrane

    DOEpatents

    Caneba, Gerard T. M.; Soong, David S.

    1987-01-01

    A method for providing anisotropic polymer membranes from a binary polymer/solvent solution using a thermal inversion process. A homogeneous binary solution is cast onto a support and cooled in such a way as to provide a differential in cooling rate across the thickness of the resulting membrane sheet. Isotropic or anisotropic structures of selected porosities can be produced, depending on the initial concentration of polymer in the selected solvent and on the extent of the differential in cooling rate. This differential results in a corresponding gradation in pore size. The method may be modified to provide a working skin by applying a rapid, high-temperature pulse to redissolve a predetermined thickness of the membrane at one of its faces and then freezing the entire structure.

  8. Wear properties of compact graphite cast iron with bionic units processed by deep laser cladding WC

    NASA Astrophysics Data System (ADS)

    Zhou, Hong; Zhang, Peng; Sun, Na; Wang, Cheng-tao; Lin, Peng-yu; Ren, Lu-quan

    2010-08-01

    By simulating the cuticles of some soil animals, the wear resistance of compact graphite cast iron (CGI) processed by laser remelting gets a conspicuous improvement. In order to get a further anti-wear enhancement of CGI, a new method of deep laser cladding was used to process bionic units. By preplacing grooves then filling with WC powders and laser cladding, the bionic units had a larger dimension in depth and higher microhardness. Fe powder with different proportions from 30% (wt.) to 60% (wt.) was added into WC before laser processing for a good incorporation with CGI substrate. The improved laser cladding units turned out to induce higher wear resistance in comparison with laser remelting ones. The depth of the layer reached up to 1 mm. The results of dry sliding wear tests indicated that the specimen processed by laser cladding has a remarkable improvement than the ones processed by laser remelting. It should be noted that the wear mass loss was essentially dependent on the increase in WC proportion.

  9. Analysis of Monolith Cores from an Engineering Scale Demonstration of a Prospective Cast Stone Process

    SciTech Connect

    Crawford, C. L.; Cozzi, A. D.; Hill, K. A.

    2016-06-01

    The primary disposition path of Low Activity Waste (LAW) at the DOE Hanford Site is vitrification. A cementitious waste form is one of the alternatives being considered for the supplemental immobilization of the LAW that will not be treated by the primary vitrification facility. Washington River Protection Solutions (WRPS) has been directed to generate and collect data on cementitious or pozzolanic waste forms such as Cast Stone. This report documents the coring and leach testing of monolithic samples cored from an engineering-scale demonstration (ES Demo) with non-radioactive simulants. The ES Demo was performed at SRNL in October of 2013 using the Scaled Continuous Processing Facility (SCPF) to fill an 8.5 ft. diameter x 3.25 ft. high container with simulated Cast Stone grout. The Cast Stone formulation was chosen from the previous screening tests. Legacy salt solution from previous Hanford salt waste testing was adjusted to correspond to the average LAW composition generated from the Hanford Tank Waste Operation Simulator (HTWOS). The dry blend materials, ordinary portland cement (OPC), Class F fly ash, and ground granulated blast furnace slag (GGBFS or BFS), were obtained from Lafarge North America in Pasco, WA. In 2014 core samples originally obtained approximately six months after filling the ES Demo were tested along with bench scale molded samples that were collected during the original pour. A latter set of core samples were obtained in late March of 2015, eighteen months after completion of the original ES Demo. Core samples were obtained using a 2” diameter x 11” long coring bit. The ES Demo was sampled in three different regions consisting of an outer ring, a middle ring and an inner core zone. Cores from these three lateral zones were further segregated into upper, middle and lower vertical segments. Monolithic core samples were tested using the Environmental Protection Agency (EPA) Method 1315, which is designed to provide mass transfer rates

  10. Effect of Rotational Speeds on the Cast Tube During Vertical Centrifugal Casting Process on Appearance, Microstructure, and Hardness Behavior for Al-2Si Alloy

    NASA Astrophysics Data System (ADS)

    Shailesh Rao, A.; Tattimani, Mahantesh S.; Rao, Shrikantha S.

    2015-04-01

    The flow of molten metal plays a crucial role in determining casting quality. During rotation of the mold, melt flow around its inner circumference determines the final configurations and properties of the cast tube. In this paper, Al-2Si alloy is cast in the vertical mold at the various rotational speeds of the mold. The uniform cylinder tube is formed at a rotational speed of 1000 rpm, while before and beyond this speed, irregular-shaped cast tube is formed. Finally, fine structured grain size with high hardness value is found in uniform cast tube compared with others.

  11. ToxCast Workflow: High-throughput screening assay data processing, analysis and management (SOT)

    EPA Science Inventory

    US EPA’s ToxCast program is generating data in high-throughput screening (HTS) and high-content screening (HCS) assays for thousands of environmental chemicals, for use in developing predictive toxicity models. Currently the ToxCast screening program includes over 1800 unique c...

  12. ToxCast Workflow: High-throughput screening assay data processing, analysis and management (SOT)

    EPA Science Inventory

    US EPA’s ToxCast program is generating data in high-throughput screening (HTS) and high-content screening (HCS) assays for thousands of environmental chemicals, for use in developing predictive toxicity models. Currently the ToxCast screening program includes over 1800 unique c...

  13. Theoretical and experimental investigation of thermal behavior of a mold powder used in the continuous casting process

    NASA Astrophysics Data System (ADS)

    Supradist, Mawin

    Mold powders are added to the mold of a continuous caster to provide a source of the liquid flux that acts as a lubricant for the casting process. Varying the nature of this powder controls the formation of the liquid flux; however, little is understood about the mechanism of heating and fluid formation during casting. The purposes of this study are to develop a better understanding of the phenomena encountered during the heating of mold powders and to develop a model to describe this behavior and to predict the melting rate of mold powders. In the theoretical study, a mathematical model was developed to explain the heating, sintering and combustion of a casting powder. Transient state heat transfer, kinetics of the carbon combustion reaction, shrinkage of the casting powder, diffusion of all gaseous species through the casting powder were taken into account in the formulation of the mathematical model. The simulation results yielded both a quantitative and a qualitative understanding of the relationship between the temperature, concentration of each gas and the concentration of carbon developed within the powder layer during heating. In the experimental study, a one-directional heating apparatus was constructed that simulated the heating pattern in the continuous casting mold and allowed an investigation of the heating, sintering and combustion of the casting powder, to be performed. After the experiment, a variation of the carbon content along the powder column was measured and the presence of the carbon-enriched layer was documented. Finally, the simulation results were compared with the experimental results to validate the mathematical model. The match between them was found to be satisfactory. The validated model was then modified to take into account the addition and the consumption of the mold powder and the kinetics of the slag pool formation. The model was then used to predict the heating and melting behavior in an actual casting mold. The simulation

  14. A Neuroeconomics Analysis of Investment Process with Money Flow Information: The Error-Related Negativity

    PubMed Central

    Wang, Cuicui; Vieito, João Paulo; Ma, Qingguo

    2015-01-01

    This investigation is among the first ones to analyze the neural basis of an investment process with money flow information of financial market, using a simplified task where volunteers had to choose to buy or not to buy stocks based on the display of positive or negative money flow information. After choosing “to buy” or “not to buy,” participants were presented with feedback. At the same time, event-related potentials (ERPs) were used to record investor's brain activity and capture the event-related negativity (ERN) and feedback-related negativity (FRN) components. The results of ERN suggested that there might be a higher risk and more conflict when buying stocks with negative net money flow information than positive net money flow information, and the inverse was also true for the “not to buy” stocks option. The FRN component evoked by the bad outcome of a decision was more negative than that by the good outcome, which reflected the difference between the values of the actual and expected outcome. From the research, we could further understand how investors perceived money flow information of financial market and the neural cognitive effect in investment process. PMID:26557139

  15. A Neuroeconomics Analysis of Investment Process with Money Flow Information: The Error-Related Negativity.

    PubMed

    Wang, Cuicui; Vieito, João Paulo; Ma, Qingguo

    2015-01-01

    This investigation is among the first ones to analyze the neural basis of an investment process with money flow information of financial market, using a simplified task where volunteers had to choose to buy or not to buy stocks based on the display of positive or negative money flow information. After choosing "to buy" or "not to buy," participants were presented with feedback. At the same time, event-related potentials (ERPs) were used to record investor's brain activity and capture the event-related negativity (ERN) and feedback-related negativity (FRN) components. The results of ERN suggested that there might be a higher risk and more conflict when buying stocks with negative net money flow information than positive net money flow information, and the inverse was also true for the "not to buy" stocks option. The FRN component evoked by the bad outcome of a decision was more negative than that by the good outcome, which reflected the difference between the values of the actual and expected outcome. From the research, we could further understand how investors perceived money flow information of financial market and the neural cognitive effect in investment process.

  16. The influence of double flask investing on tooth displacement in dentures processed by microwave irradiation.

    PubMed

    Farias Neto, Arcelino; Sousa, Rodrigo L dos Santos; Rizzatti-Barbosa, Célia M

    2012-06-01

    This study evaluated the influence of the bimaxillary flask (BMF) and two different investing materials on first molar inclination in dentures processed by microwave irradiation. The BMF may minimise tooth displacement, saving time and improving occlusion. Forty pairs of dentures were randomised into four groups: stone wall in monomaxillary flask; silicone wall in BMF; stone wall in BMF; acrylic resin retentions and silicone in BMF. Dentures were processed by microwave irradiation. Two referential points were established on tooth surface. A microscope and a digital pachymeter were used to measure the distance between these points, and the angles α (right maxillary molar), β (left maxillary molar), α' (right mandibular molar) and β' (left mandibular molar) were calculated by the law of cosines. Data were submitted to Kruskal-Wallis (5% significance). No difference was observed among the groups (p > 0.05). In the intra-group analysis, α was significantly different for groups I, II and III; α', for groups II and IV; β, for all groups; β', for groups III and IV. First molar inclination was similar for monomaxillary and BMFs. The use of stone or silicone as investing materials presented the same effect on tooth inclination. © 2011 The Gerodontology Society and John Wiley & Sons A/S.

  17. 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.

  18. Microstructure Analysis on 6061 Aluminum Alloy after Casting and Diffuses Annealing Process

    NASA Astrophysics Data System (ADS)

    Wang, H. Q.; Sun, W. L.; Xing, Y. Q.

    One factory using semi-continuous casting process produce the ф200×6000 mm 6061 aluminium alloy barstock, and then rotary forged for car wheels. 6061 distorting aluminium alloy is an forged aluminum alloy, and mainly containing Mg, Si, Cu and other alloying elements. The main strengthening phase is Mg2Si, and also has few phase of (FeMn) 3Si2Al15. In order to eliminate the segregation and separation which present in the crystal boundary, and make the distortion to be uniform, and does not present ear and fracture defects after the forging. So the 6061 distorting aluminium alloy adopt the diffusion annealing heat treatment before the forging process.According to the current conditions, we use the diffusion annealing which have the different heating temperature and different holding time.The best process we can obtain from the test which can improve the production efficiency and reduce the material waste, improve the mechanical properties, and eliminate the overheated film on the surface.Then,we using OM,SEM and EDS to analyse the microstructure and the chemical composition of compound between the surface and centre. The result shows that the amount of segregation were different in the surface and in the center, and the different diffusion annealing can cause the phase change in the surface and the center.

  19. Superior Weapons Systems Through Castings (SWC)

    DTIC Science & Technology

    2012-11-30

    Steel Castings: Principal Investigator Dr. John Griffin, University of Alabama at Birmingham 65 5. Industry Capabilities for Preparedness and...Advanced Aluminum Metal Matrix Composites for Sand and Investment Casting Applications: Principal Investigator Kenneth Kremer, M Cubed Technologies, Inc...Investment Shells used with Foam Patterns: Principal Investigators Dr. Von L. Richards, Missouri University of Science and Technology 185 10. Steel

  20. Effect of process variables on the crack in laser cladded Ni-alloy on ductile cast iron

    NASA Astrophysics Data System (ADS)

    Li, Qindong; Liu, Jichang

    2010-11-01

    Laser cladding was performed on the ductile cast iron substrate with Ni-base alloy under different process conditions. The cracks were observed. The temperature field and stress field in laser cladding under different process conditions were simulated with ANSYS finite element software. It was found that cracks were influenced by process variables. In certain ranges of laser power and scanning speed, while the other process parameters remain constant, the numbers of cracks increase with laser power increasing. Similarly the number of cracks increases with scanning velocity increasing while the other process parameters remain constant. In comparison with experimental results, the simulation with ANSYS finite element software could help to predict, to some extent, the crack of laser cladded Ni-alloy on ductile cast iron.

  1. Anisotropic constitutive model and FE simulation of the sintering process of slip cast traditional porcelain

    NASA Astrophysics Data System (ADS)

    Sarbandi, B.; Besson, J.; Boussuge, M.; Ryckelynck, D.

    2010-06-01

    Slip cast ceramic components undergo both sintering shrinkage and creep deformation caused by gravity during the firing cycle. In addition sintering may be anisotropic due to the development of preferential directions during slip casting. Both phenomena induce complex deformations of parts which make the design of casting molds difficult. To help solving this problem, anisotropic constitutive equations are proposed to represent the behavior of the ceramic compacts during sintering. The model parameters are identified using tests allowing to characterize both sintering and creep. The model was implemented in a finite element software and used to simulate the deformation of a traditional ceramic object during sintering.

  2. Anisotropic constitutive model and FE simulation of the sintering process of slip cast traditional porcelain

    SciTech Connect

    Sarbandi, B.; Besson, J.; Boussuge, M.; Ryckelynck, D.

    2010-06-15

    Slip cast ceramic components undergo both sintering shrinkage and creep deformation caused by gravity during the firing cycle. In addition sintering may be anisotropic due to the development of preferential directions during slip casting. Both phenomena induce complex deformations of parts which make the design of casting molds difficult. To help solving this problem, anisotropic constitutive equations are proposed to represent the behavior of the ceramic compacts during sintering. The model parameters are identified using tests allowing to characterize both sintering and creep. The model was implemented in a finite element software and used to simulate the deformation of a traditional ceramic object during sintering.

  3. Large Eddy Simulation of Transient Flow, Solidification, and Particle Transport Processes in Continuous-Casting Mold

    NASA Astrophysics Data System (ADS)

    Liu, Zhongqiu; Li, Linmin; Li, Baokuan; Jiang, Maofa

    2014-07-01

    The current study developed a coupled computational model to simulate the transient fluid flow, solidification, and particle transport processes in a slab continuous-casting mold. Transient flow of molten steel in the mold is calculated using the large eddy simulation. An enthalpy-porosity approach is used for the analysis of solidification processes. The transport of bubble and non-metallic inclusion inside the liquid pool is calculated using the Lagrangian approach based on the transient flow field. A criterion of particle entrapment in the solidified shell is developed using the user-defined functions of FLUENT software (ANSYS, Inc., Canonsburg, PA). The predicted results of this model are compared with the measurements of the ultrasonic testing of the rolled steel plates and the water model experiments. The transient asymmetrical flow pattern inside the liquid pool exhibits quite satisfactory agreement with the corresponding measurements. The predicted complex instantaneous velocity field is composed of various small recirculation zones and multiple vortices. The transport of particles inside the liquid pool and the entrapment of particles in the solidified shell are not symmetric. The Magnus force can reduce the entrapment ratio of particles in the solidified shell, especially for smaller particles, but the effect is not obvious. The Marangoni force can play an important role in controlling the motion of particles, which increases the entrapment ratio of particles in the solidified shell obviously.

  4. Process-directed self-assembly of multiblock copolymers: Solvent casting vs spray coating

    NASA Astrophysics Data System (ADS)

    Tang, Q.; Tang, J.; Müller, M.

    2016-10-01

    Using computer simulation of a soft, coarse-grained model and self-consistent field theory we investigate how collapsed, globular chain conformations in the initial stages of structure formation, which are produced by spray-coating, affect the single-chain structure and morphology of microphase-separated multiblock copolymers. Comparing spray-coated films with films that start from a disordered state of Gaussian chains, we observe that the collapsed molecular conformations in the initial stage give rise to (1) a smaller fraction of blocks that straddle domains (bridges), (2) a significant reduction of the molecular extension normal to the internal interfaces, and (3) a slightly larger lamellar domain spacing in the final morphology. The relaxation of molecular conformations towards equilibrium is very protracted for both processes - solvent casting and spray coating. These findings illustrate that the process conditions of the copolymer materials may significantly affect materials properties (such as mechanical properties) because the system does not reach thermal equilibrium on the relevant time scales.

  5. Metal particle compaction during drop-substrate impact for inkjet printing and drop-casting processes

    NASA Astrophysics Data System (ADS)

    Clancy, I.; Amarandei, G.; Nash, C.; Glowacki, B. A.

    2016-02-01

    Direct coating methods using metal particles from aqueous solutions or solvent-based inks become central in the roll-to-roll fabrication processes as these methods can lead to continuous or pre-defined conductive layers on a large variety of substrates. For good electrical conductivity, the metal particles have to be brought into contact, and traditionally, additional sintering treatments are required. Such treatments can degrade the sensitive substrates as paper or polymer films. In this study, the possibility of obtaining conductive layers at room temperature is investigated for direct coating methods with an emphasis on drop-casting and inkjet printing. Thus, it is shown that electrical conductive layers can be achieved if the metal particles can compact during the drop-substrate impact interaction. It is theoretically shown that the compaction process is directly related to the particle and ink drop size, the initial fractional particle loading of the ink, solvent viscosity, and drop velocity. The theoretical predictions on compaction are experimentally validated, and the particle compaction's influence on changes in the electrical conductivity of the resulting layers is demonstrated.

  6. Hydrosol droplet casting process for production of nuclear fuel and breeder material granules

    SciTech Connect

    Langen, H.; Ringel, H.; Zimmer, E.

    1980-03-18

    A hydrosol containing, in nitrate form, a fuel or fuel-andbreeder material which is projected horizontally in the form of droplets into a gas phase containing gaseous ammonia and allowed to fall in a drip-casting column into a precipitation bath containing ammonium hydroxide. In the gas phase, the droplets are hardened just enough to prevent their deformation upon penetrating into the precipitation bath where the hardening is completed. A falling height of 5 cm is suitable. The granules are washed free of ammonium nitrate, then dried, and then sintered. The heavy metal content in the hydrosol is between 1.5 and 3 moles per liter, and the pH value of the precipitation bath is between 8 and 9. The hydrosol contains the heavy metal in oxide form and the process can be used with a thorium oxide hydrosol or a hydrosol that, in addition to thorium oxide, contains the oxide of hexavalent uranium, in the latter case the hexavalent uranium being present in a proportion up to 25% by weight of the total heavy metal. The process is also applicable to producing kernels of mixed thorium and plutonium oxides. In the case of uraniumcontaining granules, the sintering step is carried out in a reducing atmosphere to convert the uranium to the tetravalent state.

  7. LLNL casting technology

    SciTech Connect

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

    1994-01-01

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

  8. Experimental investigation of the start-up phase during direct chill and low frequency electromagnetic casting of 6063 aluminum alloy processes

    NASA Astrophysics Data System (ADS)

    Wang, Xiangjie; Zhang, Haitao; Zhao, Zhihao; Zhu, Qingfeng; Wang, Gaosong; Jiang, Huixue; Cui, Jianzhong

    2010-06-01

    On the basis of conventional hot-top casting and Casting, Refining and Electromagnetic process, a lower frequency electromagnetic field was applied during the conventional hot-top casting process. Nine thermocouples (type K) were introduced into the metal to study the temperature profile in the ingot during the start-up phase of casting process. The experimental results show that under the effect of the low frequency electromagnetic filed, the heat transfer is changed greatly and the film boiling disappears, which could restrain the formation of fine subsurface cracks; the sump is shallow, and the macrostructure of the ingot butt is fine during the start-up phase of direct chill casting process.

  9. The direct strip casting concept: A low-cost, high-productivity solution for flat products of all steel grades

    SciTech Connect

    Reichelt, W.; Urlau, U.; Burstroem, E.; Nystroem, R.

    1996-12-31

    The Direct Strip Casting concept is characterized by a high degree of flexibility as regards the types of steel to be cast, at the same time guaranteeing a high production rate and low investment costs. It has been planned to cast strips of all steel grades with a thickness of approx. 10 mm. These strips will not be directly transferred to a cold rolling mill but will undergo two or three hot passes before being wound into a coil. A comparison of the economic feasibility of the DSC process with other near net shape casting processes shows that this process is suitable for small as well as large production rates (up to million tpy/strand) because of the low investment and operating costs. Casting and rolling tests performed in a pilot casting machine and in a casting machine for laboratory purposes show potentially that: the crucial element of the DSC process, the belt caster, is sufficiently stable to attain the required final strip geometry already at the time of casting; the hot shaping envisaged in the DSC concept is sufficient to remove a lack of symmetry that may arise during casting; and the rolling passes envisaged in the DSC concept are necessary and yet at the same time adequate for achieving material properties, for example, sufficiently high r-values for deep drawing grades.

  10. Correlation of solar cell electrical properties with material characteristics of silicon cast by the ubiquitous crystallization process

    NASA Technical Reports Server (NTRS)

    Hyland, S.; Leung, D.; Morrison, A.; Stika, K.; Yoo, H.

    1983-01-01

    Solar cells were fabricated using a conservative 'baseline' process on 1-3 Omega-cm p-type silicon from ingots cast by the ubiquitous crystallization process. Conversion efficiencies of the cells were measured, as well as spectral response and minority carrier diffusion length. Adjacent slices from the same ingot were studied for their grain size, dislocation distribution, and impurity distribution. Cell performance was related to the observed structural features, as well as to the chemical structure of the ingot.

  11. Correlation of solar cell electrical properties with material characteristics of silicon cast by the ubiquitous crystallization process

    NASA Technical Reports Server (NTRS)

    Hyland, S.; Leung, D.; Morrison, A.; Stika, K.; Yoo, H.

    1983-01-01

    Solar cells were fabricated using a conservative 'baseline' process on 1-3 Omega-cm p-type silicon from ingots cast by the ubiquitous crystallization process. Conversion efficiencies of the cells were measured, as well as spectral response and minority carrier diffusion length. Adjacent slices from the same ingot were studied for their grain size, dislocation distribution, and impurity distribution. Cell performance was related to the observed structural features, as well as to the chemical structure of the ingot.

  12. Effect of medium on friction and wear properties of compacted graphite cast iron processed by biomimetic coupling laser remelting process

    NASA Astrophysics Data System (ADS)

    Guo, Qing-chun; Zhou, Hong; Wang, Cheng-tao; Zhang, Wei; Lin, Peng-yu; Sun, Na; Ren, Luquan

    2009-04-01

    Stimulated by the cuticles of soil animals, an attempt to improve the wear resistance of compact graphite cast iron (CGI) with biomimetic units on the surface was made by using a biomimetic coupled laser remelting process in air and various thicknesses water film, respectively. The microstructures of biomimetic units were examined by scanning electron microscope and X-ray diffraction was used to describe the microstructure and identify the phases in the melted zone. Microhardness was measured and the wear behaviors of biomimetic specimens as functions of different mediums as well as various water film thicknesses were investigated under dry sliding condition, respectively. The results indicated that the microstructure zones in the biomimetic specimens processed with water film are refined compared with that processed in air and had better wear resistance increased by 60%, the microhardness of biomimetic units has been improved significantly. The application of water film provided finer microstructures and much more regular grain shape in biomimetic units, which played a key role in improving the friction properties and wear resistance of CGI.

  13. Process for casting hard-faced, lightweight camshafts and other cylindrical products

    SciTech Connect

    Hansen, Jeffrey S.; Turner, Paul C.; Argetsinger, Edward R.; Wilson, Rick D.

    1996-01-01

    A process for casting a hard-faced cylindrical product such as an automobile camshaft includes the steps of: (a) preparing a composition formed from a molten base metal and an additive in particle form and having a hardness value greater than the hardness value of the base metal; (b) introducing the composition into a flask containing a meltable pattern of a cylindrical product such as an automobile camshaft to be manufactured and encased in sand to allow the composition to melt the pattern and assume the shape of the pattern within the sand; and (c) rotating the flask containing the pattern about the longitudinal axes of both the flask and the pattern as the molten base metal containing the additive in particle form is introduced into the flask to cause particles of the additive entrained in the molten base metal to migrate by centrifugal action to the radial extremities of the pattern and thereby provide a cylindrical product having a hardness value greater at it's radial extremities than at its center when the molten base metal solidifies.

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

    PubMed

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

    2006-06-20

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

  15. Center Segregation with Final Electromagnetic Stirring in Billet Continuous Casting Process

    NASA Astrophysics Data System (ADS)

    Jiang, Dongbin; Zhu, Miaoyong

    2017-02-01

    With a multiphase solidification model built, the effect of F-EMS parameters on center segregation was investigated in 160 mm × 160 mm billet continuous casting process. In the model, the initial growth of equiaxed grains which could move freely with liquid was treated as slurry, while the coherent equiaxed zone was regarded as porous media. The results show that the stirring velocity is not the main factor influencing center segregation improvement, which is more affected by current intensity and stirring pool width. Because solute transport is controlled by solidification rate as stirring pool width is 73 mm, center segregation declines continuously with current intensity increasing. As liquid pool width decreases to 61 mm and less latent heat needs to dissipate in the later solidification, the center segregation could be improved more obviously by F-EMS. Due to center liquid solute enrichment and liquid phase accumulation in the stirring zone, center segregation turns to rise reversely with higher current intensity and becomes more serious with stirring pool width further decreasing to 43 mm. As the stirring pool width is 25 mm, the positive segregation has already formed and solute could still concentrate with weak stirring, leading to center segregation deterioration. With the optimized current intensity (400 A) and stirring pool width (61 mm) set for continuous mode, center segregation improvement is better than that of alternative mode.

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

    NASA Astrophysics Data System (ADS)

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

    2006-06-01

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

  17. Energy Saving Melting and Revert Reduction (E-SMARRT): Precision Casting of Steel

    SciTech Connect

    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 inspection 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

  18. Isotope biogeochemical assessment of natural biodegradation processes in open cast pit mining landscapes

    NASA Astrophysics Data System (ADS)

    Jeschke, Christina; Knöller, Kay; Koschorreck, Matthias; Ussath, Maria; Hoth, Nils

    2014-05-01

    In Germany, a major share of the energy production is based on the burning of lignite from open cast pit mines. The remediation and re-cultivation of the former mining areas in the Lusatian and Central German lignite mining district is an enormous technical and economical challenge. After mine closures, the surrounding landscapes are threatened by acid mine drainage (AMD), i.e. the acidification and mineralization of rising groundwater with metals and inorganic contaminants. The high content of sulfur (sulfuric acid, sulfate), nitrogen (ammonium) and iron compounds (iron-hydroxides) deteriorates the groundwater quality and decelerates sustainable development of tourism in (former) mining landscapes. Natural biodegradation or attenuation (NA) processes of inorganic contaminants are considered to be a technically low impact and an economically beneficial solution. The investigations of the stable isotope compositions of compounds involved in NA processes helps clarify the dynamics of natural degradation and provides specific informations on retention processes of sulfate and nitrogen-compounds in mine dump water, mine dump sediment, and residual pit lakes. In an active mine dump we investigated zones where the process of bacterial sulfate reduction, as one very important NA process, takes place and how NA can be enhanced by injecting reactive substrates. Stable isotopes signatures of sulfur and nitrogen components were examined and evaluated in concert with hydrogeochemical data. In addition, we delineated the sources of ammonium pollution in mine dump sediments and investigated nitrification by 15N-labeling techniques to calculate the limit of the conversion of harmful ammonium to nitrate in residual mining lakes. Ultimately, we provided an isotope biogeochemical assessment of natural attenuation of sulfate and ammonium at mine dump sites and mining lakes. Also, we estimated the risk potential for water in different compartments of the hydrological system. In

  19. The Through Process Simulation of Mold filling, Solidification, and Heat Treatment of the Al Alloy Bending Beam Low-pressure Casting

    NASA Astrophysics Data System (ADS)

    Yin, Yajun; Zhou, Jianxin; Guo, Zhao; Wang, Huan; Liao, Dunming; Chen, Tao

    2015-06-01

    The research on the simulation for the through process of low-pressure casting and heat treatment is conducive to combine information technology and advanced casting technology, which will help to predict the defects and mechanical properties of the castings in the through process. In this paper, we focus on the simulation for through process of low-pressure casting and heat treatment of ZL114A Bending beam. Firstly, we analyzethe distribution of the shrinkage and porosities in filling and solidification process, and simulate the distribution of stress and strain in the late solidification of casting. Then, the numerical simulation of heat treatment process for ZL114A Bending beam is realized according to the heat treatment parameters and the corresponding simulation results of temperature field, stress, strain, and aging performance are given. Finally, we verify that simulation platform for the through process of low-pressure casting and heat treatment can serve the production practice perfectly and provide technical guidance and process optimization for the through process of low-pressure casting and heat treatment.

  20. Casting alloys.

    PubMed

    Wataha, John C; Messer, Regina L

    2004-04-01

    Although the role of dental casting alloys has changed in recent years with the development of improved all-ceramic materials and resin-based composites, alloys will likely continue to be critical assets in the treatment of missing and severely damaged teeth. Alloy shave physical, chemical, and biologic properties that exceed other classes of materials. The selection of the appropriate dental casting alloy is paramount to the long-term success of dental prostheses,and the selection process has become complex with the development of many new alloys. However, this selection process is manageable if the practitioner focuses on the appropriate physical and biologic properties, such as tensile strength, modulus of elasticity,corrosion, and biocompatibility, and avoids dwelling on the less important properties of alloy color and short-term cost. The appropriate selection of an alloy helps to ensure a longer-lasting restoration and better oral health for the patient.

  1. SLIP CASTING METHOD

    DOEpatents

    Allison, A.G.

    1959-09-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2010-02-01

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

  3. Microstructure and mechanical properties of an as-cast AZ91 magnesium alloy processed by equal channel angular pressing

    NASA Astrophysics Data System (ADS)

    Chung, C. W.; Ding, R. G.; Chiu, Y. L.; Hodgson, M. A.; Gao, W.

    2009-08-01

    An as-cast AZ91 magnesium alloy was processed by equal channel angular pressing (ECAP) at 593K and its microstructure and mechanical properties were studied using electron microscopy and room temperature tensile tests, respectively. It has been found that after the first pass of ECAP, the grain size of the alloy shows a bi-modal distribution, containing fine grains of about 14 μm and large dendrite structure. The dendritic structure completely disappeared after two passes of ECAP. The average grain size of the alloy after six passes of ECAP becomes less than 10 μm. The yield stress of the alloy has significantly increased from 65 MPa of the as-cast alloy to 135 MPa after the first pass of ECAP, but does not show much change with further ECAP. However, the elongation to failure measured from the alloy processed by the first pass of ECAP is similar to that measured from the as-cast alloy. A noticeable increase of the elongation to failure has been observed after the second pass of ECAP, which then remains at the similar level with further ECAP process. The fractography of the tensile tested samples have been studied using scanning electron microscope (SEM) and focused ion beam (FIB) microscope. The facture surface of the as-cast alloy is predominated by cleavages. Although not predominantly, cleavage has also been frequently observed in the alloy processed by one pass of ECAP. With further ECAP process, the facture surface becomes profuse in dimples, characteristic of ductile facture, consistent with the ductility change observed. FIB observation suggests that the cracking is mainly initiated at the blocky particles.

  4. Statistical Study to Evaluate the Effect of Processing Variables on Shrinkage Incidence During Solidification of Nodular Cast Irons

    NASA Astrophysics Data System (ADS)

    Gutiérrez, J. M.; Natxiondo, A.; Nieves, J.; Zabala, A.; Sertucha, J.

    2017-01-01

    The study of shrinkage incidence variations in nodular cast irons is an important aspect of manufacturing processes. These variations change the feeding requirements on castings and the optimization of risers' size is consequently affected when avoiding the formation of shrinkage defects. The effect of a number of processing variables on the shrinkage size has been studied using a layout specifically designed for this purpose. The β parameter has been defined as the relative volume reduction from the pouring temperature up to the room temperature. It is observed that shrinkage size and β decrease as effective carbon content increases and when inoculant is added in the pouring stream. A similar effect is found when the parameters selected from cooling curves show high graphite nucleation during solidification of cast irons for a given inoculation level. Pearson statistical analysis has been used to analyze the correlations among all involved variables and a group of Bayesian networks have been subsequently built so as to get the best accurate model for predicting β as a function of the input processing variables. The developed models can be used in foundry plants to study the shrinkage incidence variations in the manufacturing process and to optimize the related costs.

  5. Combined multi-nozzle deposition and freeze casting process to superimpose two porous networks for hierarchical three-dimensional microenvironment.

    PubMed

    Snyder, Jessica E; Hunger, Philipp M; Wang, Chengyang; Hamid, Qudus; Wegst, Ulrike G K; Sun, Wei

    2014-03-01

    An engineered three-dimensional scaffold with hierarchical porosity and multiple niche microenvironments is produced using a combined multi-nozzle deposition-freeze casting technique. In this paper we present a process to fabricate a scaffold with improved interconnectivity and hierarchical porosity. The scaffold is produced using a two-stage manufacturing process which superimposes a printed porous alginate (Alg) network and a directionally frozen ceramic-polymer matrix. The combination of two processes, multi-nozzle deposition and freeze casting, provides engineering control of the microenvironment of the scaffolds over several length scales; including the addition of lateral porosity and the ratio of polymer to ceramic microstructures. The printed polymer scaffold is submerged in a ceramic-polymer slurry and subsequently, both structures are directionally frozen (freeze cast), superimposing and patterning both microenvironments into a single hierarchical architecture. An optional additional sintering step removes the organic material and densifies the ceramic phase to produce a well-defined network of open pores and a homogenous cell wall material composition. The techniques presented in this contribution address processing challenges, such as structure definition, reproducibility and fine adjustments of unique length scales, which one typically encounters when fabricating topological channels between longitudinal and transverse porous networks.

  6. Statistical Study to Evaluate the Effect of Processing Variables on Shrinkage Incidence During Solidification of Nodular Cast Irons

    NASA Astrophysics Data System (ADS)

    Gutiérrez, J. M.; Natxiondo, A.; Nieves, J.; Zabala, A.; Sertucha, J.

    2017-04-01

    The study of shrinkage incidence variations in nodular cast irons is an important aspect of manufacturing processes. These variations change the feeding requirements on castings and the optimization of risers' size is consequently affected when avoiding the formation of shrinkage defects. The effect of a number of processing variables on the shrinkage size has been studied using a layout specifically designed for this purpose. The β parameter has been defined as the relative volume reduction from the pouring temperature up to the room temperature. It is observed that shrinkage size and β decrease as effective carbon content increases and when inoculant is added in the pouring stream. A similar effect is found when the parameters selected from cooling curves show high graphite nucleation during solidification of cast irons for a given inoculation level. Pearson statistical analysis has been used to analyze the correlations among all involved variables and a group of Bayesian networks have been subsequently built so as to get the best accurate model for predicting β as a function of the input processing variables. The developed models can be used in foundry plants to study the shrinkage incidence variations in the manufacturing process and to optimize the related costs.

  7. Effect of Stress Ratio on the Fatigue Behavior of a Friction Stir Processed Cast Al-Si-Mg Alloy

    SciTech Connect

    Jana, Saumyadeep; Mishra, Rajiv S.; Baumann, John B.; Grant, Glenn J.

    2009-11-01

    The effect of friction stir processing (FSP) on the fatigue life of a cast Al-7Si-0.6Mg alloy at a stress ratio of R=0 was evaluated. Two types of specimen geometry were used for the FSPed condition, through-thickness processed and partial thickness processed. FSP enhanced the fatigue life by a factor of 15 for the through thickness processed samples at lower stress amplitudes. This is different from the FSP specimens tested at R=-1 and similar stress amplitudes where a 5 times improvement in fatigue life was observed. In light of these observations, various closure mechanisms were examined.

  8. 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.

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

    NASA Astrophysics Data System (ADS)

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

    2017-03-01

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

  10. Hot Deformation Behaviors and Processing Maps of 2024 Aluminum Alloy in As-cast and Homogenized States

    NASA Astrophysics Data System (ADS)

    Chen, Liang; Zhao, Guoqun; Gong, Jie; Chen, Xiaoxue; Chen, Mengmeng

    2015-12-01

    The isothermal hot compression tests of as-cast and homogenized 2024 aluminum alloy were carried out under wide range of deformation temperatures (623-773 K) and strain rates (0.001-10 s-1). The constitutive equations for both initial states were established based on Arrhenius model, and the processing maps were constructed based on the dynamic material model. The results show that the flow stress of samples is evidently affected by both the strain rate and deformation temperature, and the flow stress in homogenized state is always higher than that in as-cast state. Through calculating the correlation coefficient ( R) and average absolute relative error of the established constitutive equations, it indicates that Arrhenius model can only provide a rough estimation on the flow stress. However, a much more precise value of the flow stress was obtained by introducing the strain compensation into Arrhenius model, since the effects of strain on the material constants were well considered. Furthermore, according to the processing maps, a suggested range of deformation temperature and strain rate for hot forming process were given then: temperature range 710-773 K and strain rate range 0.001-1 s-1 for as-cast state, and temperature range 680-773 K and strain rate range 0.003-0.22 s-1 for homogenized state.

  11. Influence of Process Parameters on Microstructure and Mechanical Properties of Friction-Stir-Processed Mg-Gd-Y-Zr Casting

    NASA Astrophysics Data System (ADS)

    Yang, Q.; Xiao, B. L.; Ma, Z. Y.

    2012-06-01

    Mg-10Gd-3Y-0.5Zr (wt pct) casting was subjected to friction stir processing (FSP) at a constant rotation rate of 800 rpm and varied travel speeds of 25, 50, and 100 mm/minute. FSP resulted in the generation of fine-grained microstructure and fundamental dissolution of coarse Mg5(Gd,Y) phase at the grain boundaries, thereby enhancing the tensile properties significantly at both room and elevated temperatures. The grain size of the FSP samples decreased with the increasing travel speed, whereas the microstructure heterogeneity with the banded structure (onion rings) became evident at a higher travel speed. Tensile elongation of the FSP samples increased as the travel speed increased, whereas the highest strengths were obtained at the medium travel speed of 50 mm/minute. Higher strengths and greater elongations were observed for the FSP samples in the transverse direction (TD) than in the longitudinal direction (LD). After post-FSP aging, the strengths of the FSP samples were increased significantly with the TD and LD exhibiting the same strengths; however, the elongation was decreased remarkably with the TD having higher elongation than the LD. A variation of the tensile properties was discussed in detail based on the microstructure heterogeneity and fracture surfaces.

  12. Mathematical Modeling of the Twin Roll Casting Process for AZ31 Magnesium Alloy - Effect of Set-Back Distance

    NASA Astrophysics Data System (ADS)

    Hadadzadeh, Amir; Wells, Mary; Essadiqi, Elhachmi

    A 2-D coupled thermal-fluid-stress model was developed and used to simulate the twin roll casting (TRC) of an AZ31 magnesium alloy using the commercial software package, ALSIM. The model was used to predict the fluid flow, temperature distribution and mechanical behavior of AZ31 magnesium alloy in the roll bite. An important parameter in controlling the TRC process is the set-back distance; the distance between the nozzle entry to the kissing point of the rolls. There are two approaches to increase the set-back: 1) increasing the entry thickness and 2) decreasing the final strip thickness. In this study the effect of set-back distance and casting speed on the thermo-mechanical behavior of the strip during TRC has been studied. The thermo-mechanical behavior of the strip has a significant effect on the final quality as defect formation depends on such behavior.

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

    NASA Astrophysics Data System (ADS)

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

    2004-06-01

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

  14. Processing and Characterization of Functionally Graded Aluminum (A319)—SiCp Metallic Composites by Centrifugal Casting Technique

    NASA Astrophysics Data System (ADS)

    Jayakumar, E.; Jacob, Jibin C.; Rajan, T. P. D.; Joseph, M. A.; Pai, B. C.

    2016-08-01

    Functionally graded materials (FGM) are successfully adopted for the design and fabrication of engineering components with location-specific properties. The present study describes the processing and characterization of A319 Aluminum functionally graded metal matrix composites (FGMMC) with 10 and 15 wt pct SiCp reinforcements. The liquid stir casting method is used for composite melt preparation followed by FGMMC formation by vertical centrifugal casting method. The process parameters used are the mold preheating temperature of 523 K (250 °C), melt pouring temperature of 1013 K (740 °C), and mold rotation speed of 1300 rpm. The study analyzes the distribution and concentration of reinforcement particles in the radial direction of the FGMMC disk along with the effects of gradation on density, hardness, mechanical strength, the variation in coefficient of thermal expansion and the wear resistance properties at different zones. Microstructures of FGMMC reveal an outward radial gradient distribution of reinforcements forming different zones. Namely, matrix-rich inner, transition, particles-rich outer, and chill zone of a few millimeters thick at the outer most periphery of the casting are formed. From 10-FGM, a radial shift in the position of SiCp maxima is observed in 15-FGM casting. The mechanical characterization depicts enhanced properties for the particle-rich zone. The hardness shows a graded nature in correlation with particle concentration and a maximum of 94.4 HRB has been obtained at the particle-rich region of 15-FGM. In the particle-rich zone, the lowest CTE value of 20.1 µm/mK is also observed with a compressive strength of 650 MPa and an ultimate tensile strength of 279 MPa. The wear resistance is higher at the particle-rich zone of the FGMMC.

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

    SciTech Connect

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

    2012-09-30

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

  16. Process-conditioned investing with incomplete information using maximum causal entropy

    NASA Astrophysics Data System (ADS)

    Ziebart, Brian D.

    2012-05-01

    Investing to optimally maximize the growth rate of wealth based on sequences of event outcomes has many information-theoretic interpretations. Namely, the mutual information characterizes the benefit of additional side information being available when making investment decisions [1] in settings where the probabilistic relationships between side information and event outcomes are known. Additionally, the relative variant of the principle of maximum entropy [2] provides the optimal investment allocation in the more general setting where the relationships between side information and event outcomes are only partially known [3]. In this paper, we build upon recent work characterizing the growth rates of investment in settings with inter-dependent side information and event outcome sequences [4]. We consider the extension to settings with inter-dependent event outcomes and side information where the probabilistic relationships between side information and event outcomes are only partially known. We introduce the principle of minimum relative causal entropy to obtain the optimal worst-case investment allocations for this setting. We present efficient algorithms for obtaining these investment allocations using convex optimization techniques and dynamic programming that illustrates a close connection to optimal control theory.

  17. Evolution of halictine castes

    NASA Astrophysics Data System (ADS)

    Knerer, Gerd

    1980-03-01

    Social halictine bees have female castes that range from species with no size differences to those with a discrete bimodality. Female caste differences are inversely correlated with the number of males produced in the first brood. It is proposed that the sexual dimorphism of solitary forms is being usurped by the female caste system of species in the process of turning social. Thus, caste differences and summer male suppression are greatest in the social species originating from solitary precursors with distinct sexual dimorphism, and are least in species evolving from solitary ancestors with a continuous sexual polymorphism.

  18. Effect of TurboSwirl Structure on an Uphill Teeming Ingot Casting Process

    NASA Astrophysics Data System (ADS)

    Bai, Haitong; Ersson, Mikael; Jönsson, Pär

    2015-12-01

    To produce high-quality ingot cast steel with a better surface quality, it would be beneficial for the uphill teeming process if a much more stable flow pattern could be achieved in the runners. Several techniques have been utilized in the industry to try to obtain a stable flow of liquid steel, such as a swirling flow. Some research has indicated that a swirl blade inserted in the horizontal and vertical runners, or some other additional devices and physics could generate a swirling flow in order to give a lower hump height, avoid mold flux entrapment, and improve the quality of the ingot products, and a new swirling flow generation component, TurboSwirl, was introduced to improve the flow pattern. It has recently been demonstrated that the TurboSwirl method can effectively reduce the risk of mold flux entrapment, lower the maximum wall shear stress, and decrease velocity fluctuations. The TurboSwirl is built at the elbow of the runners as a connection between the horizontal and vertical runners. It is located near the mold and it generates a tangential flow that can be used with a divergent nozzle in order to decrease the axial velocity of the vertical flow into the mold. This stabilizes flow before the fluid enters the mold. However, high wall shear stresses develop at the walls due to the fierce rotation in the TurboSwirl. In order to achieve a calmer flow and to protect the refractory wall, some structural improvements have been made. It was found that by changing the flaring angle of the divergent nozzle, it was possible to lower the axial velocity and wall shear stress. Moreover, when the vertical runner and the divergent nozzle were not placed at the center of the TurboSwirl, quite different flow patterns could be obtained to meet to different requirements. In addition, the swirl numbers of all the cases mentioned above were calculated to ensure that the swirling flow was strong enough to generate a swirling flow of the liquid steel in the TurboSwirl.

  19. Anisotropic Responses of Mechanical and Thermal Processed Cast Al-Si-Mg-Cu Alloy

    NASA Astrophysics Data System (ADS)

    Adeosun, S. O.; Akpan, E. I.; Balogun, S. A.; Onoyemi, O. K.

    2015-05-01

    The effects of ambient directional rolling and heat treatments on ultimate tensile strength (UTS), hardness (HD), percent elongation (PE), and impact energy (IE) on Al-Si-Mg-Cu alloy casting with reference to inclination to rolling direction are discussed in this article. The results show that rolled and quenched (CQ) sample possess superior UTS and HD to as-cast and those of rolled and aged samples (CA). Improved IE resistance with ductility is shown by both CQ and CA samples. However, these mechanical properties are enhanced as changes in the test sample direction moved away from rolling direction for all heat-treated samples. The CQ samples displayed highest tensile strength (108 MPa) and PE (19.8%) in the 90° direction.

  20. Processing, Microstructure and Mechanical Behavior of Ultrasonic Assisted Cast Magnesium 1wt% Silicon Carbide Nano-Composites

    NASA Astrophysics Data System (ADS)

    Erman, Ari

    The goal of this dissertation is to establish an understanding of processing -- microstructure -- mechanical behavior relationship in Mg-1wt% SiC metal matrix nano-composites fabricated via an ultrasonic assisted casting process, with the emphasis on the effect of the distribution of nanoparticles on this relationship. Ultrasonic assisted casting has been proved as an effective technique to distribute nanoparticles in Mg metal matrix nano-composites (MMNCs). Mg MMNCs reinforced with 1 wt% SiC nanoparticles, were cast by ultrasonic cavitation-based dispersion methods. Microstructural analyses of as cast specimens were conducted to characterize the grain size, shape and distribution, SiC nanoparticle size and distribution, and nanoparticle-matrix interface. Average grain size for the ultrasonic assisted cast composite specimens was 72 mum compared to 181 mum for pure Mg samples prepared by the same method. The average measured SiC nanoparticle size was 66 nm. TEM studies showed good local dispersion of SiC nanoparticles, with only a few small, widely spaced clusters. HRTEM showed a clean interface between SiC nanoparticles and the Mg matrix, with no evidence of secondary phases. The yield strength of Mg-1 wt% SiC nanocomposites was 67 MPa, which showed improvement from 47 MPa for the pure Mg samples. This extra strengthening is due to Orowan and Hall-Petch effects. Fatigue experiments were conducted to characterize the cyclic stress-strain response of pure Mg and Mg-1wt% SiC samples at 0.2%, 0.4% and 0.6% plastic strain amplitudes. The analyses of the cyclic stress response curves and hysteresis loops, combined with post failure TEM analyses provided an understanding of the role of twinning, and twin-particle interactions on the cyclic deformation behavior of Mg MMNCs. Tensile twinning and basal slip are the main forms of deformation mechanisms under compression, followed by detwinning and basal slip in subsequent tension. Fatigue lives of Mg MMNCs are comparable to

  1. Effect of casting methods on accuracy of peridental restorations.

    PubMed

    Finger, W; Kota, K

    1982-06-01

    The present study has shown that the accuracy of peridental gold alloy castings depends 1) on the type of casting machine used, 2) on the diameter of the casting sprue, and 3) on the strength properties of the investment material. The dependence between the accuracy and the three factors mentioned is based on erosion of the investment mold by the inflow of the liquid casting alloy. The vacuum casting technique proved to be a more gentle casting method than centrifugal and vacuum/pressure techniques.

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

    SciTech Connect

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

    2007-09-01

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

  3. In-depth study of mold heat transfer for the high speed continuous casting process

    NASA Astrophysics Data System (ADS)

    Jeong, Heetae; Hwang, Jong-Yeon; Cho, Jung-Wook

    2016-03-01

    Mold heat transfer during the commercial high speed continuous casting up to 7 m/min was investigated in order to clarify the influence of various operating conditions such as casting speed, mold flux, mold thickness, thickness and height of mold coated layer and so on. A simple, but practical formula of heat flux has been derived in terms of those operating conditions by analyzing the heat flux data obtained in CEM® (Compact Endless Casting and Rolling Mill) caster based on simplified one dimensional heat transfer model. Especially, impact of mold parameters such as mold thickness, mold coated layer thickness and its height on the heat flux can be linearly expressed in the empirical formula derived. Heat flux ratio (HR), the ratio of the narrow face heat flux to the wide face one, is one of the important indicators to evaluate whether the solidified shell is evenly robust or not. Averaged HR in CEM® caster is around 0.87, which varies according to the caster specifications and operating conditions. It is suggested that the mold taper should be adjusted to maintain the HR as close to 0.87 as possible.

  4. Casting materials

    DOEpatents

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

    2011-06-14

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

  5. Effect of casting methods on castability of pure titanium.

    PubMed

    Takahashi, J; Zhang, J Z; Okazaki, M

    1993-12-01

    Two types of patterns were tested for castability: 1) polyester mesh pattern (20mm x 22mm with 100 open squares) and 2) 20mm x 20mm wax plates 1.0 and 1.5 mm in thickness. These materials were invested using a pre-arranged commercial phosphate-bonded investment for titanium. Three different types of casting machines were selected: 1) a pressure-type casting machine with separate melting and casting chambers, 2) a pressure-type casting machine with one chamber and 3) a centrifugal-type casting machine at 3000 rpm. Pure titanium (> 99.5%) was cast into the molds at a mold temperature of 100 degrees C. The castability of mesh pattern was evaluated in terms of the number of cast segment, and the cast plate was evaluated using X-ray transparent images by a digital imaging technique. The centrifugal casting method showed the best castability among these three casting methods.

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

    SciTech Connect

    Sabau, Adrian S

    2007-01-01

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

  7. Improving Microstructure and Mechanical Properties for Large-Diameter 7075 Aluminum Alloy Ingots by a Forced Convection Stirring Casting Process

    NASA Astrophysics Data System (ADS)

    Qi, Mingfan; Kang, Yonglin; Zhu, Guoming; Li, Yangde; Li, Weirong

    2017-01-01

    A simple process so-called forced convection stirring casting (FCSC) was proposed to prepare large-diameter 7075 Al alloy ingots. The flow behavior, temperature, and composition fields of the melt in the FCSC process were simulated. The macromorphology, macrosegregation, microstructure, and mechanical properties of the ingots prepared by the FCSC were studied and compared with those prepared by normal casting (NC). The results showed that in the FCS device, the strong convection caused by the axial flow and circular flow rapidly promoted the uniformity of the temperature and composition fields of the melt. Microstructures of the FCSC ingots from the edge to the center were all nearly spherical grains, which were much finer and more uniform than that of the NC ingots. The rotation speed played an important role in the microstructure of the FCSC ingots, and the grains became finer and rounder as the speed increasing. The FCSC process effectively eliminated cracks, improved macrosegregation, and decreased the eutectic phase area fraction and the average grain boundary thickness of ingots. Mechanical properties of the ingots prepared by the FCSC are far better than that of the NC ingots.

  8. Improving Microstructure and Mechanical Properties for Large-Diameter 7075 Aluminum Alloy Ingots by a Forced Convection Stirring Casting Process

    NASA Astrophysics Data System (ADS)

    Qi, Mingfan; Kang, Yonglin; Zhu, Guoming; Li, Yangde; Li, Weirong

    2017-04-01

    A simple process so-called forced convection stirring casting (FCSC) was proposed to prepare large-diameter 7075 Al alloy ingots. The flow behavior, temperature, and composition fields of the melt in the FCSC process were simulated. The macromorphology, macrosegregation, microstructure, and mechanical properties of the ingots prepared by the FCSC were studied and compared with those prepared by normal casting (NC). The results showed that in the FCS device, the strong convection caused by the axial flow and circular flow rapidly promoted the uniformity of the temperature and composition fields of the melt. Microstructures of the FCSC ingots from the edge to the center were all nearly spherical grains, which were much finer and more uniform than that of the NC ingots. The rotation speed played an important role in the microstructure of the FCSC ingots, and the grains became finer and rounder as the speed increasing. The FCSC process effectively eliminated cracks, improved macrosegregation, and decreased the eutectic phase area fraction and the average grain boundary thickness of ingots. Mechanical properties of the ingots prepared by the FCSC are far better than that of the NC ingots.

  9. Evolution of microstructure, texture and inhibitor along the processing route for grain-oriented electrical steels using strip casting

    SciTech Connect

    Liu, Hai-Tao; Yao, Sheng-Jie; Sun, Yu; Gao, Fei; Song, Hong-Yu; Liu, Guo-Huai; Li, Lei; Geng, Dian-Qiao; Liu, Zhen-Yu; Wang, Guo-Dong

    2015-08-15

    In the present work, a regular grade GO sheet was produced successively by strip casting, hot rolling, normalizing annealing, two-stage cold rolling with intermediate annealing, primary recrystallization annealing, secondary recrystallization annealing and purification. The aim of this paper was to characterize the evolution of microstructure, texture and inhibitor along the new processing route by comprehensive utilization of optical microscopy, X-ray diffraction and transmission electron microscopy. It was found that a fine microstructure with the ferrite grain size range of 7–12 μm could be obtained in the primary recrystallization annealed sheet though a very coarse microstructure was produced in the initial as-cast strip. The main finding was that the “texture memory” effect on Goss texture started on the through-thickness intermediate annealed strip after first cold rolling, which was not similar to the “texture memory” effect on Goss texture starting on the surface layers of the hot rolled strip in the conventional production route. As a result, the origin of Goss nuclei capable of secondary recrystallization lied in the grains already presented in Goss orientation in the intermediate annealed strip after first cold rolling. Another finding was that fine and dispersive inhibitors (mainly AlN) were easy to be produced in the primary recrystallization microstructure due to the initial rapid solidification during strip casting and the subsequent rapid cooling, and the very high temperature reheating usually used before hot rolling in the conventional production route could be avoided. - Highlights: • A regular grade grain-oriented electrical steel was produced. • Evolution of microstructure, texture and inhibitor was characterized. • Origin of Goss nuclei lied in the intermediate annealed strip. • A fine primary recrystallization microstructure could be produced. • Effective inhibitors were easy to be obtained in the new processing route.

  10. The Role of Lug Preheating, Melt Pool Temperature, and Lug Entrance Delay on the Cast-on-Strap Joining Process

    NASA Astrophysics Data System (ADS)

    Pahlavan, Sohrab; Nikpour, Saman; Mirjalili, Mostafa; Alagheband, Ali; Azimi, Mohammadyousef; Taji, Iman

    2017-07-01

    This work deals with effective parameters in the cast-on-strap (COS) process during which grid lugs of a lead-acid battery are joined together by a strap. The effects of lug preheating, melt pool temperature, and lug entrance delay on the quality of joints and casting defects were investigated. Lug preheating was found to propitiously reduce joint internal voids because of flux elimination. Its adverse effect on lowering lug wettability, however, made it unfavorable under the experimental conditions. The melt pool temperature also showed a two-sided effect depending on the process conditions. Raising the temperature increases the strap melt fluidity, which improves the joint contact area; however, it has a negative effect on lug wettability by flux evaporation. Besides, higher temperatures cause more lug back-melting and, hence, lower relative contact lengths. Therefore, an intermediate temperature of 683 K (410 °C) was found to make the most proper condition. Moreover, the case at which the lugs enter the mold coincident with its filling by the melt rendered the best joint quality. In this condition, the melt flows through the interlug spaces, which helps the voids to escape, resulting in the better joint interface. As the conclusion, the lug entrance time has the most effective role on joint quality, considering that lug preheating does not show any improving effect.

  11. Numerical Simulation and Experimental Casting of Nickel-Based Single-Crystal Superalloys by HRS and LMC Directional Solidification Processes

    NASA Astrophysics Data System (ADS)

    Yan, Xuewei; Wang, Run'nan; Xu, Qingyan; Liu, Baicheng

    2017-04-01

    Mathematical models for dynamic heat radiation and convection boundary in directional solidification processes are established to simulate the temperature fields. Cellular automaton (CA) method and Kurz-Giovanola-Trivedi (KGT) growth model are used to describe nucleation and growth. Primary dendritic arm spacing (PDAS) and secondary dendritic arm spacing (SDAS) are calculated by the Ma-Sham (MS) and Furer-Wunderlin (FW) models respectively. The mushy zone shape is investigated based on the temperature fields, for both high-rate solidification (HRS) and liquid metal cooling (LMC) processes. The evolution of the microstructure and crystallographic orientation are analyzed by simulation and electron back-scattered diffraction (EBSD) technique, respectively. Comparison of the simulation results from PDAS and SDAS with experimental results reveals a good agreement with each other. The results show that LMC process can provide both dendritic refinement and superior performance for castings due to the increased cooling rate and thermal gradient.

  12. Elastomeric inverse moulding and vacuum casting process characterization for the fabrication of arrays of concave refractive microlenses

    NASA Astrophysics Data System (ADS)

    Desmet, L.; Van Overmeire, S.; Van Erps, J.; Ottevaere, H.; Debaes, C.; Thienpont, H.

    2007-01-01

    We present a complete and precise quantitative characterization of the different process steps used in an elastomeric inverse moulding and vacuum casting technique. We use the latter replication technique to fabricate concave replicas from an array of convex thermal reflow microlenses. During the inverse elastomeric moulding we obtain a secondary silicone mould of the original silicone mould in which the master component is embedded. Using vacuum casting, we are then able to cast out of the second mould several optical transparent poly-urethane arrays of concave refractive microlenses. We select ten particular representative microlenses on the original, the silicone moulds and replica sample and quantitatively characterize and statistically compare them during the various fabrication steps. For this purpose, we use several state-of-the-art and ultra-precise characterization tools such as a stereo microscope, a stylus surface profilometer, a non-contact optical profilometer, a Mach-Zehnder interferometer, a Twyman-Green interferometer and an atomic force microscope to compare various microlens parameters such as the lens height, the diameter, the paraxial focal length, the radius of curvature, the Strehl ratio, the peak-to-valley and the root-mean-square wave aberrations and the surface roughness. When appropriate, the microlens parameter under test is measured with several different measuring tools to check for consistency in the measurement data. Although none of the lens samples shows diffraction-limited performance, we prove that the obtained replicated arrays of concave microlenses exhibit sufficiently low surface roughness and sufficiently high lens quality for various imaging applications.

  13. Precision cast vs. wrought superalloys

    NASA Technical Reports Server (NTRS)

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

    1986-01-01

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

  14. Precision cast vs. wrought superalloys

    NASA Technical Reports Server (NTRS)

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

    1986-01-01

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

  15. Energy use in selected metal casting facilities - 2003

    SciTech Connect

    Eppich, Robert E.

    2004-05-01

    This report represents an energy benchmark for various metal casting processes. It describes process flows and energy use by fuel type and processes for selected casting operations. It also provides recommendations for improving energy efficiency in casting.

  16. Clean Metal Casting

    SciTech Connect

    Makhlouf M. Makhlouf; Diran Apelian

    2002-02-05

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

  17. System and process for the abatement of casting pollution, reclaiming resin bonded sand, and/or recovering a low Btu fuel from castings

    DOEpatents

    Scheffer, K.D.

    1984-07-03

    Air is caused to flow through the resin bonded mold to aid combustion of the resin binder to form a low Btu gas fuel. Casting heat is recovered for use in a waste heat boiler or other heat abstraction equipment. Foundry air pollutis reduced, the burned portion of the molding sand is recovered for immediate reuse and savings in fuel and other energy is achieved. 5 figs.

  18. System and process for the abatement of casting pollution, reclaiming resin bonded sand, and/or recovering a low BTU fuel from castings

    DOEpatents

    Scheffer, Karl D.

    1984-07-03

    Air is caused to flow through the resin bonded mold to aid combustion of the resin binder to form a low BTU gas fuel. Casting heat is recovered for use in a waste heat boiler or other heat abstraction equipment. Foundry air pollution is reduced, the burned portion of the molding sand is recovered for immediate reuse and savings in fuel and other energy is achieved.

  19. Model Investigations on the Stability of the Steel-Slag Interface in Continuous-Casting Process

    NASA Astrophysics Data System (ADS)

    Hagemann, René; Schwarze, Rüdiger; Heller, Hans P.; Scheller, Piotr R.

    2013-02-01

    In the continuous-casting mold, the mold powder in contact with the liquid steel surface forms a liquid slag layer. The flow along the steel-slag interface generates shear stress at the interface, waves, and leads to fingerlike protrusions of liquid slag into steel. Reaching a critical flow velocity and thereby shear stress, the protrusions can disintegrate into slag droplets following the flow in the liquid steel pool. These entrained droplets can form finally nonmetallic inclusions in steel material, cause defects in the final product, and therefore, should be avoided. In the current work, the stability of a liquid-liquid interface without mass transfer between phases was investigated in cold model study using a single-roller driven flow in oil-water systems with various oil properties. Applying the similarity theory, two dimensionless numbers were identified, viz. capillary number Ca and the ratio of kinematic viscosities ν 1/ ν 2, which are suitable to describe the force balance for the problem treated. The critical values of the dimensionless capillary number Ca* marking the start of lighter phase entrainment into the heavier fluid, are determined over a wide range of fluid properties. The dimensionless number ν 1/ ν 2 was defined as the ratio of kinematic viscosities of the lighter phase ν 1 and heavier phase ν 2. The ratios of kinematic viscosities of different steel-slag systems were calculated using measured thermophysical properties. With the knowledge of thermophysical properties of steel-slag systems, Ca* for slag entrainment as a function of v 1/ v 2 is derived. Assuming no reaction between the phases and no interfacial flow, slag entrainment should not occur under the usual casting conditions.

  20. DOE applied to study the effect of process parameters on silicon spacing in lost foam Al-Si-Cu alloy casting

    NASA Astrophysics Data System (ADS)

    Shayganpour, A.; Idris, M. H.; Izman, S.; Jafari, H.

    2012-09-01

    Lost foam casting as a relatively new manufacturing process is extensively employed to produce sound complicated castings. In this study, an experimental investigation on lost foam casting of an Al-Si-Cu aluminium cast alloy was conducted. The research was aimed in evaluating the effect of different pouring temperatures, slurry viscosities, vibration durations and sand grain sizes on eutectic silicon spacing of thin-wall castings. A stepped-pattern was used in the study and the focus of the investigations was at the thinnest 3 mm section. A full two-level factorial design experimental technique was used to plan the experiments and afterwards identify the significant factors affecting casting silicon spacing. The results showed that pouring temperature and its interaction with vibration time have pronounced effect on eutectic silicon phase size. Increasing pouring temperature coarsened the eutectic silicon spacing while the higher vibration time diminished coarsening effect. Moreover, no significant effects on silicon spacing were found with variation of sand size and slurry viscosity.

  1. Producing Nanocomposite Layer on the Surface of As-Cast AZ91 Magnesium Alloy by Friction Stir Processing

    NASA Astrophysics Data System (ADS)

    Asadi, P.; Besharati Givi, M. K.; Faraji, G.

    Friction stir processing (FSP) is an effective tool to produce a surface composite layer with enhanced mechanical properties and modified microstructure of as-cast and sheet metals. In the present work, the mechanical and microstructural properties of as-cast AZ91 magnesium alloy were enhanced by FSP and an AZ91/SiC surface nanocomposite layer has been produced using 30 nm SiC particles. Effect of the FSP pass number on the microstructure, grain size, microhardness, and powder distributing pattern of the surface developed has been investigated. The developed surface nanocomposite layer presents a higher hardness, an ultra fine grain size and a better homogeneity. Results show that, increasing the number of FSP passes enhances distribution of nano-sized SiC particles in the AZ91 matrix, decreases the grain size, and increases the hardness significantly. Also, changing of the tool rotating direction results much uniform distribution of the SiC particles, finer grains, and a little higher hardness.

  2. Effect of Friction Stir Processing on Microstructure and Mechanical Properties of AZ91C Magnesium Cast Alloy Weld Zone

    NASA Astrophysics Data System (ADS)

    Hassani, Behzad; Karimzadeh, Fathallah; Enayati, Mohammad Hossein; Sabooni, Soheil; Vallant, Rudolf

    2016-07-01

    In this study, friction stir processing (FSP) was applied to the GTAW (TIG)-welded AZ91C cast alloy to refine the microstructure and optimize the mechanical properties of the weld zone. Microstructural investigation of the samples was performed by optical microscopy and the phases in the microstructure were determined by x-ray diffraction (XRD). The microstructural evaluations showed that FSP destroys the coarse dendritic microstructure. Furthermore, it dissolves the secondary hard and brittle β-Mg17Al12 phase existing at grain boundaries of the TIG weld zone. The closure and decrease in amount of porosities along with the elimination of the cracks in the microstructure were observed. These changes were followed by a significant grain refinement to an average value of 11 µm. The results showed that the hardness values increased to the mean ones, respectively, for as-cast (63 Hv), TIG weld zone (67 Hv), and stir zone (79 Hv). The yield and ultimate strength were significantly enhanced after FSP. The fractography evaluations, by scanning electron microscopy (SEM), indicated to a transition from brittle to ductile fracture surface after applying FSP to the TIG weld zone.

  3. Experimental and Numerical Modeling of Fluid Flow Processes in Continuous Casting: Results from the LIMMCAST-Project

    NASA Astrophysics Data System (ADS)

    Timmel, K.; Kratzsch, C.; Asad, A.; Schurmann, D.; Schwarze, R.; Eckert, S.

    2017-07-01

    The present paper reports about numerical simulations and model experiments concerned with the fluid flow in the continuous casting process of steel. This work was carried out in the LIMMCAST project in the framework of the Helmholtz alliance LIMTECH. A brief description of the LIMMCAST facilities used for the experimental modeling at HZDR is given here. Ultrasonic and inductive techniques and the X-ray radioscopy were employed for flow measurements or visualizations of two-phase flow regimes occurring in the submerged entry nozzle and the mold. Corresponding numerical simulations were performed at TUBAF taking into account the dimensions and properties of the model experiments. Numerical models were successfully validated using the experimental data base. The reasonable and in many cases excellent agreement of numerical with experimental data allows to extrapolate the models to real casting configurations. Exemplary results will be presented here showing the effect of electromagnetic brakes or electromagnetic stirrers on the flow in the mold or illustrating the properties of two-phase flows resulting from an Ar injection through the stopper rod.

  4. Study on the Manufacture Technology of the Zirconia Tubes III: Research on the Slip Casting Process of the Zirconia Tubes

    NASA Astrophysics Data System (ADS)

    Qiu, Suntai; Xu, Jiayin; Shao, Changgui

    The properties of (ZrO2·Y2O3·Gd2O3) slip with intermediate diameter (The raw materials bellow 1 μm in diameter exceed 60wt%) were studied in this paper. The slip casting was performed using plaster mold. It is found that several factors, including the pH value of suspension slip, the concentration of dispersing agent (PAA) and Arab gum etc., have effects on the stability and mobility of the slip. Sick suspending slip with good suspension, small sedimentation volume, high solid volume fraction can be synthesized by modifying the prominent factors and optimizing parameters that affect the slip seability and the property of final product, which resulting in high green cast density (3.80g/cm3). The optimized powder (ZrO2·Y2O3·Gd2O3) and slip can enhance the point diffusion and the microstructure of the final production during the firing process. On the other hand, the enhanced plaster mold with good properties was obtained, which can be used up to 40 50 times.

  5. Development of Secondary Recrystallization in high permeability grain oriented Silicon steel produced by Thin Slab Casting and Rolling process

    NASA Astrophysics Data System (ADS)

    Fan, L. F.; Liu, S. M.; Guo, F.; He, J. Z.; Lu, B.; Dong, R. F.

    2017-02-01

    Texture evolution during high temperature annealing process in high permeability grain oriented(Hi-B)silicon steel, produced by Thin Slab Casting and Rolling(TSCR) process, was investigated using macro-/microtexture analysis. Goss texture appears in ODF at 800°C, the intensity of Goss texture is very weak until 950°CGoss grains grow abnormally during 980°C∼1000°C, grain size reached centimeter level at 1000°C instead of Primary Grains, Goss grains were obtained fully at 1020°C, Secondary recrystallization completed at 1040°C The deviation angle of Goss grain orientation decreases gradually with increasing temperature, and it reached the minimum at 1040°C.

  6. Materials Science Laboratory - Columnar-to-Equiaxed Transition in Solidification Processing and Microstructure Formation in Casting of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions

    NASA Technical Reports Server (NTRS)

    Gandin, Charles-Andre; Ratke, Lorenz

    2008-01-01

    The Materials Science Laboratory - Columnar-to-Equiaxed Transition in Solidification Processing and Microstructure Formation in Casting of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions (MSL-CETSOL and MICAST) are two investigations which supports research into metallurgical solidification, semiconductor crystal growth (Bridgman and zone melting), and measurement of thermo-physical properties of materials. This is a cooperative investigation with the European Space Agency (ESA) and National Aeronautics and Space Administration (NASA) for accommodation and operation aboard the International Space Station (ISS). Research Summary: Materials Science Laboratory - Columnar-to-Equiaxed Transition in Solidification Processing (CETSOL) and Microstructure Formation in Casting of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions (MICAST) are two complementary investigations which will examine different growth patterns and evolution of microstructures during crystallization of metallic alloys in microgravity. The aim of these experiments is to deepen the quantitative understanding of the physical principles that govern solidification processes in cast alloys by directional solidification.

  7. Final Technical Report Quantification and Standardization of Pattern Properties for the Control of the Lost Foam Casting Process

    SciTech Connect

    Ronald Michaels

    2005-09-30

    This project takes a fresh look at the ''white side'' of the lost foam casting process. We have developed the gel front hypothesis for foam pyrolysis behavior and the magnetic metal pump method for controlling lost foam casting metal fill event. The subject of this report is work done in the improvement of the Lost Foam Casting Process. The original objective of this project was to improve the control of metal fill by understanding the influence of foam pattern and coating properties on the metal fill event. Relevant pattern properties could then be controlled, providing control of the metal fill event. One of the original premises of this project was that the process of metal fill was relatively well understood. Considerable previous work had been done to develop fluid mechanical and heat transfer models of the process. If we could just incorporate measured pattern properties into these models we would be able predict accurately the metal fill event. As we began to study the pyrolysis behavior of EPS during the metal fill event, we discovered that the chemical nature of this event had been completely overlooked in previous research. Styrene is the most prevalent breakdown product of EPS pyrolysis and it is a solvent for polystyrene. Much of the styrene generated by foam pyrolysis diffuses into intact foam, producing a molten gel of mechanically entangled polystyrene molecules. Much of the work of our project has centered on validation of this concept and producing a qualitative model of the behavior of EPS foam undergoing pyrolysis in a confined environment. A conclusion of this report is that styrene dissolution in EPS is a key phenomenon in the pyrolysis process and deserves considerable further study. While it is possible to continue to model the metal fill event parametrically using empirical data, we recommend that work be undertaken by qualified researchers to directly characterize and quantify this phenomenon for the benefit of modelers, researchers, and

  8. Titanium Aluminide Casting Technology Development

    NASA Astrophysics Data System (ADS)

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

    2017-08-01

    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.

  9. Distributed cognition and social brains: reductions in mushroom body investment accompanied the origins of sociality in wasps (Hymenoptera: Vespidae)

    PubMed Central

    O'Donnell, Sean; Bulova, Susan J.; DeLeon, Sara; Khodak, Paulina; Miller, Skye; Sulger, Elisabeth

    2015-01-01

    The social brain hypothesis assumes the evolution of social behaviour changes animals' ecological environments, and predicts evolutionary shifts in social structure will be associated with changes in brain investment. Most social brain models to date assume social behaviour imposes additional cognitive challenges to animals, favouring the evolution of increased brain investment. Here, we present a modification of social brain models, which we term the distributed cognition hypothesis. Distributed cognition models assume group members can rely on social communication instead of individual cognition; these models predict reduced brain investment in social species. To test this hypothesis, we compared brain investment among 29 species of wasps (Vespidae family), including solitary species and social species with a wide range of social attributes (i.e. differences in colony size, mode of colony founding and degree of queen/worker caste differentiation). We compared species means of relative size of mushroom body (MB) calyces and the antennal to optic lobe ratio, as measures of brain investment in central processing and peripheral sensory processing, respectively. In support of distributed cognition predictions, and in contrast to patterns seen among vertebrates, MB investment decreased from solitary to social species. Among social species, differences in colony founding, colony size and caste differentiation were not associated with brain investment differences. Peripheral lobe investment did not covary with social structure. These patterns suggest the strongest changes in brain investment—a reduction in central processing brain regions—accompanied the evolutionary origins of eusociality in Vespidae. PMID:26085587

  10. CENTRIFUGAL CASTING MACHINE

    DOEpatents

    Shuck, A.B.

    1958-04-01

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

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

    PubMed

    Fuchs, P; Küfmann, W

    1978-07-01

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

  12. Control of Crystal Morphology for Mold Flux During High-Aluminum AHSS Continuous Casting Process

    NASA Astrophysics Data System (ADS)

    GUO, Jing; SEO, Myung-Duk; SHI, Cheng-Bin; CHO, Jung-Wook; KIM, Seon-Hyo

    2016-08-01

    In the present manuscript, the efforts to control the crystal morphology are carried out aiming at improving the lubrication of lime-alumina-based mold flux for casting advanced high-strength steel with high aluminum. Jackson α factors for crystals of melt crystallization in multi-component mold fluxes are established and reasonably evaluated by applying thermodynamic databases to understand the crystal morphology control both in lime-alumina-based and lime-silica-based mold fluxes. The results show that Jackson α factor and supercooling are the most critical factors to determine the crystal morphology in a mold flux. Crystals precipitating in mold fluxes appear with different morphologies due to their different Jackson α factors and are likely to be more faceted with higher Jackson α factor. In addition, there is a critical supercooling degree for crystal morphology dendritic transition. When the supercooling over the critical value, the crystals transform from faceted shape to dendritic ones in morphology as the kinetic roughening occurs. Typically, the critical supercooling degrees for cuspidine dendritic transition in the lime-silica-based mold fluxes are evaluated to be between 0.05 and 0.06. Finally, addition of a small amount of Li2O in the mold flux can increase the Jackson α factor and decrease the supercooling for cuspidine precipitation; thus, it is favorable to enhance a faceted cuspidine crystal.

  13. Resource-saving technologies of making advanced cast and deformable superalloys with allowance for processing all types of wastes

    NASA Astrophysics Data System (ADS)

    Kablov, E. N.; Sidorov, V. V.; Kablov, D. E.; Min, P. G.; Rigin, V. E.

    2016-12-01

    The results of thermodynamic analysis of the vacuum-melt-ceramic system and experimental investigations of using up to 100% wastes during vacuum-induction melting are presented. An important role of rare-earth and alkaline-earth metals and heat treatment is shown for effective refining of a melt from impurities and gases. As a result, a resource-saving technology of making advanced cast and deformable nickel superalloys is developed with allowance for processing all types of wastes, including off-grade wastes. The developed technology of refining wastes under vacuum makes it possible to manufacture the alloys that fully meet the requirements of alloy specifications from 100% wastes. This technology is now used for the mass production of nickel superalloys in a research complex at FGUP VIAM.

  14. Influences of process parameters on tensile strength of friction stir welded cast A319 aluminium alloy joints

    NASA Astrophysics Data System (ADS)

    Jayaraman, M.; Sivasubramanian, R.; Balasubramanian, V.; Babu, S.

    2009-04-01

    Fusion welding of cast A319 (Al-Si-Cu) alloy will lead to many problems including porosity, micro-fissuring, and hot cracking. Friction Stir Welding (FSW) can be used to weld A319 alloy without these defects. In this investigation, an attempt has been made to study the effect of FSW process parameters on the tensile strength of A319 alloy welded joints. Joints were made using different combinations of tool rotation speed, welding speed, and axial force, each at four levels. The quality of weld zone was analyzed using macrostructure and microstructure analysis. Tensile strength of the joints were evaluated and correlated with the weld zone microstructure. The joint fabricated with a 1200 rpm tool rotation speed, 40 mm/min welding speed, and 4 kN axial force showed superior tensile strength compared with the other joints.

  15. Annealing Effects in Twin-Roll Cast AA8006 Aluminium Sheets Processed by Accumulative Roll-Bonding

    PubMed Central

    Cieslar, Miroslav; Poková, Michaela

    2014-01-01

    Ultrafine grained sheets were prepared from a twin-roll cast AA8006 aluminium alloy using accumulative roll-bonding process at room temperature. The evolution of microstructure of sheets after three accumulative roll-bonding passes during isochronal annealing with a constant step of 20 °C/20 min was studied by light and electron microscopy. The influence of the resulting microstructure on mechanical properties was monitored by microhardness measurements. The microhardness increases when the material is annealed up to 160 °C. Above this temperature a fast drop of microhardness occurs followed by a negligible variation at annealing temperatures exceeding 300 °C. In order to map continuously the microstructure changes during annealing, the in situ TEM experiments in the heating stage were performed as a supplement to post-mortem TEM observations. PMID:28788290

  16. Annealing Effects in Twin-Roll Cast AA8006 Aluminium Sheets Processed by Accumulative Roll-Bonding.

    PubMed

    Cieslar, Miroslav; Poková, Michaela

    2014-12-15

    Ultrafine grained sheets were prepared from a twin-roll cast AA8006 aluminium alloy using accumulative roll-bonding process at room temperature. The evolution of microstructure of sheets after three accumulative roll-bonding passes during isochronal annealing with a constant step of 20 °C/20 min was studied by light and electron microscopy. The influence of the resulting microstructure on mechanical properties was monitored by microhardness measurements. The microhardness increases when the material is annealed up to 160 °C. Above this temperature a fast drop of microhardness occurs followed by a negligible variation at annealing temperatures exceeding 300 °C. In order to map continuously the microstructure changes during annealing, the in situ TEM experiments in the heating stage were performed as a supplement to post-mortem TEM observations.

  17. Casting larger polycrystalline silicon ingots

    SciTech Connect

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

    1995-08-01

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

  18. The relationship between the fit of MOD inlays and the storage time and conditions of investing.

    PubMed

    Davis, D R; Nguyen, J H; Watters, J L

    1991-01-01

    It has been traditional either to cast invested wax patterns immediately after the investment has set or to store the invested patterns in a humidor for casting later. This study compared the fit of MOD inlays to parent dies after casting immediately following set of the investment, after casting 1 hour following the setting of the investment in air, storage in a humidor for 7 days, and after storage in air for 7 days. The only significant differences in fit were in the group stored in a humidor, and then only at the axiogingival junctions.

  19. An experimental AWTS process and comparisons of ONERA T2 and 0.3-m TCT AWTS data for the ONERA CAST-10 aerofoil

    NASA Technical Reports Server (NTRS)

    Wolf, Stephen; Jenkins, Renaldo

    1989-01-01

    An experimental Adaptive Wall Test Section (AWTS) process is described. Comparisons of the ONERA T2 and the 0.3-m TCT (transonic cryogenic tunnel) AWTS data for the ONERA CAST-10 airfoil are presented. Most of the 0.3-m TCT data is new and preliminary and no sidewall boundary layer control is involved. No conclusions are given.

  20. A three-dimensional hybrid finite element-volume tracking model for mould filling in casting processes

    NASA Astrophysics Data System (ADS)

    Gao, D. M.

    1999-04-01

    Metal casting is a complicated process in which flow momentum plays a crucial role in the mould filling process due to the high velocity of the liquid metal. Inertia and gravity effects may cause splashing, jetting or undesirable filling of the metal flow into the mould cavity. When considering complex parts, the accurate prediction of mould filling behaviour using empirical knowledge and intuition is nearly impossible. Therefore, numerical modelling and simulation are essential to predict such a complex physical problem and assist in part with mould design. A mould filling analysis can help the mould designer to determine the size and location of the gate as well as a proper runner system design for ensuring a complete and balanced filling of the part. Such an analysis can also be used to predict potential product defects, such as air entrapment, porosities, and help in correct positioning of overflows and venting systems. A three-dimensional finite element model combined with a volume tracking method has been developed in this work to simulate the cavity filling for casting processes. A mixed formulation based on a four node tetrahedral element with a bubble function at the centroid (P1+/P1) is employed to solve the flow equations. Such a finite element provides a small dimension of the element matrices and satisfies the Brezzi-Babuska condition to ensure a stable solution of the Navier-Stokes equations. A slip boundary condition combined with a friction model is implemented to better simulate the metal flow near the mould walls. An algebraic model is used to account for the turbulence effects during the mould filling. The flow fronts are tracked by a volume tracking method developed for the tetrahedral elements. This method can handle complicated flow front shapes and complex situations like merging and separation of flow fronts. The combination of a volume tracking technique with a FEM flow solver in three-dimensional unstructured meshes constitutes the major

  1. Lost-Soap Aluminum Casting.

    ERIC Educational Resources Information Center

    Mihalow, Paula

    1980-01-01

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

  2. Lost-Soap Aluminum Casting.

    ERIC Educational Resources Information Center

    Mihalow, Paula

    1980-01-01

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

  3. Melting and casting of FeAl-based cast alloy

    SciTech Connect

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

    1998-11-01

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

  4. Microstructures and Casting Defects of Magnesium Alloy Made By A New Type of Semisolid Injection Process

    NASA Astrophysics Data System (ADS)

    Murakami, Yuichiro; Omura, Naoki; Li, Mingjun; Tamura, Takuya; Tada, Shuji; Miwa, Kenji

    We have developed a new type of semisolid injection process that allows magnesium alloys to be formed in high material yields approximating 90%. In this process, generic magnesium billets are heated into their semisolid temperature range in an injection cylinder, without cover gas, and then the material is injected into a mold.

  5. Development of Casting Process for Pressings of Pistons of Car Augmented Engines

    NASA Astrophysics Data System (ADS)

    Korostelev, V. F.; Denisov, M. S.

    2017-01-01

    Results of a study aimed at formation of a single-phase fine-grained structure in pistons during their production process involving isostatic pressing of liquid metal prior to the start of crystallization, pressing of the crystallizing metal, and holding under pressure in the process of cooling to the shop temperature are presented.

  6. Microstructural Evolution and Local Mechanical Properties of Friction Stir Processed Mg-3Gd-1Zn Cast Alloy

    NASA Astrophysics Data System (ADS)

    Sabbaghian, M.; Mahmudi, R.

    2016-05-01

    Microstructural evolution, hardness, and shear strength of the cast plates of GZ31 magnesium alloy were investigated after friction stir processing (FSP). Due to severe plastic deformation and dynamic recrystallization, FSP breaks the dendrites and results in a fine homogenous structure in the stirred zone (SZ) having average grain sizes of about 4.0 and 2.5 μm in the one and two-pass FSPed plates, respectively. As a novel approach, strength of the processed plates was examined by shear punch testing in three regions of the SZ on the surface layer, namely, center line (CL), retreating side (RS), and advancing side (AS). FSP showed great potential in the enhancement of SZ ultimate shear strength from 114 to about 152 and 155 MPa in the one and two-pass FSPed materials, respectively. The same trend was observed in hardness values of the SZ, where the average hardness of the base material increased from 41 to 60 and 68 Vickers after one and two passes of FSP, respectively. The variations in the shear strength of the CL, RS, and AS zones of the SZ were about 5% for the first pass of FSP, the effect which was decreased to less than 2% after two passes of FSP.

  7. Cast dielectric composite linear accelerator

    DOEpatents

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

    2009-11-10

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

  8. The Effect of Aluminum Content and Processing on the Tensile Behavior of High Pressure Die Cast Mg Alloys

    NASA Astrophysics Data System (ADS)

    Deda, Erin M.

    Due to their high specific strength and good castability, magnesium alloys are desirable for use in weight reduction strategies in automotive applications. However, the mechanical properties of high pressure die cast (HPDC) magnesium can be highly variable and dependent on location in the casting. To better understand the relationship between microstructure and tensile properties, the influence of alloying and section thickness on the microstructural features and tensile properties of Mg-Al and Mg-Al-Mn alloys is quantified. This investigation provides experimental input to modeling activities for the development of an Integrated Computational Materials Engineering capability, to assess and quantify the impact of microstructure on the tensile behavior of HPDC Mg AM series (magnesium-aluminum-manganese) alloys. As a result of this work, it is found that with increasing aluminum content, the yield strength increases and the ductility decreases. Increasing the plate thickness results in a decrease in both the yield strength and ductility. HPDC components have varying microstructural features through the plate thickness, developing a "skin" and "core". The grain size, beta-Mg 17Al12 phase, and solute content are all quantified through the thickness of the plates. By quantifying microstructural variations, a physics-based model has been developed which is able to predict the effects of alloying and plate thickness on yield strength. The primary factors affecting strengthening are accounted for using a linear superposition model of solid solution, grain size, and dispersion hardening. This model takes into account through-thickness microstructure gradients that exist in HPDC components by using a composite model to incorporate the skin and core changes. The yield strength in these alloys is dominated by grain boundary strengthening and solute hardening effects. In order to isolate the effects of eutectic phases, shrinkage porosity and oxide films on strength and

  9. 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.

  10. Method For Removing Volatile Components From A Gel-Cast Ceramic Article

    DOEpatents

    Klug, Frederic Joseph; DeCarr, Sylvia Marie

    2004-09-07

    A method of removing substantially all of the volatile component in a green, volatile-containing ceramic article is disclosed. The method comprises freezing the ceramic article; and then subjecting the frozen article to a vacuum for a sufficient time to freeze-dry the article. Frequently, the article is heated while being freeze-dried. Use of this method efficiently reduces the propensity for any warpage of the article. The article is often formed from a ceramic slurry in a gel-casting process. A method for fabricating a ceramic core used in investment casting is also described.

  11. Investment Avenues

    NASA Astrophysics Data System (ADS)

    Jain, Priyanka

    2012-11-01

    Investors are a heterogeneous group, they may be large or small, rich or poor, expert or lay man and not all investors need equal degree of protection (Mayya, 1996). An investor has three objectives while investing his money, namely safety of invested money, liquidity position of invested money and return on investment. The return on investment may further be divided into capital gain and the rate of return on investment as interest or dividend. Among all investment options available, securities are considered the most challenging as well as rewarding. Securities include shares, debentures, derivatives, units of mutual funds, Government securities etc. An investor may be an individual or corporate legal entity investing funds with a view to derive maximum economic advantage from investment such as rate of return, capital appreciation, marketability, tax advantage and convenience of investment.The Capital market facilitates mobilization of savings of individuals and pools them into reservoir of capital which can be used for the economic development of a country. An efficient capital market is essential for raising capital by the corporate sector of the economy and for the protection of the interest of investors in corporate securities. There arises a need to strike a balance between raising of capital for economic development on one side and protection of investors on the other. Unless the interests of investors are protected, raising of capital, by corporates is not possible. Like, the primary objective of a senior citizenís asset allocation is the generation of regular income.

  12. Friction Stir Processing of As-Cast AA5083: Superplastic Response

    DTIC Science & Technology

    2009-06-01

    2005), pp. 1-78. [23] J.-Q. Su, T.W. Nelson and C.J. Sterling, “Microstructure evolution during FSW /FSP of high strength aluminum alloys...TERMS Friction Stir Processing, Superplasticity, Elevated Temperature, Aluminum , Grain Refinement, Strain Rate 16. PRICE CODE 17. SECURITY...3 A. ALUMINUM ALLOY 5083............................................................................3 B. SUPERPLASTICITY

  13. Microstructure evolution of eutectic Al-Cu strips by high-speed twin-roll strip casting process

    NASA Astrophysics Data System (ADS)

    Sahoo, Seshadev; Ghosh, Sudipto

    2015-10-01

    In the present investigation, microstructural evolutions of functionally graded eutectic Al-Cu strips prepared by high-speed twin-roll strip caster at different casting speeds and liquid melt superheats were studied. The as-cast sample was subjected to scanning electron microscope to study the evolution of microstructure of the strip at different casting speeds and liquid melt superheats. At different casting speeds, non-equilibrium eutectic structure observed on the Al-Cu eutectic strip consists of lamellar as well as wavy structure with a distinct boundary. The lamellar microstructure consists of alternating layers of well-bonded α-Al phase and θ-Al2Cu phase. The globular flowery structure within the eutectic matrix was observed on the strip at different liquid melt superheats. The microhardness of the as-cast strip was studied by Vickers hardness tester, and it was found that hardness value increases with increasing casting speed and decreases with increasing liquid melt superheat.

  14. Bio-inspired wearable characteristic surface: Wear behavior of cast iron with biomimetic units processed by laser

    NASA Astrophysics Data System (ADS)

    Zhou, Hong; Sun, Na; Shan, Hongyu; Ma, Dianyi; Tong, Xin; Ren, Luquan

    2007-10-01

    Stimulated by the cuticles of soil animals, an attempt to improve the wear resistance of compact graphite cast iron (CGI) with biomimetic units on the surface was made by using a biomimetic coupled laser remelting (BCLR) process. The microstructure and microhardness of biomimetic units were examined. The wear behaviors of biomimetic specimens as functions of laser input energy and biomimetic unit shape were investigated under dry sliding condition, respectively. The results indicated that the biomimetic specimens had better wear resistance than the untreated specimens. The wear resistance of the biomimetic specimens increases with the increase of laser input energy due to the increase of the depth and the width of biomimetic units as well as the increase of the microhardness. The specimen with grid biomimetic units had the best resistance, the stria took the second place and the convex showed the worst. The application of laser remelting provided desirable microstructural changes in biomimetic units, which generated the intensified particles effect for improving the wear resistance. The adhesive wear was the dominative wear mechanism for the biomimetic specimens.

  15. Application of the lattice Boltzmann method for simulation of the mold filling process in the casting industry

    NASA Astrophysics Data System (ADS)

    Szucki, Michal; Suchy, J. S.; Lelito, J.; Malinowski, P.; Sobczyk, J.

    2017-06-01

    The aim of this work is the development of the lattice Boltzmann model for simulation of the mold filling process. The authors present a simplified approach to the modeling of liquid metal-gas flows with particular emphasis on the interactions between these phases. The boundary condition for momentum transfer of the moving free surface to the gaseous phase is shown. Simultaneously, the method for modeling influence of gas back pressure on a position and shape of the interfacial boundary is explained in details. The problem of the lattice Boltzmann method (LBM) stability is also analyzed. Since large differences in viscosity of both fluids are a source of the model instability, the so-called fractional step (FS) method allowing to improve the computation stability is applied. The presented solution is verified on the bases of the available reference data and the results of experiments. It is shown that the model describes properly such effects as: gas bubbles formation and air back pressure, accompanying liquid-gas flows in the casting mold. At the same time the proposed approach is easy to be implemented and characterized by a lower demand of operating memory as compared to typical LBM models of two-phase flows.

  16. Documenting investment policy boosts safety, returns.

    PubMed

    Kovener, R R

    1992-02-01

    The process and responsibility for a healthcare organization's investment decisions should be clearly documented in an investment policy. Any investment policy should contain at least seven elements: how investments relate to the organization's mission; responsibilities of involved parties; long- and short-term objectives; desired balance between return and risk; proportions of a portfolio held in stocks, bonds, and other investments; disposition of donated assets; desired investment reports; and the process for keeping the policy current.

  17. Energy Consumption of Die Casting Operations

    SciTech Connect

    Jerald Brevick; clark Mount-Campbell; Carroll Mobley

    2004-03-15

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

  18. INFORMATION TECHNOLOGY INVESTMENT MANAGEMENT: A Framework for Assessing and Improving Process Maturity. Exposure Draft

    DTIC Science & Technology

    2000-05-01

    Economic Value Added (EVA), Internal Rate of Return (IRR), Net Present Value ( NPV ), Payback , and the use of nominal qualitative measures. Risk: A term... advantage of technology changes • Learn from others by benchmarking processes • Development of mature evaluation processes • Capability to modify IT...or use it as a managerial support tool. Regardless of the implementation technique, the following important factors should be considered when using

  19. Pollution Prevention, An Investment Decision Model to Assess Financial Feasibility for Application to Air Force Processes

    DTIC Science & Technology

    1992-09-01

    FEASIBILITY FOR APPLICATION TO AIR FORCE PROCESSES THESIS Debra S. Rankin, Captain, USAF Clare R. Mendelsohn , GS-12 AFIT/GEE/ENV/92S-15 93-04147 ~I Ill l...Engineering and Environmental Management Clare R. Mendelsohn , B.S. Debra S. Rankin, B.S. GS-12 Captain, USAF September 1992 Approved for public release...for their tremendous amount of moral support durino both the ups and downs during the entire research process. Debra S. Rankin Clare R. Mendelsohn

  20. Microstructure Evolution in As-Cast and SIMA-Processed AE42 Magnesium Alloy

    NASA Astrophysics Data System (ADS)

    Nayyeri, Mohammad Javad; Dehghani, Kamran

    2014-09-01

    In the present study, microstructural evolutions of AE42 magnesium alloy via strain-induced melt activation process and the effect of different process parameters are studied. Scanning electron microscope, metallographic observations, and quantitative metallographic method were used for microstructural characterization. The results show that the consumption of supersaturated aluminum during partial remelting led to a decrease in Al/RE ratio and consequently blocky shape Al2RE starts to appear in the microstructure. Furthermore, it was seen that lanthanum and praseodymium did not contribute in precipitate formation and only improved the hardness of the matrix. The effect of compression ratio on the microstructure of treated alloys was confirmed through the increase of both liquid fraction and entrapped pool as well as the kinetic of microstructural changes. Moreover, the effect of compression ratio and holding time on shape factor, liquid fraction, and particle size of the globular structure were measured. It was found that the best result could be achieved at 35% deformation and 40 min holding of the samples at 610 °C.

  1. A model of amorphous and nano-crystalline ribbon processing by planar-flow casting

    NASA Astrophysics Data System (ADS)

    Levin, Yu B.; Shumakov, A. N.; Filonov, M. R.; Anikin, Yu A.

    2008-02-01

    This paper provides a mathematical model describing the processing of amorphous and nano-crystalline ribbon. The developed model is based on averaging of the equations of non-equilibrium thermodynamics over a forming zone. The model describes an effect of the various technological parameters on the geometry and temperature of the zone. These parameters are: the overpressure, the speed of rotation of a cooling disc, the value of a gap, the thickness of a nozzle, the initial overheating, the atmosphere pressure, and the evenness of the disc surface. Model allows to take into account various random factors such as vibrations, etc. Considered time-dependent quantities are: the temperature of the formation zone, the length of the zone, the thickness of the ribbon, the curvature radius of the rear part of the zone, the nozzle outflow speed. Model takes into account the following physical properties as determining the process: viscosity, density, surface tension, heat capacity, temperature of solidification, heat transfer. Relief of the free and contact surfaces can also be regarded as parameters of the model. Correlation between the quantities mentioned above is considered without introduction of any phenomenological constants.

  2. Environment, Trade, and Investment

    EPA Pesticide Factsheets

    Environment, trade, and investment are fundamentally linked as the environment provides many basic inputs of economic activity – forests, fisheries, metals, minerals – as well as the energy used to process those materials.

  3. A Political Investment: Revisiting Race and Racism in the Research Process

    ERIC Educational Resources Information Center

    Rollock, Nicola

    2013-01-01

    This paper draws upon a two-year Economic and Social Research Council (ESRC) funded study into the educational strategies of the black middle classes to examine the role of race and racism in the research process. Specifically, it explores how my political positioning and experiences of racism, as a black female scholar, shaped not only my…

  4. (The formation of ordered microstructures by slip casting and related processes)

    SciTech Connect

    Not Available

    1992-01-01

    The existing three-year grant pertaining to The control of microstructures during consolidation and injection molding of colloidal dispersions'' began July 1, 1988 as a continuation of a previous grant. The overall effort seeks to answer fundamental questions relevant to the colloidal processing of submicron particles leading to ceramic materials for structural, electronic, or optical applications. At the outset two distinct projects were envisioned, an exploration of the ultrasonic enhancement of disorder-order transitions and a detailed study of injection molding of very dense dispersions, with each weighted toward experiments but with theoretical components. As the effort evolved the focus shifted in response to the interests of the students attracted to the project, the identification of interesting related problems through technical meetings, and different insights gained during participation in a DOE sponsored workshop. The scope that has emerged encompasses completion of research begun during the first grant period on disorder-order transitions occurring during sedimentation, the consolidation of flocculated dispersions via filtration, and the assembly of nanometer- sized particle into dense packings.

  5. [The formation of ordered microstructures by slip casting and related processes]. Progress report

    SciTech Connect

    Not Available

    1992-03-01

    The existing three-year grant pertaining to ``The control of microstructures during consolidation and injection molding of colloidal dispersions`` began July 1, 1988 as a continuation of a previous grant. The overall effort seeks to answer fundamental questions relevant to the colloidal processing of submicron particles leading to ceramic materials for structural, electronic, or optical applications. At the outset two distinct projects were envisioned, an exploration of the ultrasonic enhancement of disorder-order transitions and a detailed study of injection molding of very dense dispersions, with each weighted toward experiments but with theoretical components. As the effort evolved the focus shifted in response to the interests of the students attracted to the project, the identification of interesting related problems through technical meetings, and different insights gained during participation in a DOE sponsored workshop. The scope that has emerged encompasses completion of research begun during the first grant period on disorder-order transitions occurring during sedimentation, the consolidation of flocculated dispersions via filtration, and the assembly of nanometer- sized particle into dense packings.

  6. Fillability of Thin-Wall Steel Castings

    SciTech Connect

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

    2002-07-30

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

  7. Cool Cast Facts

    MedlinePlus

    ... moving. The outer layer is usually made of plaster or fiberglass. Fiberglass casts are made of fiberglass, ... color! These casts are lighter and stronger than plaster casts. Plaster casts are usually white and made ...

  8. Modern technologies of processing municipal solid waste: investing in the future

    NASA Astrophysics Data System (ADS)

    Rumyantseva, A.; Berezyuk, M.; Savchenko, N.; Rumyantseva, E.

    2017-06-01

    The problem of effective municipal solid waste (MSW) management is known to all the municipal entities of the Russian Federation. The problem is multifaceted and complex. The article analyzes the dynamics of municipal solid waste formation and its utilization within the territory of the EU and Russia. The authors of the paper suggest a project of a plant for processing municipal solid waste into a combustible gas with the help of high temperature pyrolysis. The main indicators of economic efficiency are calculated.

  9. Some properties of a stir-cast Ni-Cr based dental alloy.

    PubMed

    Boswell, P G; Stevens, L

    1980-06-01

    A Ni-Cr based crown and bridge alloy has been successfully stir-cast into small investment mould spaces using a modified induction melting and casting machine. Stir-casting produced substantial improvements to the mechanical properties of the cast alloy. A model for the development of the stir-cast microstructure is described and the clinical significance of the improvements in the alloy's properties is discussed.

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

    PubMed

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

    1981-01-01

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

  11. CASTING FURNACES

    DOEpatents

    Ruppel, R.H.; Winters, C.E.

    1961-01-01

    A device is described for casting uranium which comprises a crucible, a rotatable table holding a plurality of molds, and a shell around both the crucible and the table. The bottom of the crucible has an eccentrically arranged pouring hole aligned with one of the molds at a time. The shell can be connected with a vacuum.

  12. Project CAST.

    ERIC Educational Resources Information Center

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

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

  13. Paper Casting.

    ERIC Educational Resources Information Center

    Arrasjid, Dorine A.

    1980-01-01

    Describes an art project, based on the work of artist Chew Teng Beng, in the molding of wet paper on a plaster cast to create embossed paper designs. The values of such a project are outlined, including a note that its tactile approach makes it suitable to visually handicapped students. (SJL)

  14. Paper Casting.

    ERIC Educational Resources Information Center

    Arrasjid, Dorine A.

    1980-01-01

    Describes an art project, based on the work of artist Chew Teng Beng, in the molding of wet paper on a plaster cast to create embossed paper designs. The values of such a project are outlined, including a note that its tactile approach makes it suitable to visually handicapped students. (SJL)

  15. [Stocking process for consumables and investement goods in the Italian public health service (part II)].

    PubMed

    Fiorini, Fulvio; Ameri, Cinzia; Tarchini, Renzo; Granata, Antonio; Zuccardi Merli, Mara

    2013-01-01

    The necessity for fairness and transparency during the processes of supply of consumables and capital goods within the Italian Health Service together with that of containing costs in line with budget reductions, are points outlined in the 2006 public and European Union allocation codes and related procedures. These include methods to guarantee open, limited negotiation both without or after the official announcement for competitive bidding has been made, plus mediation and framework agreement. The publicizing of announcements of bidding to potential Health Service suppliers, criteria for applicant selection and selection of personnel to comprise the panels who effectively make the choice of suppliers, are all phases that are carefully regulated at a legal level. Even small expenditures (down to 20,000) are covered by these regulations. An overview of specific responsibilities, the institution of boards of physicians and the application of sanctions ends the present review.

  16. [Stocking process for consumables and investement goods in the public health service (first part)].

    PubMed

    Fiorini, Fulvio; Ameri, Cinzia; Tarchini, Renzo; Granata, Antonio; Zuccardi Merli, Mara

    2013-01-01

    Hospital procedures to stock tools and equipment supplies for day-by-day clinical diagnosis and treatment place physicians to face up with their ones responsibilities. Nephrologists have to deal with dialysis machines, related technology updating and associated consumables. Overall they have to cope with local health service reality, which looks for progressive doctors skill improvement at lowest or no cost at all. Aim of the first part of this review is to analyze all these issues according European Union, Italian and local main lines and associated laws. Moreover, will be reviewed purchase strategies always looking at patient wellness as final aim of the entire process. They will be illustrated sequences of administrative measures, recent Central Commissioning Headquarters, and laws that since 2006 have defined the related procedures (i.e. open, limited, negotiated, and competitive).

  17. A Novel Method to Reduce Time Investment When Processing Videos from Camera Trap Studies

    PubMed Central

    Swinnen, Kristijn R. R.; Reijniers, Jonas; Breno, Matteo; Leirs, Herwig

    2014-01-01

    Camera traps have proven very useful in ecological, conservation and behavioral research. Camera traps non-invasively record presence and behavior of animals in their natural environment. Since the introduction of digital cameras, large amounts of data can be stored. Unfortunately, processing protocols did not evolve as fast as the technical capabilities of the cameras. We used camera traps to record videos of Eurasian beavers (Castor fiber). However, a large number of recordings did not contain the target species, but instead empty recordings or other species (together non-target recordings), making the removal of these recordings unacceptably time consuming. In this paper we propose a method to partially eliminate non-target recordings without having to watch the recordings, in order to reduce workload. Discrimination between recordings of target species and non-target recordings was based on detecting variation (changes in pixel values from frame to frame) in the recordings. Because of the size of the target species, we supposed that recordings with the target species contain on average much more movements than non-target recordings. Two different filter methods were tested and compared. We show that a partial discrimination can be made between target and non-target recordings based on variation in pixel values and that environmental conditions and filter methods influence the amount of non-target recordings that can be identified and discarded. By allowing a loss of 5% to 20% of recordings containing the target species, in ideal circumstances, 53% to 76% of non-target recordings can be identified and discarded. We conclude that adding an extra processing step in the camera trap protocol can result in large time savings. Since we are convinced that the use of camera traps will become increasingly important in the future, this filter method can benefit many researchers, using it in different contexts across the globe, on both videos and photographs. PMID:24918777

  18. Mathematical modeling of the evolution of thermal field during start-up phase of the direct chill casting process for AA5182 sheet ingots

    NASA Astrophysics Data System (ADS)

    Sengupta, Joydeep

    The control of the thermal cooling conditions at the start-up phase of the Direct Chill (DC) casting process for aluminum sheet ingots is difficult, and is critical from the standpoint of defect formation. Firstly, boiling water heat transfer governs the secondary cooling experienced by the ingot surfaces as they emerge from the mould. This results in varying rates of heat transfer from the ingot faces as the surface temperature of the ingot changes with time during the start-up phase. Moreover, if the ingot surface temperature at locations below the point of water impingement is high enough to promote film boiling, the water is ejected away from the surface. This can result in a sudden decrease in heat transfer and the formation of local hot spots. Also, the chill water may enter into the gap formed between the ingot base and the bottom block with the evolution of the butt curl. This process of water incursion alters the heat transfer from the base of the ingot, and in turn affects the surface temperature of the ingot faces. A comprehensive mathematical model has been developed to describe heat transfer during the start-up phase of the D.C. casting process. The model, based on the commercial finite element package ABAQUS, includes primary cooling to the mould, secondary cooling to water, and ingot base cooling. The algorithm used to account for secondary cooling to the water includes boiling curves that are a function of surface temperature, water flow rate, impingement point temperature, and position relative to the point of water impingement. In addition, the secondary cooling algorithm accounts for water ejection, which can occur at low water flow rates (low heat extraction rates). The algorithm used to describe ingot base cooling includes the drop in contact heat transfer due to base deformation (butt curl), and also the increase in heat transfer due to the process of water incursion between the ingot base and bottom block. The model has been extensively

  19. 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.

  20. Value of patient time invested in the colonoscopy screening process: time requirements for colonoscopy study.

    PubMed

    Jonas, Daniel E; Russell, Louise B; Sandler, Robert S; Chou, Jon; Pignone, Michael

    2008-01-01

    Previous cost-effectiveness analyses of colorectal cancer screening have not considered the value of patient time despite consensus recommendations to do so. The authors sought to estimate the amount and value of patient time required for screening colonoscopy. Patients who were scheduled to undergo screening colonoscopy were recruited from a university endoscopy center. Participants completed a time diary for the screening colonoscopy process, including time spent in preparation, travel, waiting, colonoscopy, and recovery. The authors defined several time intervals and estimated their value. The primary time interval of interest, called occupied time, included preparation, travel, waiting, the colonoscopy procedure, and on-site recovery. Time was valued at the 2005 average wage rate. The authors performed sensitivity analyses to test other time intervals and wage rates. They then incorporated patient time costs into a previously published cost-effectiveness analysis of colorectal cancer screening to examine their impact. One hundred ten subjects completed the study. The sample was 57% female, 85% Caucasian, and 90% insured (40% Medicare, 4% Medicaid). The mean occupied time was 23.2 hours, worth $432 at the average wage rate. The authors estimate that including patient time costs in cost-effectiveness analysis would increase the cost per life-year saved with screening colonoscopy by 68%, from $13,100 to $22,000. Sensitivity analyses showed that the increase could range from 17% to 224% depending on the time interval valued. Patient time constitutes an important cost in colonoscopy screening and should be included in cost-effectiveness analyses.

  1. A simple calibration approach based on film-casting for confocal Raman microscopy to support the development of a hot-melt extrusion process.

    PubMed

    Netchacovitch, L; Thiry, J; De Bleye, C; Dumont, E; Dispas, A; Hubert, C; Krier, F; Sacré, P-Y; Evrard, B; Hubert, Ph; Ziemons, E

    2016-07-01

    When developing a new formulation, the development, calibration and validation steps of analytical methods based on vibrational spectroscopy are time-consuming. For each new formulation, real samples must be produced and a "reference method" must be used in order to determine the Active Pharmaceutical Ingredient (API) content of each sample. To circumvent this issue, the paper presents a simple approach based on the film-casting technique used as a calibration tool in the framework of hot-melt extrusion process. Confocal Raman microscopic method was successfully validated for the determination of itraconazole content in film-casting samples. Then, hot-melt extrusion was carried out to produce real samples in order to confront the results obtained with confocal Raman microscopy and Ultra High Performance Liquid Chromatography (UHPLC). The agreement between both methods was demonstrated using a comparison study based on the Bland and Altman's plot.

  2. LBM-LES Simulation of the Transient Asymmetric Flow and Free Surface Fluctuations under Steady Operating Conditions of Slab Continuous Casting Process

    NASA Astrophysics Data System (ADS)

    Zhao, Peng; Li, Qiang; Kuang, S. B.; Zou, Zongshu

    2017-02-01

    Transient flow structures in a continuous casting mold can strongly influence the slag entrainment in liquid steel and the bubbles capture in the initial solidified shell, both of which are associated with the quality of the final product. This paper presents a numerical study of the turbulent flow with a top free surface in the continuous casting mold at a meso-scale level by a three-dimensional combined approach of Free Surface Lattice Boltzmann Method and Large Eddy Simulation (FSLBM-LES). The validity of the model is verified by the good agreement between the calculated results and the measurements from various water experiments in terms of the flow velocity and free surface profile. The mathematical model is then used to reveal the transient and spatiotemporal asymmetric characteristics associated with the transient flow field and the free surface fluctuation, although the steady state operation is considered during the continuous casting process. The results show that the locations of the jets of liquid steel from the two out ports of the Submerged Entry Nozzle (SEN) always fluctuate alternatively within a certain range, and periodically deviate from the design angle of the SEN within the same time period. The oscillating behavior of the jets promotes the asymmetric flow patterns and multi-scale vortices at both sides of the SEN. By introducing the Q-criterion in the results analysis, the formation, development, and shedding of the coherent structure (CS) of the turbulent flow are quantitatively characterized. The interaction between the transient flow patterns and the fluctuations of the top free surface as well as the evolution of the transient profile and velocities of the free surface are also demonstrated. The results obtained from the current study suggest that the FSLBM-LES model offers a promising way to study the complex flows and related transfer phenomena in the continuous casting process.

  3. Casting methods

    DOEpatents

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

    2012-12-18

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

  4. Distributed cognition and social brains: reductions in mushroom body investment accompanied the origins of sociality in wasps (Hymenoptera: Vespidae).

    PubMed

    O'Donnell, Sean; Bulova, Susan J; DeLeon, Sara; Khodak, Paulina; Miller, Skye; Sulger, Elisabeth

    2015-07-07

    The social brain hypothesis assumes the evolution of social behaviour changes animals' ecological environments, and predicts evolutionary shifts in social structure will be associated with changes in brain investment. Most social brain models to date assume social behaviour imposes additional cognitive challenges to animals, favouring the evolution of increased brain investment. Here, we present a modification of social brain models, which we term the distributed cognition hypothesis. Distributed cognition models assume group members can rely on social communication instead of individual cognition; these models predict reduced brain investment in social species. To test this hypothesis, we compared brain investment among 29 species of wasps (Vespidae family), including solitary species and social species with a wide range of social attributes (i.e. differences in colony size, mode of colony founding and degree of queen/worker caste differentiation). We compared species means of relative size of mushroom body (MB) calyces and the antennal to optic lobe ratio, as measures of brain investment in central processing and peripheral sensory processing, respectively. In support of distributed cognition predictions, and in contrast to patterns seen among vertebrates, MB investment decreased from solitary to social species. Among social species, differences in colony founding, colony size and caste differentiation were not associated with brain investment differences. Peripheral lobe investment did not covary with social structure. These patterns suggest the strongest changes in brain investment--a reduction in central processing brain regions--accompanied the evolutionary origins of eusociality in Vespidae. © 2015 The Author(s) Published by the Royal Society. All rights reserved.

  5. Slip-Cast Superconductive Parts

    NASA Technical Reports Server (NTRS)

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

    1993-01-01

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

  6. Slip-Cast Superconductive Parts

    NASA Technical Reports Server (NTRS)

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

    1993-01-01

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

  7. CASTING APPARATUS

    DOEpatents

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

    1958-09-23

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

  8. Emulsion based cast booster - a priming system

    SciTech Connect

    Gupta, R.N.; Mishra, A.K.

    2005-07-01

    This paper explores the potential of emulsion based cast booster to be used as primer to initiate bulk delivered emulsion explosives used in mines. An attempt has been made for comparative study between conventional cast booster and emulsion based cast booster in terms of the initiation process developed and their capability to develop and maintain the stable detonation process in the column explosives. The study has been conducted using a continuous velocity of detonation (VOD) measuring instrument. During this study three blasts have been monitored. In each blast two holes have been selected for study, the first hole being initiated with conventional cast booster while the other one with emulsion based cast booster. The findings of the study advocates that emulsion based cast booster is capable of efficient priming of bulk delivered column explosive with stable detonation process in the column. Further, the booster had advantages over the conventional PETN/TNT based cast booster. 5 refs., 2 figs., 1 tab., 1 photo.

  9. Prediction of Microporosity in Shrouded Impeller Castings

    SciTech Connect

    Viswanathan, S. Nelson, C.D.

    1998-09-01

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

  10. How to convince your manager to invest in an HIS preimplementation methodology for appraisal of material, process and human costs and benefits.

    PubMed

    Bossard, B; Renard, J M; Capelle, P; Paradis, P; Beuscart, M C

    2000-01-01

    Investing in information technology has become a crucial process in hospital management today. Medical and administrative managers are faced with difficulties in measuring medical information technology costs and benefits due to the complexity of the domain. This paper proposes a preimplementation methodology for evaluating and appraising material, process and human costs and benefits. Based on the users needs and organizational process analysis, the methodology provides an evaluative set of financial and non financial indicators which can be integrated in a decision making and investment evaluation process. We describe the first results obtained after a few months of operation for the Computer-Based Patient Record (CPR) project. Its full acceptance, in spite of some difficulties, encourages us to diffuse the method for the entire project.

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

    NASA Astrophysics Data System (ADS)

    Tiberto, Dario; Klotz, Ulrich E.

    2012-07-01

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

  12. Uniform distribution of BeO particles in Be casting produced in rocket free fall. [for space processing feasibility

    NASA Technical Reports Server (NTRS)

    Wouch, G.; Frost, R. T.; Pinto, N. P.; Keith, G. H.; Lord, A. E., Jr.

    1978-01-01

    An experiment at zero-g aboard a NASA sounding rocket was conducted to evaluate the distribution of BeO particles in a Be casting. A distinction is drawn between the downward settling of particles in a quiescent melt, and the velocity gradient collisions of particles in a melt agitated by electromagnetic stirring. A similar experiment was conducted on earth using the same melting and solidification of a 0.922 cm spheroid of HIP-50 as was carried out in space; the only difference arising from the effect of gravity. Under zero-g conditions, the time needed for agglomeration was lengthened considerably, but the result was a casting of more uniform particle distribution.

  13. Use of Copper Cast Alloys To Control Escherichia coli O157 Cross-Contamination during Food Processing

    PubMed Central

    Noyce, J. O.; Michels, H.; Keevil, C. W.

    2006-01-01

    The most notable method of infection from Escherichia coli O157 (E. coli O157) is through contaminated food products, usually ground beef. The objective of this study was to evaluate seven cast copper alloys (61 to 95% Cu) for their ability to reduce the viability of E. coli O157, mixed with or without ground beef juice, and to compare these results to those for stainless steel. E. coli O157 (NCTC 12900) (2 × 107 CFU) mixed with extracted beef juice (25%) was inoculated onto coupons of each copper cast alloy or stainless steel and incubated at either 22°C or 4°C for up to 6 h. E. coli O157 viability was determined by plate counts in addition to staining in situ with the respiratory indicator fluorochrome 5-cyano-2,3-ditolyl tetrazolium. Without beef extract, three alloys completely killed the inoculum during the 6-h exposure at 22°C. At 4°C, only the high-copper alloys (>85%) significantly reduced the numbers of O157. With beef juice, only one alloy (95% Cu) completely killed the inoculum at 22°C. For stainless steel, no significant reduction in cell numbers occurred. At 4°C, only alloys C83300 (93% Cu) and C87300 (95% Cu) significantly reduced the numbers of E. coli O157, with 1.5- and 5-log kills, respectively. Reducing the inoculum to 103 CFU resulted in a complete kill for all seven cast copper alloys in 20 min or less at 22°C. These results clearly demonstrate the antimicrobial properties of cast copper alloys with regard to E. coli O157, and consequently these alloys have the potential to aid in food safety. PMID:16751537

  14. Capillarity in metal casting mold filling

    NASA Astrophysics Data System (ADS)

    Hilden, Jon L.

    In metal casting processes, surface tension of the molten metal typically resists filling of the metal into the mold. The effects are greater for smaller mold cavities, and ultimately, the smallest cavities may not be filled. Surface tension forces can be overcome by applying pressure (head) to the molten metal, thus forcing metal into the cavities. However, a pressure-window will exist, too little pressure resulting in non-filled cavities and too much pressure resulting in penetration of the mold, which is itself porous. Filling-pressure windows are investigated for cylindrical-shaped mold cavities on both a theoretical and experimental basis. The lower bound of the filling pressure window is examined by treating cylindrical mold cavities as cylinders lined with packed spheres representing mold particles. The upper bound is examined by treating the mold as a 3-D array of close-packed spheres. The experimental work concerns industrial-scale vacuum investment casting of superalloy IN718 into molds containing various cylindrical mold cavities at various heights (heads). The experimental results are found to be in good agreement with the numerical modeling predictions for filling of rough (sphere-lined) cylindrical mold cavities.

  15. The Investment Committee. Effective Committees. Board Basics.

    ERIC Educational Resources Information Center

    Biggs, John H.

    1997-01-01

    The investment committee of the college or university governing board is charged with determining, overseeing, and assessing the policies and processes by which institutional funds are invested. The committee has fiduciary duty to ensure that the terms of investment of donors' gifts are met and to maximize investment returns within an appropriate…

  16. The Investment Committee. Effective Committees. Board Basics.

    ERIC Educational Resources Information Center

    Biggs, John H.

    1997-01-01

    The investment committee of the college or university governing board is charged with determining, overseeing, and assessing the policies and processes by which institutional funds are invested. The committee has fiduciary duty to ensure that the terms of investment of donors' gifts are met and to maximize investment returns within an appropriate…

  17. Government Strategic Support for Investment Activity

    ERIC Educational Resources Information Center

    Turekulova, Assiya N.; Mukhambetova, Lyazzat K.; Doshan, Almagul S.; Issabekov, Baurzhan N.; Chimgentbayeva, Gulbakyt K.; Turegeldinova, Aliya Zh.

    2016-01-01

    When system risks are high most investors choose to exit the market; however, there are some contrarian investors who opt to make investments. The authors analyzed the main goals of the investment process and measures that should be provided by the government to stimulate investments and innovation especially by means of investment banking. The…

  18. Prediction of Part Distortion in Die Casting

    SciTech Connect

    R. Allen Miller

    2005-03-30

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

  19. Comparison of the Microstructure and Mechanical Properties of As-Cast A356/SiC MMC Processed by ARB and CAR Methods

    NASA Astrophysics Data System (ADS)

    Jamaati, Roohollah; Amirkhanlou, Sajjad; Toroghinejad, Mohammad Reza; Niroumand, Behzad

    2012-07-01

    Accumulative roll bonding (ARB) and continual annealing and roll-bonding (CAR) processes were used in this study for improving the microstructure and mechanical properties of the A356/10 vol.% SiC metal matrix composite (MMC) produced by semi-solid metal processing (SSM). The results showed that using the ARB and CAR processes led to the following points: (a) the uniformity of the silicon and silicon carbide in the aluminum matrix improved, (b) the Si particles became finer and more spheroidal in appearance, (c) the porosity disappeared, (d) the bonding quality between the reinforcement and the matrix improved, (e) the particle-free zone disappeared, and therefore (f) the tensile strength (TS), elongation, and formability index of the MMC samples improved. However, it was found that the CAR process is a better method for improvement of microstructure and mechanical properties of as-cast MMC compared to ARB process.

  20. Effects of colloidal silica suspension mixing on porosity of phosphate-bonded investments after setting and heating processes.

    PubMed

    Bae, Ji-Young; Asaoka, Kenzo

    2013-01-01

    A numerical simulation model, which was based on the setting and heating reactions of the binder phase of phosphate-bonded investment compacts, was developed to compute the porosities of set and burnout compacts. Densities and concentrations of microsilica particles in dilute suspension were measured and input into the simulation model. Validity of the model was confirmed by experimental results, that is, colloidal silica suspensions were prepared using different silica concentrations and mixed with investment powders. Porosities of these set and burnout compacts were experimentally measured. Effects of these factors on the porosity of compacts were examined using the developed simulation model: liquid/powder (L/P) ratio, concentration of microsilica particles in colloidal silica suspension, and ratio of binder component (NH₄H₂PO₄) in investment powder. It was concluded that numerical simulation is a viable tool for dental materials research.

  1. Fabrication of high permeability non-oriented electrical steels by increasing <0 0 1> recrystallization texture using compacted strip casting processes

    NASA Astrophysics Data System (ADS)

    Liu, Hai-Tao; Schneider, J.; Li, Hua-Long; Sun, Yu; Gao, Fei; Lu, Hui-Hu; Song, Hong-Yu; Li, Lei; Geng, Dian-Qiao; Liu, Zhen-Yu; Wang, Guo-Dong

    2015-01-01

    In this paper we will report on the application of the twin-roll casting technique to get a 2 mm thick material of Fe-3.2%Si alloy, which was finally hot rolled, cold rolled and annealed. After a mild hot rolling to a thickness of 1 mm and a mild cold rolling to a thickness of 0.35 mm, we obtained a high intensity of λ-fiber (<0 0 1>|| ND) and η-fiber (<0 0 1>|| RD) texture concentrated on cube ({0 0 1}<0 1 0>) component and a diminishing intensity of the γ-fiber (<1 1 1>|| ND) texture, and a large average grain size in the final processed material. The experimental results for the evolution of the microstructure and texture along the used processing routes were described within the paper in detail. The formation mechanism for the desired recrystallization textures were explained in terms of oriented nucleation, micro-growth selection, accumulated deformation stored energy, geometric softening and orientation pinning. It will be demonstrated that this new processing route using the compact strip casting offers the possibility to fabricate high permeability non-oriented electrical steels without additional fabrication steps like hot band annealing or two step cold rolling with intermediate annealing as in the case of conventional processing route.

  2. Biomimetic Materials by Freeze Casting

    NASA Astrophysics Data System (ADS)

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

    2013-06-01

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

  3. Influence of casting procedures on the corrosion resistance of clinical dental alloys containing palladium.

    PubMed

    Viennot, Stéphane; Lissac, Michèle; Malquarti, Guillaume; Dalard, Francis; Grosgogeat, Brigitte

    2006-05-01

    The aim of this study was to compare the in vitro corrosion resistance in artificial saliva of two palladium-silver alloys (a Pd-Ag (Pors on 4) and an Ag-Pd (Palliag LTG)), with and without casting defects; 1 nickel-chrome alloy and 1 high-gold alloy, cast under recommended conditions, served as controls. For each of the palladium-based alloys, three specimens corresponding to three different casting conditions were used: under recommended conditions, with the use of a graphite-containing investment and crucible, and by reusing the sprues and sprue button. The electrochemical tests were run in Fusayama-Meyer artificial saliva. The open-circuit potential was recorded in mV/SCE at t=24h. Then, potentiodynamic polarization was performed to measure the polarization resistance (R(p)) in kOmega cm(2) and the corrosion current (i(corr)) in microA cm(-2). Data were evaluated with one-way analysis of variance and multiple comparisons test (alpha=0.05). In addition, each specimen was examined by scanning electron microscopy. Compared to the control alloys, the electrochemical experiments in artificial saliva indicated satisfactory corrosion resistance for the Pd-Ag and Ag-Pd alloys; these results are related to their high noble metal content and stable substructure. The Pd-Ag alloy displayed superior electrochemical properties to those of the Ag-Pd alloy regardless of the casting condition. The use of the graphite-containing crucible and investment during the cast process did not dramatically reduce the corrosion resistance values, but the reuse of sprues and the sprue button did. The optimal corrosion resistance values were obtained for the alloys cast according to the recommended conditions.

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

    NASA Astrophysics Data System (ADS)

    Bruneel, David; Kearsley, Andrew; Karnakis, Dimitris

    2015-07-01

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

  5. Computer cast blast modelling

    SciTech Connect

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

    1994-07-01

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

  6. Sixty Years of Casting Research

    NASA Astrophysics Data System (ADS)

    Campbell, John

    2015-11-01

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

  7. Investigation on the Effect of Mold Constraints and Cooling Rate on Residual Stress During the Sand-Casting Process of 1086 Steel by Employing a Thermomechanical Model

    NASA Astrophysics Data System (ADS)

    Baghani, Amir; Davami, Parviz; Varahram, Naser; Shabani, Mohsen Ostad

    2014-06-01

    In this study, the effects of mold constraints and cooling rate on residual stress were analyzed during the shaped casting process. For this purpose, an H-shaped sample was designed in which the contraction of its middle portion is highly restricted by the mold during the cooling process. The effects of an increasing cooling rate combined with mold constraints were analyzed by reducing the thickness of the middle portion in the second sample. A three-dimensional coupled temperature-displacement analysis was performed in finite-element code ABAQUS to simulate residual stress distribution, and then numerical results were verified by the hole-drilling strain-gauge method. It was concluded that the mold constraints have a greater effect on the values of residual stress than the cooling rate (thin section) in steel sand casting. Increasing the cooling rate would increase the amount of residual stress, only in the presence of mold constraints. It is also suggested that employing the elastic-plastic stress model for the sand mold will satisfy the experimental results and avoid exaggerated values of residual stress in simulation.

  8. Interplay of processing, morphological order, and charge-carrier mobility in polythiophene thin films deposited by different methods: comparison of spin-cast, drop-cast, and inkjet-printed films.

    PubMed

    Wong, Loke-Yuen; Png, Rui-Qi; Silva, F B Shanjeera; Chua, Lay-Lay; Repaka, D V Maheswar; Shi-Chen; Gao, Xing-Yu; Ke, Lin; Chua, Soo-Jin; Wee, Andrew T S; Ho, Peter K H

    2010-10-05

    The dependence of morphology and polymer-chain orientation of regioregular poly(3-hexylthiophene) (rrP3HT) thin films on processing conditions have been widely studied. However, their possible variation across the film thickness direction remains largely unknown. We report here a marked difference in the optical dielectric (n,k) spectra between the top and bottom interfaces of spin-cast (sc) rrP3HT films deposited from chlorobenzene solutions. These spectra were obtained from reflection variable-angle spectroscopic ellipsometry using a self-consistent graded optical model with self-imposed Kramers-Krönig consistency. The top interface shows a red-shifted absorption that is characteristic of better order than at the bottom, across a wide range of film thicknesses. This disparity diminishes in drop-cast (dc) and multipass inkjet-printed (ijp) films, and disappears in amorphous films such as those of polystyrene and of a green-emitting phenyl-substituted poly(p-phenylenevinylene). The (n,k) spectra also reveal that crystallinity increases across sc < dc < ijp films. This is supported by cross section scanning electron microscopy of the cleaved edges and measurement of the microroughness of both the film interfaces. Furthermore, optical anisotropy decreases across sc > dc > ijp films. Finally, near-edge X-ray absorption fine structure spectroscopy also shows the frontier chains in ijp and dc films are more isotropically oriented than those in sc films. These results suggest that semicrystalline conjugated polymer films can be produced far from equilibrium. This explains the marked variation in their (opto)electronic properties between the top and bottom surfaces that has sometimes been found depending on the film deposition method. In particular, an unusually pronounced crystallization is induced by ijp. We label this marked ijp-induced crystallization the "ijp morphology", which appears to be general, as it is found also in single-inkjet-droplet films. It appears

  9. Centrifugal slip casting of components

    SciTech Connect

    Steinlage, G.A.; Roeder, R.K.; Trumble, K.P.; Bowman, K.J.

    1996-05-01

    Research in layered and functionally gradient materials has emerged because of the increasing demand for high-performance engineering materials. Many techniques have been used to produce layered and functionally gradient components. Common examples include thermal spray processing, powder processing, chemical and physical vapor deposition, high-temperature or combustion synthesis, diffusion treatments, microwave processing and infiltration. Of these techniques, powder processing routes offer excellent microstructural control and product quality, and they are capable of producing large components. Centrifugal slip casting is a powder-processing technique combining the effects of slip casting and centrifugation. In slip casting, consolidation takes place as fluid is removed by the porous mold. Particles within the slip move with the suspending fluid until reaching the mold wall, at which point they are consolidated. In centrifugation, particles within the slip move through the fluid at a rate dependent upon the gravitational force and particle drag.

  10. Study on the microstructural evolution of AZ31 magnesium alloy in a vertical twin-roll casting process

    NASA Astrophysics Data System (ADS)

    Chen, Ming; Hu, Xiao-Dong; Han, Bing; Deng, Xiao-Hu; Ju, Dong-Ying

    2016-02-01

    Finite element method was employed to calculate the macroflow velocity and temperature distribution of the pool domain's biting zone in twin-roll casting. Macroanalysis results were inducted as boundary conditions into microanalysis. Phase field method (PFM) was adopted to investigate the microstructure evolution. Based on the Kim-Kim-Suzuki model, the effect of metal flow velocity was coupled on the solute gradient item, and the real physical parameters of AZ31 were inducted into the numerical calculation. We used the marker and cell method in the discrete element solution of microstructural pattern prediction of AZ31 magnesium alloys. The different flow velocity values that predicted the columnar dendrite evolution were discussed in detail. Numerical simulation results were also compared with the experiment analysis. The microstructure obtained by PFM agrees with the actual pattern observed via optical microscopy.

  11. Thin Wall Iron Castings

    SciTech Connect

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

    2001-10-31

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

  12. Investing in Youth: Brazil

    ERIC Educational Resources Information Center

    OECD Publishing, 2014

    2014-01-01

    The series Investing in Youth builds on the expertise of the Organisation for Economic Cooperation and Development (OECD) on youth employment, social support and skills. It covers both OECD countries and countries in the process of accession to the OECD, as well as some emerging economies. This report provides a detailed diagnosis of the youth…

  13. Investing in Youth: Latvia

    ERIC Educational Resources Information Center

    OECD Publishing, 2015

    2015-01-01

    The series Investing in Youth builds on the expertise of the Organisation for Economic Cooperation and Development (OECD) on youth employment, social support and skills. It covers both OECD countries and countries in the process of accession to the OECD, as well as some emerging economies. This report provides a detailed diagnosis of the youth…

  14. Investing in Youth: Lithuania

    ERIC Educational Resources Information Center

    OECD Publishing, 2016

    2016-01-01

    The series Investing in Youth builds on the expertise of the Organisation for Economic Cooperation and Development (OECD) on youth employment, social support and skills. It covers both OECD countries and countries in the process of accession to the OECD, as well as some emerging economies. The present report on Lithuania is the fourth of a new…

  15. Investing in Youth: Lithuania

    ERIC Educational Resources Information Center

    OECD Publishing, 2016

    2016-01-01

    The series Investing in Youth builds on the expertise of the Organisation for Economic Cooperation and Development (OECD) on youth employment, social support and skills. It covers both OECD countries and countries in the process of accession to the OECD, as well as some emerging economies. The present report on Lithuania is the fourth of a new…

  16. Investing in Youth: Latvia

    ERIC Educational Resources Information Center

    OECD Publishing, 2015

    2015-01-01

    The series Investing in Youth builds on the expertise of the Organisation for Economic Cooperation and Development (OECD) on youth employment, social support and skills. It covers both OECD countries and countries in the process of accession to the OECD, as well as some emerging economies. This report provides a detailed diagnosis of the youth…

  17. Investing in Youth: Brazil

    ERIC Educational Resources Information Center

    OECD Publishing, 2014

    2014-01-01

    The series Investing in Youth builds on the expertise of the Organisation for Economic Cooperation and Development (OECD) on youth employment, social support and skills. It covers both OECD countries and countries in the process of accession to the OECD, as well as some emerging economies. This report provides a detailed diagnosis of the youth…

  18. Effects of Friction Stir Processing Parameters and In Situ Passes on Microstructure and Tensile Properties of Al-Si-Mg Casting

    NASA Astrophysics Data System (ADS)

    Cui, G. R.; Ni, D. R.; Ma, Z. Y.; Li, S. X.

    2014-11-01

    Friction stir processing (FSP) was applied to modify the microstructure of an as-cast A356 alloy. The effects of rotation rate, travel speed, in situ FSP pass, FSP direction, and artificial aging on microstructures and tensile properties were investigated. FSP broke up the coarse eutectic Si phase into 2.5 to 3.5 μm particles and distributed them homogeneously, and resulted in the dissolution of the coarse Mg2Si particles and the elimination of porosity, thereby improving both the strength and the ductility of the casting. Increasing the rotation rate was beneficial to breaking up and dissolving the particles, but it contributed little to eliminating the porosity. The travel speed did not affect the size of the particles apparently, but lower speed was beneficial to eliminating the porosity. 2-pass FSP showed an obvious advantage in the microstructure modification and tensile properties compared with the single-pass. However, a further increase of FSP passes only resulted in slight improvement. The FSP direction of the following pass did not show distinct effect on the microstructure and tensile properties. After post-FSP artificial aging, the strengthening phase (β″-Mg2Si) precipitated, which increased the strength and decreased the ductility of the FSP samples.

  19. Some Metallurgical Issues Concerning Austenite Conditioning in Nb-Ti and Nb-Mo Microalloyed Steels Processed by Near-Net-Shape Casting and Direct Rolling Technologies

    NASA Astrophysics Data System (ADS)

    López, Beatriz; Rodriguez-Ibabe, Jose M.

    2017-06-01

    As thin slab direct rolling technologies are moving to the production of higher quality steel grades, chemical compositions based on Nb-Ti and Nb-Mo become a good option. However, with the use of multiple microalloying additions, the as-cast austenite conditioning becomes more complex. This paper analyzes some of the microstructural features that should be taken into account during the as-cast austenite conditioning in Nb-Ti and Nb-Mo microalloyed steel grades. In the case of Nb-Ti grades, it has been observed that the process parameters during solidification and post-solidification steps affect the austenite evolution during hot rolling. This is due to the differences in the size and volume fraction of TiN particles that can be formed. Fine TiN precipitates have been shown to be able to delay recrystallization kinetics. Moreover, the solute drag effect of Ti cannot be ignored in the case of hyperstoichiometric Ti/N ratios. It is observed that Nb-Ti grades tend to have lower non-recrystallization temperatures compared to Nb grades, which means that pancaking of the austenite is more difficult for these steels. The opposite is observed for the Nb-Mo grades, although in both cases the behavior is affected by the nominal content of Nb.

  20. Mathematical Modeling of High-Temperature Constitutive Equations and Hot Processing Maps for As-Cast SA508-3 Steel

    NASA Astrophysics Data System (ADS)

    Sui, Dashan; Wang, Tao; Zhu, Lingling; Gao, Liang; Cui, Zhenshan

    2016-11-01

    The hot deformation behavior and hot workability characteristics of as-cast SA508-3 steel were studied by modeling the constitutive equations and developing hot processing maps. The isothermal compression experiments were carried out at temperatures of 950°C, 1050°C, 1150°C, and 1250°C and strain rates of 0.001 s-1, 0.01 s-1, 0.1 s-1, and 1 s-1 respectively. The two-stage flow stress models were established through the classical theories on work hardening and softening, and the solution of activation energy for hot deformation was 355.0 kJ mol-1 K-1. Based on the dynamic material model, the power dissipation and instability maps were developed separately at strains of 0.2, 0.4, 0.6 and 0.8. The power dissipation rate increases with both the increase of temperature and the decrease of strain rate, and the instable region mainly appears on the conditions of low temperature and high strain rate. The optimal hot working parameters for as-cast SA508-3 steel are 1050-1200°C/0.001-0.1 s-1, with about 25-40% peak efficiency of power dissipation.

  1. Some Metallurgical Issues Concerning Austenite Conditioning in Nb-Ti and Nb-Mo Microalloyed Steels Processed by Near-Net-Shape Casting and Direct Rolling Technologies

    NASA Astrophysics Data System (ADS)

    López, Beatriz; Rodriguez-Ibabe, Jose M.

    2016-08-01

    As thin slab direct rolling technologies are moving to the production of higher quality steel grades, chemical compositions based on Nb-Ti and Nb-Mo become a good option. However, with the use of multiple microalloying additions, the as-cast austenite conditioning becomes more complex. This paper analyzes some of the microstructural features that should be taken into account during the as-cast austenite conditioning in Nb-Ti and Nb-Mo microalloyed steel grades. In the case of Nb-Ti grades, it has been observed that the process parameters during solidification and post-solidification steps affect the austenite evolution during hot rolling. This is due to the differences in the size and volume fraction of TiN particles that can be formed. Fine TiN precipitates have been shown to be able to delay recrystallization kinetics. Moreover, the solute drag effect of Ti cannot be ignored in the case of hyperstoichiometric Ti/N ratios. It is observed that Nb-Ti grades tend to have lower non-recrystallization temperatures compared to Nb grades, which means that pancaking of the austenite is more difficult for these steels. The opposite is observed for the Nb-Mo grades, although in both cases the behavior is affected by the nominal content of Nb.

  2. Maritime Cast Shop Integrated Improvement Plan

    DTIC Science & Technology

    2010-08-20

    as well as the risers, sprues and runners that are cut off as scrap from the cast component. The post cast component clean up process should...include several steps  Revert from all sources, risers, sprues, runners and pigged material, must be weighed  The revert must be marked with alloy and...heat all surfaces of the mold to 250F. The higher interior temperature is advantageous in pouring castings with thin sections such as impeller blades

  3. A Homogeneous Billet Layer Casting Fabrication Method

    NASA Astrophysics Data System (ADS)

    Ren, FengLi; Wang, JunGe; Ge, HongHao; Li, Jun; Hu, Qiaodan; Nadendla, Hari-Babu; Xia, MingXu; Li, JianGuo

    2017-10-01

    A novel additive casting approach, termed as layer casting (LC), was proposed to fabricate ingots with homogeneous composition and grain structure distribution. Ingots of Al-4.5 wt pct Cu were fabricated using conventional and novel methods to verify the feasibility of this novel approach. The results show that the novel processing not only alleviates macrosegregation but also reduces the shrinkage cavity and improves the tensile properties of the as-cast condition.

  4. Friction Stir Welding in Wrought and Cast Aluminum Alloys: Weld Quality Evaluation and Effects of Processing Parameters on Microstructure and Mechanical Properties

    NASA Astrophysics Data System (ADS)

    Pan, Yi; Lados, Diana A.

    2017-04-01

    Friction stir welding (FSW) is a solid-state process widely used for joining similar and dissimilar materials for critical applications in the transportation sector. Understanding the effects of the process on microstructure and mechanical properties is critical in design for structural integrity. In this study, four aluminum alloy systems (wrought 6061-T651 and cast A356, 319, and A390) were processed in both as-fabricated and pre-weld heat-treated (T6) conditions using various processing parameters. The effects of processing and heat treatment on the resulting microstructures, macro-/micro-hardness, and tensile properties were systematically investigated and mechanistically correlated to changes in grain size, characteristic phases, and strengthening precipitates. Tensile tests were performed at room temperature both along and across the welding zones. A new method able to evaluate weld quality (using a weld quality index) was developed based on the stress concentration calculated under tensile loading. Optimum processing parameter domains that provide both defect-free welds and good mechanical properties were determined for each alloy and associated with the thermal history of the process. These results were further related to characteristic microstructural features, which can be used for component design and materials/process optimization.

  5. Friction Stir Welding in Wrought and Cast Aluminum Alloys: Weld Quality Evaluation and Effects of Processing Parameters on Microstructure and Mechanical Properties

    NASA Astrophysics Data System (ADS)

    Pan, Yi; Lados, Diana A.

    2017-01-01

    Friction stir welding (FSW) is a solid-state process widely used for joining similar and dissimilar materials for critical applications in the transportation sector. Understanding the effects of the process on microstructure and mechanical properties is critical in design for structural integrity. In this study, four aluminum alloy systems (wrought 6061-T651 and cast A356, 319, and A390) were processed in both as-fabricated and pre-weld heat-treated (T6) conditions using various processing parameters. The effects of processing and heat treatment on the resulting microstructures, macro-/micro-hardness, and tensile properties were systematically investigated and mechanistically correlated to changes in grain size, characteristic phases, and strengthening precipitates. Tensile tests were performed at room temperature both along and across the welding zones. A new method able to evaluate weld quality (using a weld quality index) was developed based on the stress concentration calculated under tensile loading. Optimum processing parameter domains that provide both defect-free welds and good mechanical properties were determined for each alloy and associated with the thermal history of the process. These results were further related to characteristic microstructural features, which can be used for component design and materials/process optimization.

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

    NASA Astrophysics Data System (ADS)

    Singh, Rupinder; Singh, Harvir

    2016-04-01

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

  7. Final report on Expendable Pattern Casting Technology

    SciTech Connect

    Not Available

    1990-07-01

    The Expendable Pattern Casting (EPC) process is a potential casting process breakthrough which could dramatically improve the competitiveness of the US foundry industry. Cooperatively supported by US Industry and the Department of Energy and managed by the American Foundrymen's Society, a project was started in May 1989 to develop and optimize expendable pattern casting technology. Four major tasks were conducted in the first phase of the project. Those tasks involved: (1) reviewing published literature to determine the major problems in the EPC process, (2) evaluating factors influencing sand flow and compaction, (3) evaluating and comparing factors influencing sand flow and compaction, (3) evaluating and comparing casting precision obtained in the EPC process with that obtained in other processes, and (4) identifying critical parameters that control dimensional precision and defect formation in EP castings. 26 refs., 27 figs., 11 tabs.

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

    NASA Technical Reports Server (NTRS)

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

    1993-01-01

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

  9. A Study on Hot Tearing Behavior of Al-1 Wt Pct Cu Alloy Under Various Strain Rates During Casting Process

    NASA Astrophysics Data System (ADS)

    Bagheri, Majid; Alizadeh, Mostafa; Ahmadi, Ali R.

    2017-04-01

    Objective of this work is to study the generation of hot tears during solidification of Al-1 wt pct Cu alloy, which contain both columnar and equiaxed structures at various strain rates. To reach this goal, an experimental test was designed for applying tensile load on the solidifying shell. The shells were loaded at various pull-rates of 0.1, 0.2, and 0.3 mm/s. The produced samples were studied using scanning electron microscope (SEM) equipped with energy dispersive X-ray spectroscopy probe and metallography techniques. SEM images revealed that both segregated hot tear ( i.e., filled or healed crack) and open hot tears were formed. Hot tears had created severely segregated zones with high concentration of Cu and Fe elements formed in between dendrite arms along the primary grain boundaries. In all cases, open hot tears were formed due to cracking of the segregated zones. With increasing strain rate, lengths of segregated hot tears were increased, moving closer toward the center of the cast. At the highest strain rate, segregated hot tears were formed in the equiaxed grain region along the primary grain boundary.

  10. Fiberglass cast application.

    PubMed

    Smith, Gillian D; Hart, Raymond G; Tsai, Tsu-Min

    2005-05-01

    Plaster of Paris has been largely superceded for casting in orthopedic departments by synthetic cast materials. Despite its weight, its relative brittleness, its unpopularity with patients, and its messiness in application, plaster of Paris remains the mainstay of casting in the emergency department. This is due to a combination of economic reasons, the belief that synthetic casts leave less room for swelling and its relative ease of application compared to synthetic materials. We present a technique for synthetic cast application that avoids the problems of the rapidly setting cast and therefore allows the time for less experienced hands to produce a well-fitting cast or splint. We believe that this option, which allows the patient to have a lighter synthetic cast, rather than the traditional plaster of Paris cast, will be welcomed by both the patient and physician.

  11. Reline 33 year old kettle for more corrosive process at about 1/3 cost of new unit: lightweight foamed glass block protects corroded cast iron cover

    SciTech Connect

    Not Available

    1982-06-01

    This article presents a solution to a chemical plant's need for a lining material to reline a 33 year old kettle that would be resistant to attack by aqueous bromine and hydrochloric, nitrous, and bromic acid. The solution was to use an elastomeric polyisobutylene sheeting as a primary lining for the kettle. The problem was also solved by using a light weight foamed glass block which protected the corroded cast iron dome cover for the kettle. Installation of the two-step lining for the kettle and cover by Chemsteel Construction Company of New Kensington, PA was completed in 5 weeks. The cost was about 1/3 as much as fabricating, installing, and lining a new steel 5000 gal vessel. The kettle has been in service about 12 months and the acid brick/polyisobutylene membrance liner shows no signs of damage from the highly corrosive chemicals and elevated temperatures required for the process change.

  12. Evaluation of Mechanical Properties and Marginal Fit of Crowns Fabricated Using Commercially Pure Titanium and FUS-Invest

    PubMed Central

    Wu, Jinshuang; Wang, Xianli; Xing, Helin; Guo, Tianwen; Dong, Chaofang

    2017-01-01

    This study investigated the mechanical properties and single crown accuracy of the tailor-made Fourth University Stomatology investment (FUS-invest) for casting titanium. Background. Current investment for casting titanium is not optimal for obtaining high-quality castings, and the commercially available titanium investment is costly. Methods. Titanium specimens were cast using the tailor-made FUS-invest. The mechanical properties were tested using a universal testing machine. Fractured castings were characterized by energy-dispersive spectroscopy. 19 titanium crowns were produced using FUS-invest and another 19 by Symbion. The accuracy of crowns was evaluated. Results. The mechanical properties of the titanium cast by FUS-invest were elastic modulus 125.6 ± 8.8 GPa, yield strength 567.5 ± 11.1 MPa, tensile strength 671.2 ± 15.6 MPa, and elongation 4.6 ± 0.2%. For marginal fit, no significant difference (P > 0.05) was found at four marker points of each group. For internal fit, no significant difference (P > 0.05) was found between two groups, whereas significant difference (P < 0.01) was found at different mark point of each group. Conclusions. The mechanical properties of titanium casted using FUS-invest fulfilled the ISO 9693 criteria. The marginal and internal fit of the titanium crowns using either the FUS-invest or Symbion were similar. PMID:28913355

  13. INTERIOR VIEW WITH CASTING MACHINE AND CASTING FOREMAN OBSERVING OPERATION ...

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

    INTERIOR VIEW WITH CASTING MACHINE AND CASTING FOREMAN OBSERVING OPERATION TO ENSURE MAXIMUM PRODUCTION AND QUALITY. - McWane Cast Iron Pipe Company, Pipe Casting Area, 1201 Vanderbilt Road, Birmingham, Jefferson County, AL

  14. Whose crazy investment in sex?

    PubMed

    Mandlis, Lane R

    2011-01-01

    By probing the processes of exclusion of transsexuals from the political sphere, this article offers contributions to social and political theory through an examination of the processes of exclusion from the category "human." This article considers how the erasure of investment in their own embodied sex constructs a platform from which to blame others for sex/gender variance, as well as to justify that blaming. Bringing together Giorgio Agamben, Georges Bataille, Judith Butler, and Nikolas Rose with transphobia, medicalization in psychiatry, law, and ethopolitics, this article questions whose investment in sexed embodiment counts and why that investment might be seen as "crazy."

  15. Iron/Phosphorus Alloys for Continuous Casting

    NASA Technical Reports Server (NTRS)

    Dufresne, E. R.

    1986-01-01

    Continuous casting becomes practicable because of reduced eutectic temperature. Experimental ferrous alloy has melting point about 350 degrees C lower than conventional steels, making possible to cast structural members and eliminating need for hot rolling. Product has normal metal structure and good physical properties. Process used to make rails, beams, slabs, channels, and pipes.

  16. Iron/Phosphorus Alloys for Continuous Casting

    NASA Technical Reports Server (NTRS)

    Dufresne, E. R.

    1986-01-01

    Continuous casting becomes practicable because of reduced eutectic temperature. Experimental ferrous alloy has melting point about 350 degrees C lower than conventional steels, making possible to cast structural members and eliminating need for hot rolling. Product has normal metal structure and good physical properties. Process used to make rails, beams, slabs, channels, and pipes.

  17. Engineering design of centrifugal casting machine

    NASA Astrophysics Data System (ADS)

    Kusnowo, Roni; Gunara, Sophiadi

    2017-06-01

    Centrifugal casting is a metal casting process in which metal liquid is poured into a rotating mold at a specific temperature. Given round will generate a centrifugal force that will affect the outcome of the casting. Casting method is suitable in the manufacture of the casting cylinder to obtain better results. This research was performed to design a prototype machine by using the concept of centrifugal casting. The design method was a step-by-step systematic approach in the process of thinking to achieve the desired goal of realizing the idea and build bridges between idea and the product. Design process was commenced by the conceptual design phase and followed by the embodiment design stage and detailed design stage. With an engineering design process based on the method developed by G. E. Dieter, draft prototype of centrifugal casting machine with dimension of 550×450×400 mm, ¼ HP motor power, pulley and belt mechanism, diameter of 120-150mm, simultaneously with the characteristics of simple casting product, easy manufacture and maintenance, and relatively inexpensive, was generated.

  18. An investigation of squeeze-cast alloy 718

    NASA Technical Reports Server (NTRS)

    Gamwell, W. R.

    1993-01-01

    Alloy 718 billets produced by the squeeze-cast process have been evaluated for use as potential replacements for propulsion engine components which are normally produced from forgings. Alloy 718 billets were produced using various processing conditions. Structural characterizations were performed on 'as-cast' billets. As-cast billets were then homogenized and solution treated and aged according to conventional heat-treatment practices for this alloy. Mechanical property evaluations were performed on heat-treated billets. As-cast macrostructures and microstructures varied with squeeze-cast processing parameters. Mechanical properties varied with squeeze-cast processing parameters and heat treatments. One billet exhibited a defect free, refined microstructure, with mechanical properties approaching those of wrought alloy 718 bar, confirming the feasibility of squeeze-casting alloy 718. However, further process optimization is required, and further structural and mechanical property improvements are expected with process optimization.

  19. Evolution of aluminide coating microstructure on nickel-base cast superalloy CM-247 in a single-step high-activity aluminizing process

    SciTech Connect

    Das, D.K.; Joshi, S.V.; Singh, V.

    1998-08-01

    This study deals with the aluminizing of a directionally cast Ni-base superalloy, namely CM-247, by a single-step process using a high-activity pack. It is observed that significant incorporation of Al into the substrate surface during aluminizing continues over a period of about 1 hour and is not restricted merely to the first few minutes, as reported in the literature. Based on the microstructural details of the coatings formed at various stages of aluminizing, it is concluded that the coating growth in the above process takes place primarily by inward Al diffusion initially, followed by an intermediate stage when the growth involves both inward Al and outward Ni diffusion. In the final stages, the outward diffusion of Ni dominates the coating formation process. The above mechanism of coating formation is different from the one that prevails in the conventional two-step high-activity coating process in that the reaction front for the formation of NiAl remains spatially stationary despite the outward diffusion of nickel during the intermediate stage. It is also shown in the present study that the content of the Al source in the pack affects the coating structure significantly. It is further demonstrated that the microstructure of the aluminide coatings depends not only on the amount of Al incorporated in the sample during aluminizing but also on the time over which the uptake of this Al takes place.

  20. Plastic casting resin poisoning

    MedlinePlus

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

  1. Cool Cast Facts

    MedlinePlus

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

  2. Cast Aluminum Alloy for High Temperature Applications

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A.

    2003-01-01

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

  3. 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.

  4. Cast articulation accuracy using rigid cast stabilization.

    PubMed

    Gunderson, Ronald Bruce; Siegel, Sharon Crane

    2002-06-01

    This study evaluated the positional accuracy of casts articulated on a semi-adjustable articulator, with and without rigid cast stabilization using either laboratory plaster or mounting plaster. A reference articulation of melamine casts in maximum articulation was established and recorded in the horizontal and vertical dimensions using a verification device. The same casts were subsequently remounted 24 times using either laboratory plaster or mounting plaster. Half of the articulations from each group were stabilized using detachable mounting rods and sticky wax, and half were hand-articulated without stabilization, for a total of 6 articulations in each of 4 test groups. The resulting spatial positions established on the articulator were compared to the initial reference position on the verification device grid. Means and standard deviations of the absolute values of the horizontal and vertical displacement for each group were determined separately and compared using a one-way anaylsis of variance. Significant differences (p <0.05) were identified using Tukey's honestly significant difference multiple comparison test. Mean vertical mandibular cast displacement ranged from 0.26 +/-0.21mm for stabilized casts mounted with laboratory plaster to 1.58 +/-0.32 mm for unstabilized casts mounted with mounting plaster. For each mounting material, significantly less vertical displacement (p <0.001) was observed with the mandibular cast stabilized before mounting. The cast mounted with laboratory plaster exhibited horizontal displacement (0.87 +/-0.29 mm) that was significantly greater than the remaining groups (p <0.001), which did not differ from each other. Rigid stabilization of the mandibular to maxillary cast during mounting with laboratory and mounting plaster improved articulation accuracy. Copyright 2002 by The American College of Prosthodontists.

  5. Melt Conditioned DC (MC-DC) Casting of Magnesium Alloys

    NASA Astrophysics Data System (ADS)

    Zuo, Y. B.; Jiang, B.; Zhang, Y.; Fan, Z.

    A new melt conditioned direct chill (MC-DC) casting process has been developed for producing high quality magnesium alloy billets and slabs. In the MC-DC casting process, intensive melt shearing provided by a high shear device is applied directly to the alloy melt in the sump during DC casting. The high shear device provides intensive melt shearing to disperse potential nucleating particles, creates a macroscopic melt flow to distribute uniformly the dispersed particles, and maintains a uniform temperature and chemical composition throughout the melt in the sump. Experimental results have demonstrated that the MC-DC casting process can produce magnesium alloy billets with significantly refined microstructure and reduced cast defects. In this paper, we introduce the new MC-DC casting process, report the grain refining effect of intensive melt shearing during the MC-DC casting process and discuss the grain refining mechanism.

  6. Possible segregation caused by centrifugal titanium casting.

    PubMed

    Watanabe, K; Okawa, S; Kanatani, M; Nakano, S; Miyakawa, O; Kobayashi, M

    1996-12-01

    The possibility of the segregation under solidification process using a centrifugal casting machine was investigated using an electron probe microanalyzer with elemental distribution map, line analysis and quantitative analysis. When a very small quantity of platinum was added to local molten titanium during the casting process, macroscopic segregation was observed under conditions of density difference of 0.1 g/cm3 at the most, confirming that the centrifugal force of the casting machine is extremely strong. When a Ti-6Al-4V alloy was cast, however, no macroscopic segregation was observed. The centrifugal force of the casting machine examined in the present study hardly results in the body-force segregation in this titanium alloy.

  7. Clean Cast Steel Technology - Machinability and Technology Transfer

    SciTech Connect

    C. E. Bates; J. A. Griffin

    2000-05-01

    There were two main tasks in the Clean Cast Steel Technology - Machinability and Technology Transfer Project. These were (1) determine the processing facts that control the machinability of cast steel and (2) determine the ability of ladle stirring to homogenize ladle temperature, reduce the tap and pouring temperatures, and reduce casting scrap.

  8. Application of TRIZ Theory in Patternless Casting Manufacturing Technique

    NASA Astrophysics Data System (ADS)

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

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

  9. The continuous production of stir cast material

    NASA Astrophysics Data System (ADS)

    Hamoen, A.

    1986-06-01

    The production of AlSi8 extrusion billets using a semicontinuous caster is described. The continuous casting process and the process parameters are outlined. The mathematical model, developed to calculate the temperature distribution within the billet during casting as a function of the process parameters, is explained. Quality control focussed on inversion segregation which causes the formation of a surface layer with a different structure and composition, imposing peeling of billets. Product development focussed on the production of stir-cast material of the same AlSi8 alloy. The use of AlSi8 as a wrought alloy by modification of the structure by stirring is discussed.

  10. Advanced Lost Foam Casting Technology

    SciTech Connect

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

    2000-11-30

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

  11. Optimizing strength and fracture toughness of a cast titanium alloy through heat treatment and microstructure control

    NASA Astrophysics Data System (ADS)

    Robinson, Amy C.

    The relationship between the microstructure and tensile ductility and fracture toughness for cast Ti-5111 was determined and compared to that of hot-rolled and annealed Ti-5111. Graphite mold cast Ti-5111 plate material was examined in the as-received condition and after six different heat treatments involving elevated temperature anneals followed by an air or furnace cool. Three investment cast Ti-5111 plates were also examined after annealing followed by either a fan cool, air cool, or furnace cool. All castings developed a lamellar colony microstructure consisting of aligned lamellae of alpha and beta phases. Altering the cooling rate from the annealing temperature had the most influence on the microstructure such that plates with a slower cooling rate typically developed coarser grain boundary alpha, larger alpha colonies, thicker alpha laths, and greater volume fractions of alpha phase. The average prior beta grain size for the graphite mold cast specimens ranged from 920 mum to 1360 mum, while that for the investment cast specimens was approximately 1750 mum. The tensile behavior of the castings was characterized by a crack initiation and propagation process where the ductility was often limited by the strain required to initiate a large crack. The cracks formed along planar slip bands that crossed alpha colonies or in some cases, entire prior beta grains. Thus, reducing the alpha colony size and prior beta grain size should improve the casting ductility by limiting the length of slip-induced cracks. Due to the large grain and colony sizes present in the castings, the strength and ductility was observed to be sensitive to specimen size such that a smaller tensile diameter (i.e. 3.2 mm as compared to 12.5 mm) decreased the tensile and yield strengths due to the high fraction of large grains located on the specimen surface that can yield by predominantly single slip. The scatter in ductility values in the smaller specimens was significantly greater as a result

  12. Numerical study of porosity in titanium dental castings.

    PubMed

    Wu, M; Sahm, P R; Augthun, M; Spiekermann, H; Schädlich-Stubenrauch, J

    1999-09-01

    A commercial software package, MAGMASOFT (MAGMA Giessereitechnologie GmbH, Aachen, Germany), was used to study shrinkage and gas porosity in titanium dental castings. A geometrical model for two simplified tooth crowns connected by a connector bar was created. Both mold filling and solidification of this casting model were numerically simulated. Shrinkage porosity was quantitatively predicted by means of a built-in feeding criterion. The risk of gas pore formation was investigated using the numerical filling and solidification results. The results of the numerical simulations were compared with experiments, which were carried out on a centrifugal casting machine with an investment block mold. The block mold was made of SiO2 based slurry with a 1 mm thick Zr2 face coat to reduce metal-mold reactions. Both melting and casting were carried out under protective argon (40 kPa). The finished castings were sectioned and the shrinkage porosity determined. The experimentally determined shrinkage porosity coincided with the predicted numerical simulation results. No apparent gas porosity was found in these model castings. Several running and gating systems for the above model casting were numerically simulated. An optimized running and gating system design was then experimentally cast, which resulted in porosity-free castings.

  13. [Studies on application of pure titanium for cast plate].

    PubMed

    Sakai, M

    1990-06-01

    Pure titanium produced by a commercial pure titanium casting system was studied for use as a cast plate for clinical application. The mechanical properties, elemental analysis, castability, adaptability of pure titanium and adhesion to denture base resin were investigated. The interfacial zone of the pure titanium castings was composed of a layered structure obtained by reaction with phosphate bonded Al2O3/SiO2 investment material. Vicher's hardness at 100 microns thick from the surface was higher than that in the inner part by oxidation. Cast pure titanium showed tensile strength, elongation and hardness close to those of the type III or IV dental gold alloy. The castability of pure titanium was lower than that of Co-Cr alloy and pure titanium castings also had large casting defects. Adaptability between pure titanium cast plate and the working model was satisfactory when reversible hydrocolloid impression material was used with heating-bath treatment in the refractory model. The tensile and compressive shear bonding strength of pure titanium to heat-curing or self-curing resin were similar to that of the Co-Cr alloy, and surface treatment using a solution containing 2-vol% 3-methacryloxypropyltrimethoxysilane produced a higher bonding strength than non-treatment, MKV treatment and 4-META treatment. These findings suggest that pure titanium castings produced by this system have suitable mechanical properties, adaptability and adhesion to denture base resin, and is available for cast plate in clinical application.

  14. Synthesis of aluminum-rich coatings on new high-temperature cast austenitic steel CF8C-Plus by a pack cementation process

    NASA Astrophysics Data System (ADS)

    Hall, Alex Keith

    2011-12-01

    In this research, a pack cementation process is developed for coating the newly developed cast austenitic steel CF8C-Plus. The developed coating process is capable of producing pack particle free coatings on large fatigue test specimens in a horizontal laboratory tube furnace as well as smaller oxidation and creep test samples. Several methods for the production of the pack powder free Al-rich coating are presented and evaluated for samples of both sizes. The developed coating is intended to compete with coatings of a similar quality produced with chemical vapor deposition and slurry coating methods. Additionally, because CF8C-Plus has only recently become available there is currently no available data on the effect of the fabrication of an Al-rich coating on the substrates properties. This research used advanced characterization methods to evaluate the coating surface and cross-sectional features. These methods include scanning electron microscopy, X-ray diffraction, electron probe microanalysis and energy dispersive spectroscopy analysis. This is the first time that this information has been made available to the scientific community. Also, the oxidation performance of the coating will be tested and compared to other coatings developed with CVD and slurry coating methods and the preliminary results of the effect of the coating on the alloys fatigue performance will be presented.

  15. Biomaterials by freeze casting.

    PubMed

    Wegst, Ulrike G K; Schecter, Matthew; Donius, Amalie E; Hunger, Philipp M

    2010-04-28

    The functional requirements for synthetic tissue substitutes appear deceptively simple: they should provide a porous matrix with interconnecting porosity and surface properties that promote rapid tissue ingrowth; at the same time, they should possess sufficient stiffness, strength and toughness to prevent crushing under physiological loads until full integration and healing are reached. Despite extensive efforts and first encouraging results, current biomaterials for tissue regeneration tend to suffer common limitations: insufficient tissue-material interaction and an inherent lack of strength and toughness associated with porosity. The challenge persists to synthesize materials that mimic both structure and mechanical performance of the natural tissue and permit strong tissue-implant interfaces to be formed. In the case of bone substitute materials, for example, the goal is to engineer high-performance composites with effective properties that, similar to natural mineralized tissue, exceed by orders of magnitude the properties of its constituents. It is still difficult with current technology to emulate in synthetic biomaterials multi-level hierarchical composite structures that are thought to be the origin of the observed mechanical property amplification in biological materials. Freeze casting permits to manufacture such complex, hybrid materials through excellent control of structural and mechanical properties. As a processing technique for the manufacture of biomaterials, freeze casting therefore has great promise.

  16. Women's Political Empowerment and Investments in Primary Schooling in India.

    PubMed

    Halim, Nafisa; Yount, Kathryn M; Cunningham, Solveig A; Pande, Rohini P

    2016-02-01

    Using a national district-level dataset of India composed of information on investments in primary schooling (data from the District Information Survey for Education [DISE, 2007/8]) and information on demographic characteristics of elected officials (data from the Election Commission of India [ECI, 2000/04]), we examined the relationship between women's representation in State Legislative Assembly (SLA) seats and district-level investments in primary schooling. We used OLS regressions adjusting for confounders and spatial autocorrelation, and estimated separate models for North and South India. Women's representation in general SLA seats typically was negatively associated with investments in primary-school amenities and teachers; women's representation in SLA seats reserved for under-represented minorities, i.e., scheduled castes and scheduled tribes, typically was positively associated with investments in primary schooling, especially in areas addressing the basic needs of poor children. Women legislators' gender and caste identities may shape their decisions about redistributive educational policies.

  17. Riser Feeding Evaluation Method for Metal Castings Using Numerical Analysis

    NASA Astrophysics Data System (ADS)

    Ahmad, Nadiah

    One of the design aspects that continues to create a challenge for casting designers is the optimum design of casting feeders (risers). As liquid metal solidifies, the metal shrinks and forms cavities inside the casting. In order to avoid shrinkage cavities, risers are added to the casting shape to supply additional molten metal when shrinkage occurs during solidification. The shrinkage cavities in the casting are compensated by controlling the cooling rate to promote directional solidification. This control can be achieved by designing the casting such that the cooling begins at the sections that are farthest away from the risers and ends at the risers. Therefore, the risers will solidify last and feed the casting with the molten metal. As a result, the shrinkage cavities formed during solidification are in the risers which are later removed from the casting. Since casting designers have to usually go through iterative processes of validating the casting designs which are very costly due to expensive simulation processes or manual trials and errors on actual casting processes, this study investigates more efficient methods that will help casting designers utilize their casting experiences systematically to develop good initial casting designs. The objective is to reduce the casting design method iterations; therefore, reducing the cost involved in that design processes. The aim of this research aims at finding a method that can help casting designers design effective risers used in sand casting process of aluminum-silicon alloys by utilizing the analysis of solidification simulation. The analysis focuses on studying the significance of pressure distribution of the liquid metal at the early stage of casting solidification, when heat transfer and convective fluid flow are taken into account in the solidification simulation. The mathematical model of casting solidification was solved using the finite volume method (FVM). This study focuses to improve our

  18. The role of water in slip casting

    NASA Astrophysics Data System (ADS)

    McCauley, R. A.; Phelps, G. W.

    1984-05-01

    Slips and casting are considered in terms of physical and colloidal chemistry. Casting slips are polydisperse suspensions of lyophobic particles in water, whose degree of coagulation is controlled by interaction of flocculating and deflocculating agents. Slip casting rate and viscosity are functions of temperature. Slip rheology and response to deflocculating agents varies significantly as the kinds and amounts of colloid modifiers change. Water is considered as a raw material. Various concepts of water/clay interactions and structures are discussed. Casting is a de-watering operation in which water moves from slip to cast to mold in response to a potential energy termed moisture stress. Drying is an evaporative process from a free water surface.

  19. The role of water in slip casting

    NASA Technical Reports Server (NTRS)

    Mccauley, R. A.; Phelps, G. W.

    1984-01-01

    Slips and casting are considered in terms of physical and colloidal chemistry. Casting slips are polydisperse suspensions of lyophobic particles in water, whose degree of coagulation is controlled by interaction of flocculating and deflocculating agents. Slip casting rate and viscosity are functions of temperature. Slip rheology and response to deflocculating agents varies significantly as the kinds and amounts of colloid modifiers change. Water is considered as a raw material. Various concepts of water/clay interactions and structures are discussed. Casting is a de-watering operation in which water moves from slip to cast to mold in response to a potential energy termed moisture stress. Drying is an evaporative process from a free water surface.

  20. Effect of process parameters on properties of Al-Si alloys cast by Rapid Slurry Formation (RSF) technique

    NASA Astrophysics Data System (ADS)

    Ratke, L.; Sharma, A.; Kohli, D.

    2012-01-01

    Rapid slurry formation is a semi-solid metal forming technique, which is based on a so-called solid enthalpy exchange material (EEM). It is a fascinating technology offering the opportunity to manufacture net-shaped metal components of complex geometry in a single forming operation. At the same time, high mechanical properties can be achieved due to the unique microstructure and flow behaviour. The major process parameters used in the RSF process are rotation speed of the EEM, melt superheat, amount of EEM added (determining fs), and holding time. The process parameters can be well controlled with clear effects on the microstructure. There is a lack of theoretical modelling of the morphological evolution in these two-phase slurries.

  1. Fractal analysis of complex microstructure in castings

    SciTech Connect

    Lu, S.Z.; Lipp, D.C.; Hellawell, A.

    1995-12-31

    Complex microstructures in castings are usually characterized descriptively which often raises ambiguity and makes it difficult to relate the microstructure to the growth kinetics or mechanical properties in processing modeling. Combining the principle of fractal geometry and computer image processing techniques, it is feasible to characterize the complex microstructures numerically by the parameters of fractal dimension, D, and shape factor, a, without ambiguity. Procedures of fractal measurement and analysis are described, and a test case of its application to cast irons is provided. The results show that the irregular cast structures may all be characterized numerically by fractal analysis.

  2. Castings, Steel, Homogenization of Steel Castings

    DTIC Science & Technology

    1942-12-05

    diffraction pattern of quenched and tempered steel castings. 2. Calculations based upon known diffusion rates show: A. Practical homogenizing heat ...will be largely eliminated by either the usual heating for nuenching or a homo- genizing treatment. C. Interdendritic segregation of sulfur will...26 Appendix A - History of the Heat Treatment and Composition of Centrifugal Gun Castings at W-tertown Ar- sen-.l. ..... ..................... 2

  3. Vacuum casting of thick polymeric films

    NASA Technical Reports Server (NTRS)

    Cuddihy, E. F.; Moacanin, J.

    1979-01-01

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

  4. Glovebox Advanced Casting System Casting Optimization

    SciTech Connect

    Fielding, Randall Sidney

    2016-03-01

    Casting optimization in the GACS included three broad areas; casting of U-10Zr pins, incorporation of an integral FCCI barrier, and development of a permanent crucible coating. U-10Zr casting was improved over last year’s results by modifying the crucible design to minimize contact with the colder mold. Through these modifications casting of a three pin batch was successful. Incorporation of an integral FCCI barrier also was optimized through furnace chamber pressure changes during the casting cycle to reduce gas pressures in the mold cavities which led to three full length pins being cast which incorporated FCCI barriers of three different thicknesses. Permanent crucible coatings were tested against a base case; 1500°C for 10 minutes in a U-20Pu-10Zr molten alloy. None of the candidate coating materials showed evidence of failure upon initial visual examination. In all areas of work a large amount of characterization will be needed to fully determine the effects of the optimization activities. The characterization activities and future work will occur next year.

  5. The Investment Paradigm

    ERIC Educational Resources Information Center

    Perna, Mark C.

    2005-01-01

    Is marketing an expense or an investment? Most accountants will claim that marketing is an expense, and clearly that seems true when cutting the checks to fund these efforts. When it is done properly, marketing is the best investment. A key principle to Smart Marketing is the Investment Paradigm. The Investment Paradigm is understanding that every…

  6. The Investment Paradigm

    ERIC Educational Resources Information Center

    Perna, Mark C.

    2005-01-01

    Is marketing an expense or an investment? Most accountants will claim that marketing is an expense, and clearly that seems true when cutting the checks to fund these efforts. When it is done properly, marketing is the best investment. A key principle to Smart Marketing is the Investment Paradigm. The Investment Paradigm is understanding that every…

  7. Investing for the Future.

    ERIC Educational Resources Information Center

    Goodall, Leonard E.

    1992-01-01

    Four steps to retirement planning, intended to demystify retirement investment, are offered for college faculty: (1) establish diversification goals; (2) urge their institutions to offer more investment options; (3) coordinate retirement investments with other investments; and (4) take steps to guarantee against inflation. Typical age-related…

  8. Preferred Orientation Contribution to the Anisotropic Normal State Resistivity in Superconducting Melt-Cast Processed Bi2Sr2CaCu2O8+δ

    PubMed Central

    Dellicour, Aline; Vertruyen, Benedicte; Rikel, Mark O.; Lutterotti, Luca; Pautrat, Alain; Ouladdiaf, Bachir; Chateigner, Daniel

    2017-01-01

    We describe how the contribution of crystallographic texture to the anisotropy of the resistivity of polycrystalline samples can be estimated by averaging over crystallographic orientations through a geometric mean approach. The calculation takes into account the orientation distribution refined from neutron diffraction data and literature values for the single crystal resistivity tensor. The example discussed here is a melt-cast processed Bi2Sr2CaCu2O8+δ (Bi-2212) polycrystalline tube in which the main texture component is a <010> fiber texture with relatively low texture strength. Experimentally-measured resistivities along the longitudinal, radial, and tangential directions of the Bi-2212 tube were compared to calculated values and found to be of the same order of magnitude. Calculations for this example and additional simulations for various texture strengths and single crystal resistivity anisotropies confirm that in the case of highly anisotropic phases such as Bi-2212, even low texture strengths have a significant effect on the anisotropy of the resistivity in polycrystalline samples. PMID:28772894

  9. Influence of processing route on electrical properties of Bi{sub 4}Ti{sub 3}O{sub 12} ceramics obtained by tape-casting technology

    SciTech Connect

    Ranieri, M.G.A.; Aguiar, E.C.; Cilense, M.; Stojanovic, B.D.; Simões, A.Z.; Varela, J.A.

    2015-10-15

    Highlights: • Bi{sub 4}Ti{sub 3}O{sub 12} thick films were obtained by SSR and PPM methods. • Both systems crystallize in an orthorhombic structure. • Textured characteristics were evidenced. • Grain morphology affects the P–E loops. - Abstract: Bismuth titanate powders (Bi{sub 4}Ti{sub 3}O{sub 12}-BIT) were fabricated by solid state reaction (SSR) and polymeric precursor method (PPM). From these powders, Bi{sub 4}Ti{sub 3}O{sub 12} pellets were obtained by tape-casting using plate-like templates particles prepared by a molten salt method. The BIT phase crystallizes in an orthorhombic structure type with space group Fmmm. Agglomeration of the particles, which affects the densification of the ceramic, electrical conduction and leakage current at high electric fields, was monitored by transmission electronic microscopy (TEM) analyses. FEG-SEM indicated that different shape of grains of BIT ceramics was influenced by the processing route. Both SSR and PPM methods lead to unsaturated P–E loops of BIT ceramics originating from the highly c-axis orientation and high conductivity which was affected by charge carriers flowing normally to the grain boundary of the crystal lattice.

  10. Effects of the pouring temperature on the formation of the bonding zone between AZ91 and AlSi17 in the compound casting process

    NASA Astrophysics Data System (ADS)

    Mola, R.; Bucki, T.; Dziadoń, A.

    2017-02-01

    The compound casting process was used to join AZ91 magnesium alloy to AlSi17 aluminium alloy. Liquid AZ91 was poured onto a solid AlSi17 insert placed in a steel mould heated to 370 °C. The experimental results showed that the temperature of the AZ91 melt affected the formation of the bonding zone between the two alloys. A continuous bonding zone was formed by applying a pouring temperature of 650 °C. The use of higher temperatures, i.e. 680 °C and 700 °C, did not lead to the formation of a continuous metallurgical transition zone at the AZ91/AlSi17 interface. The bonding zone was analysed using an optical microscope and a scanning electron microscope equipped with an energy dispersive X-ray (EDS) detector. The structural constituents of the bonding zone near the AlSi17 alloy were: an Al3Mg2 intermetallic phase, primary Si particles surrounded by a rim of an Mg2Si intermetallic phase and fine Mg2Si particles. The area of the bonding zone that was adjacent to the AZ91 alloy had a eutectic structure composed of an Mg17Al12 intermetallic phase and a solid solution of Al and Si in Mg.

  11. Heat Transfer Model of Directional Solidification by LMC Process for Superalloy Casting Based on Finite Element Method

    NASA Astrophysics Data System (ADS)

    Cao, Liu; Liao, Dunming; Lu, Yuzhang; Chen, Tao

    2016-09-01

    With the rapid development of the aviation industry, the turbine blade, a critical component of the aeronautical engine, has come to be widely produced by liquid-metal cooling (LMC) process. A temperature- and time-dependent heat transfer coefficient was used to represent the heat convection between the shell and the cooling liquid, and an improved Monte Carlo ray-tracing approach was adopted to handle the boundary of radiation heat transfer. Unstructured mesh was used to fit the irregular shell boundary, and the heat transfer model of directional solidification by LMC process based on finite element method (FEM) was established. The concept of local matrix was here proposed to guarantee computational efficiency. The pouring experiments of directional solidification by LMC process were carried out, then simulation and experimental results were compared here. The accuracy of the heat transfer model was validated by the cooling curves and grain morphology, and the maximum relative error between simulation and experimental cooling curve was 2 pct. The withdrawal rate showed an important influence on the shape of solidification interface, and stray grain is liable to be generated on the bottom of platform at an excessive withdrawal rate.

  12. Effect of processing parameters on surface finish for fused deposition machinable wax patterns

    NASA Technical Reports Server (NTRS)

    Roberts, F. E., III

    1995-01-01

    This report presents a study on the effect of material processing parameters used in layer-by-layer material construction on the surface finish of a model to be used as an investment casting pattern. The data presented relate specifically to fused deposition modeling using a machinable wax.

  13. Ladle and Continuous Casting Process Models for Reduction of SiO2 in SiO2-Al2O3-CaO Slags by Al in Fe-Al(-Si) Melts

    NASA Astrophysics Data System (ADS)

    Park, Jiwon; Sridhar, S.; Fruehan, Richard J.

    2015-02-01

    Based on a mixed control or two-phase mass transfer model considering mass transport in the metal and the slag phases, process models for ladle and continuous castor mold were developed to predict the changes in the metal and the slag chemistry and viscosity. In the ladle process model, the rate of reaction is primarily determined by stirring gas flow rate, which greatly alters the mass transports of the metal and the slag phases. In the continuous casting process model, the effects of the Al, Si, and SiO2 contents in the incoming flow of the fluid phases, casting speed, mold flux consumption rate, and depth of the liquid mold flux pool on the steady-state compositions of the metal and the mold flux were assessed.

  14. Durability and Damage Tolerance of Aluminum Castings

    DTIC Science & Technology

    1988-09-01

    casting alloys A357 and A201. On completion of the program, revisions to material, process, and DADT specifications will be recommended, if necessary...and the effects of process variables on the properties of A357 -T6 and A201-T7 castings were described. This second interim report covers additional...damage tolerance properties of A357 -T6 and A201-T7 produced using the specifications selected earlier [1] in Task 2 were determined. These alloys were

  15. 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.

  16. Effect of Casting Material on the Cast Pressure After Sequential Cast Splitting.

    PubMed

    Roberts, Aaron; Shaw, K Aaron; Boomsma, Shawn E; Cameron, Craig D

    2017-01-01

    Circumferential casting is a vital component of nonoperative fracture management. These casts are commonly valved to release pressure and decrease the risk of complications from swelling. However, little information exists regarding the effect of different casting supplies on the pressure within the cast. Seventy-five long-arm casts were performed on human volunteers, divided between 5 experimental groups with 15 casts in each groups. Testing groups consisted of 2 groups with a plaster short-arm cast overwrapped with fiberglass to a long arm with either cotton or synthetic cast padding. The 3 remaining groups included fiberglass long-arm casts with cotton, synthetic, or waterproof cast padding. A pediatric blood pressure cuff bladder was placed within the cast and inflated to 100 mm Hg. After inflation, the cast was sequentially released with pressure reading preformed after each stage. Order of release consisted of cast bivalve, cast padding release, and cotton stockinet release. After release, the cast was overwrapped with a loose elastic bandage. Difference in pressure readings were compared based upon the cast material. Pressures within the cast were found to decrease with sequential release of cast. The cast type had no effect of change in pressure. Post hoc testing demonstrated that the type of cast padding significantly affected the cast pressures with waterproof padding demonstrating the highest pressure readings at all time-points in the study, followed by synthetic padding. Cotton padding had the lowest pressure readings at all time-points. Type of cast padding significantly influences the amount of pressure within a long-arm cast, even after bivalving the cast and cutting the cast padding. Cotton cast padding allows for the greatest change in pressure. Cotton padding demonstrates the greatest change in pressure within a long-arm cast after undergoing bivalve. Synthetic and waterproof cast padding should not be used in the setting of an acute fracture to

  17. From SRI to ESG: The Changing World of Responsible Investing

    ERIC Educational Resources Information Center

    Caplan, Lauren; Griswold, John S.; Jarvis, William F.

    2013-01-01

    Thoughtful investment professionals continue to debate whether a portfolio's long-term performance can be enhanced by including environmental, social, and governance (ESG) considerations in the security selection process, but responsible investing is more than a passing trend. The terms socially-responsible investing, mission-related investing,…

  18. 13 CFR 301.7 - Investment Assistance application.

    Code of Federal Regulations, 2013 CFR

    2013-01-01

    ... 13 Business Credit and Assistance 1 2013-01-01 2013-01-01 false Investment Assistance application... COMMERCE ELIGIBILITY, INVESTMENT RATE AND APPLICATION REQUIREMENTS Application Requirements; Evaluation Criteria § 301.7 Investment Assistance application. (a) The EDA Investment Assistance process begins with...

  19. 13 CFR 301.7 - Investment Assistance application.

    Code of Federal Regulations, 2014 CFR

    2014-01-01

    ... 13 Business Credit and Assistance 1 2014-01-01 2014-01-01 false Investment Assistance application... COMMERCE ELIGIBILITY, INVESTMENT RATE AND APPLICATION REQUIREMENTS Application Requirements; Evaluation Criteria § 301.7 Investment Assistance application. (a) The EDA Investment Assistance process begins with...

  20. 13 CFR 301.7 - Investment Assistance application.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... 13 Business Credit and Assistance 1 2012-01-01 2012-01-01 false Investment Assistance application... COMMERCE ELIGIBILITY, INVESTMENT RATE AND APPLICATION REQUIREMENTS Application Requirements; Evaluation Criteria § 301.7 Investment Assistance application. (a) The EDA Investment Assistance process begins with...