Direct metal laser sintering: a digitised metal casting technology.

PubMed

Venkatesh, K Vijay; Nandini, V Vidyashree

2013-12-01

Dental technology is undergoing advancements at a fast pace and technology is being imported from various other fields. One such imported technology is direct metal laser sintering technology for casting metal crowns. This article will discuss the process of laser sintering for making metal crowns and fixed partial dentures with a understanding of their pros and cons.

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.

Metallic Fuel Casting Development and Parameter Optimization Simulations

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

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

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

Melt Conditioning of Light Metals by Application of High Shear for Improved Microstructure and Defect Control

NASA Astrophysics Data System (ADS)

Patel, Jayesh B.; Yang, Xinliang; Mendis, Chamini L.; Fan, Zhongyun

2017-04-01

Casting is the first step toward the production of majority of metal products whether the final processing step is casting or other thermomechanical processes such as extrusion or forging. The high shear melt conditioning provides an easily adopted pathway to producing castings with a more uniform fine-grained microstructure along with a more uniform distribution of the chemical composition leading to fewer defects as a result of reduced shrinkage porosities and the presence of large oxide films through the microstructure. The effectiveness of high shear melt conditioning in improving the microstructure of processes used in industry illustrates the versatility of the high shear melt conditioning technology. The application of high shear process to direct chill and twin roll casting process is demonstrated with examples from magnesium melts.

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

NASA Technical Reports Server (NTRS)

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

2003-01-01

Metal matrix composites for propulsion components offer high performance and affordability, resulting in low weight and cost. The following sections in this viewgraph presentation describe the pressure infiltration casting of a metal matrix composite LOX turbopump housing: 1) Baseline Pump Design and Stress Analysis; 2) Tool-less Advanced Pressure Infiltration Casting Process; 3) Preform Splicing and Joining for Large Components such as Pump Housing; 4) Fullscale Pump Housing Redesign.

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

PubMed

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

2018-05-04

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

Clean Metal Casting

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

Makhlouf M. Makhlouf; Diran Apelian

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

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

ERIC Educational Resources Information Center

Rasmussen, Bonnie

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

Method for fabricating laminated uranium composites

DOEpatents

Chapman, L.R.

1983-08-03

The present invention is directed to a process for fabricating laminated composites of uranium or uranium alloys and at least one other metal or alloy. The laminated composites are fabricated by forming a casting of the molten uranium with the other metal or alloy which is selectively positioned in the casting and then hot-rolling the casting into a laminated plate in or around which the casting components are metallurgically bonded to one another to form the composite. The process of the present invention provides strong metallurgical bonds between the laminate components primarily since the bond disrupting surface oxides on the uranium or uranium alloy float to the surface of the casting to effectively remove the oxides from the bonding surfaces of the components.

Fracture behavior of metal-ceramic fixed dental prostheses with frameworks from cast or a newly developed sintered cobalt-chromium alloy.

PubMed

Krug, Klaus-Peter; Knauber, Andreas W; Nothdurft, Frank P

2015-03-01

The aim of this study was to investigate the fracture behavior of metal-ceramic bridges with frameworks from cobalt-chromium-molybdenum (CoCrMo), which are manufactured using conventional casting or a new computer-aided design/computer-aided manufacturing (CAD/CAM) milling and sintering technique. A total of 32 metal-ceramic fixed dental prostheses (FDPs), which are based on a nonprecious metal framework, was produced using a conventional casting process (n = 16) or a new CAD/CAM milling and sintering process (n = 16). Eight unveneered frameworks were manufactured using each of the techniques. After thermal and mechanical aging of half of the restorations, all samples were subjected to a static loading test in a universal testing machine, in which acoustic emission monitoring was performed. Three different critical forces were revealed: the fracture force (F max), the force at the first reduction in force (F decr1), and the force at the critical acoustic event (F acoust1). With the exception of the veneered restorations with cast or sintered metal frameworks without artificial aging, which presented a statistically significant but slightly different F max, no statistically significant differences between cast and CAD/CAM sintered and milled FDPs were detected. Thermal and mechanical loading did not significantly affect the resulting forces. Cast and CAD/CAM milled and sintered metal-ceramic bridges were determined to be comparable with respect to the fracture behavior. FDPs based on CAD/CAM milled and sintered frameworks may be an applicable and less technique-sensitive alternative to frameworks that are based on conventionally cast frameworks.

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

PubMed Central

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

2018-01-01

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

A transparent model of the human scala tympani cavity.

PubMed

Rebscher, S J; Talbot, N; Bruszewski, W; Heilmann, M; Brasell, J; Merzenich, M M

1996-01-01

A dimensionally accurate clear model of the human scala tympani has been produced to evaluate the insertion and position of clinically applied intracochlear electrodes for electrical stimulation. Replicates of the human scala tympani were made from low melting point metal alloy (LMA) and from polymethylmeth-acrylate (PMMA) resin. The LMA metal casts were embedded in blocks of epoxy and in clear silicone rubber. After removal of the metal alloy, a cavity was produced that accurately models the human scala tympani. Investment casting molds were made from the PMMA scala tympani casts to enable production of multiple LMA casts from which identical models were fabricated. Total dimensional distortion of the LMA casting process was less than 1% in length and 2% in diameter. The models have been successfully integrated into the design process for the iterative development of advanced intracochlear electrode arrays at UCSF. These fabrication techniques are applicable to a wide range of biomedical design problems that require modelling of visually obscured cavities.

Mechanical properties of aluminium fused SiO2 particulate composites cast using metallic and non-metallic chills

NASA Astrophysics Data System (ADS)

Harshith, H. S.; Hemanth, Joel

2018-04-01

This research work aims at developing and mechanical characterization of aluminium (LM13) based metal matrix composite reinforced with varying percentage of fused SiO2 (3%,6%,9%,12%). The mechanical properties are completely dependent on the microstructural parameters of the system. Also the microstructure further depends on the cooling rates during solidification process. Various Chills like Silicon carbide, Mild steel, Copper were used during the casting process to increase the rate of solidification, which enhances the mechanical properties of the composite. The chill casted specimens were subjected to tensile and hardness tests followed by microstructure studies. A casting produced using mild steel chill exhibited higher young's modulus and was found to be maximum at 9% reinforcement. Finer microstructure and better UTS were seen for specimen's casted using copper chills, whereas silicon carbide and mild steel chills gave rise to very coarse structure with reduced UTS values compared to copper chills.

Fixture for forming evaporative pattern (EPC) process patterns

DOEpatents

Turner, Paul C.; Jordan, Ronald R.; Hansen, Jeffrey S.

1993-01-01

A method of casting metal using evaporative pattern casting process patterns in combination with a fixture for creating and maintaining a desired configuration in flexible patterns. A pattern is constructed and gently bent to the curvature of a suitable fixture. String or thin wire, which burns off during casting, is used to tie the pattern to the fixture. The fixture with pattern is dipped in a commercially available refractory wash to prevent metal adherence and sticking to the fixture. When the refractory wash is dry, the fixture and pattern are placed in a flask, and sand is added and compacted by vibration. The pattern remains in position, restrained by the fixture. Metal that is poured directly into the pattern replaces the pattern exactly but does not contact or weld to the fixture due to the protective refractory layer. When solid, the casting is easily separated from the fixture. The fixture can be cleaned for reuse in conventional casting cleaning equipment.

A combined arc-melting and tilt-casting furnace for the manufacture of high-purity bulk metallic glass materials.

PubMed

Soinila, E; Pihlajamäki, T; Bossuyt, S; Hänninen, H

2011-07-01

An arc-melting furnace which includes a tilt-casting facility was designed and built, for the purpose of producing bulk metallic glass specimens. Tilt-casting was chosen because reportedly, in combination with high-purity processing, it produces the best fatigue endurance in Zr-based bulk metallic glasses. Incorporating the alloying and casting facilities in a single piece of equipment reduces the amount of laboratory space and capital investment needed. Eliminating the sample transfer step from the production process also saves time and reduces sample contamination. This is important because the glass forming ability in many alloy systems, such as Zr-based glass-forming alloys, deteriorates rapidly with increasing oxygen content of the specimen. The challenge was to create a versatile instrument, in which high purity conditions can be maintained throughout the process, even when melting alloys with high affinity for oxygen. Therefore, the design provides a high-vacuum chamber to be filled with a low-oxygen inert atmosphere, and takes special care to keep the system hermetically sealed throughout the process. In particular, movements of the arc-melting electrode and sample manipulator arm are accommodated by deformable metal bellows, rather than sliding O-ring seals, and the whole furnace is tilted for tilt-casting. This performance of the furnace is demonstrated by alloying and casting Zr(55)Cu(30)Al(10)Ni(5) directly into rods up to ø 10 mm which are verified to be amorphous by x-ray diffraction and differential scanning calorimetry, and to exhibit locally ductile fracture at liquid nitrogen temperature.

Experimental investigation on in-situ microwave casting of copper

NASA Astrophysics Data System (ADS)

Raman Mishra, Radha; Sharma, Apurbba Kumar

2018-04-01

The in-situ microwave casting of metallic materials is a recently developed casting process. The process works on the principles of hybrid microwave heating and is accomplished inside the applicator cavity. The process involves – melting of the charge, in-situ pouring and solidification of the melt. The electromagnetic and thermal properties of the charge affects microwave-material interaction and hence melting of the charge. On the other hand, cooling conditions inside the applicator controls solidification process. The present work reports on in-situ casting of copper developed inside a multimode cavity at 2.45 GHz using 1400 W. The molten metal was allowed to get poured in-situ inside a graphite mold and solidification was carried out in the same mold inside the applicator cavity. The interaction of microwave with the charge during exposure was studied and the role of oxide layer during meltingthe copper blocks has been presented. The developed in-situ cast was characterized to access the cast quality. Microstructural study revealed the homogeneous and dense structure of the cast. The X-ray diffraction pattern indicated presence of copper in different orientations with (1 1 1) as the dominant orientation. The average micro indentation hardness of the casts was found 93±20 HV.

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.

Electroslag Treatment of Liquid Cast Iron

NASA Astrophysics Data System (ADS)

Grachev, V. A.

2018-01-01

The processes that occur in the liquid metal-slag system during electroslag treatment of cast iron are studied from an electrochemical standpoint. The role of electrolysis in the electroslag process is shown, and a method for producing high-strength cast iron with globular graphite using electrolysis of a slag containing magnesium oxides and fluorides is proposed and tested.

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

NASA Astrophysics Data System (ADS)

Singh, Rupinder

2018-02-01

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

Method and apparatus for planar drag strip casting

DOEpatents

Powell, John C.; Campbell, Steven L.

1991-01-01

The present invention is directed to an improved process and apparatus for strip casting. The combination of a planar flow casting nozzle positioned back from the top dead center position with an attached nozzle extension, provides an increased level of casting control and quality. The nozzle extension provides a means of containing the molten pool above the rotating substrate to increase the control of molten metal at the edges of the strip and increase the range of coating thicknesses which may be produced. The level of molten metal in the containment means is regulated to be above the level of melt supplying the casting nozzle which produces a condition of planar drag flow with the casting substrate prior to solidification.

Method and apparatus for planar drag strip casting

DOEpatents

Powell, J.C.; Campbell, S.L.

1991-11-12

The present invention is directed to an improved process and apparatus for strip casting. The combination of a planar flow casting nozzle positioned back from the top dead center position with an attached nozzle extension, provides an increased level of casting control and quality. The nozzle extension provides a means of containing the molten pool above the rotating substrate to increase the control of molten metal at the edges of the strip and increase the range of coating thicknesses which may be produced. The level of molten metal in the containment means is regulated to be above the level of melt supplying the casting nozzle which produces a condition of planar drag flow with the casting substrate prior to solidification. 5 figures.

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

USGS Publications Warehouse

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

2011-01-01

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

Process for forming unusually strong joints between metals and ceramics by brazing at temperatures that do not exceed 750/sup 0/C

DOEpatents

Hammond, J.P.; David, S.A.; Woodhouse, J.J.

1984-12-04

This invention is a process for joining metals to ceramics to form very strong bonds using low brazing temperature, i.e., less than 750/sup 0/C, and particularly for joining nodular cast iron to partially stabilized zirconia. The process provides that the ceramic be coated with an active metal, such as titanium, that can form an intermetallic with a low melting point brazing alloy such as 60Ag-30Cu-10Sn. The nodular cast iron is coated with a noncarbon containing metal, such as copper, to prevent carbon in the nodular cast iron from dissolving in the brazing alloy. These coated surfaces can be brazed together with the brazing alloy between at less than 750/sup 0/C to form a very strong joint. An even stronger bond can be formed if a transition piece is used between the metal and ceramic. It is preferred for the transition piece to have a coefficient of thermal expansion compatible with the coefficient of thermal expansion of the ceramic, such as titanium.

Process for forming unusually strong joints between metals and ceramics by brazing at temperatures that do no exceed 750 degree C.

DOEpatents

Hammond, Joseph P.; David, Stan A.; Woodhouse, John J.

1986-01-01

This invention is a process for joining metals to ceramics to form very strong bonds using low brazing temperature, i.e., less than 750.degree. C., and particularly for joining nodular cast iron to partially stabilized zirconia. The process provides that the ceramic be coated with an active metal, such as titanium, that can form an intermetallic with a low melting point brazing alloy such as 60Ag-30Cu-10Sn. The nodular cast iron is coated with a noncarbon containing metal, such as copper, to prevent carbon in the nodular cast iron from dissolving in the brazing alloy. These coated surfaces can be brazed together with the brazing alloy between at less than 750.degree. C. to form a very strong joint. An even stronger bond can be formed if a transition piece is used between the metal and ceramic. It is preferred for the transition piece to have a coefficient of thermal compatible with the coefficient of thermal expansion of the ceramic, such as titanium.

Producing Hybrid Metal Composites by Combining Additive Manufacturing and Casting

DOE PAGES

Pawlowski, Alex E.; Splitter, Derek A.; Muth, Thomas R.; ...

2017-10-01

Additive manufacturing by itself provides many benefits, but by combining different materials processing techniques like traditional casting with additive manufacturing to create hybrid processes, custom materials can be tailor-made and mass produced for applications with specific performance needs.

Effects of Casting Conditions on End Product Defects in Direct Chill Casted Hot Rolling Ingots

NASA Astrophysics Data System (ADS)

Yorulmaz, Arda; Yüksel, Çağlar; Erzi, Eraz; Dispinar, Derya

Direct chill casting is a reliable casting process for almost any wrought aluminum alloy for subsequent deformation via hot rolling to supply vital industries such as aerospace, automotive, construction, packaging and maritime. While some defects occur during casting, like hot tearing, some others like surface defect causing blisters, appear after hot rolling process or annealing after final cold rolling steps. It was found that some of these defects are caused by melt impurities formed from entrained folded aluminum oxides or bifilms. A study in a hot rolling casting facility was carried out with different melt cleaning practices, launder and molten metal transferring designs. Bifilm index and reduced pressure test were used for determining melt cleanliness measurement. It was found that porous plug gas diffusons for degassing are more effective than lance type degassers and a design towards less turbulent molten metal flow from furnace to mould cavity are necessary for reducing defects caused by bifilms.

Bond and fracture strength of metal-ceramic restorations formed by selective laser sintering

PubMed Central

Bae, Eun-Jeong; Kim, Woong-Chul; Kim, Hae-Young

2014-01-01

PURPOSE The purpose of this study was to compare the fracture strength of the metal and the bond strength in metal-ceramic restorations produced by selective laser sintering (SLS) and by conventional casting (CAST). MATERIALS AND METHODS Non-precious alloy (StarLoy C, DeguDent, Hanau, Germany) was used in CAST group and metal powder (SP2, EOS GmbH, Munich, Germany) in SLS group. Metal specimens in the form of sheets (25.0 × 3.0 × 0.5 mm) were produced in accordance with ISO 9693:1999 standards (n=30). To measure the bond strength, ceramic was fired on a metal specimen and then three-point bending test was performed. In addition, the metal fracture strength was measured by continuing the application of the load. The values were statistically analyzed by performing independent t-tests (α=.05). RESULTS The mean bond strength of the SLS group (50.60 MPa) was higher than that of the CAST group (46.29 MPa), but there was no statistically significant difference. The metal fracture strength of the SLS group (1087.2 MPa) was lower than that of the CAST group (2399.1 MPa), and this difference was statistically significant. CONCLUSION In conclusion the balling phenomenon and the gap formation of the SLS process may increase the metal-ceramic bond strength. PMID:25177469

[Effect of preparation methods on the metal-porcelain bond strength of Co-Cr alloys].

PubMed

Liu, Jie; Chi, Shuai; Xu, Jin; Wang, Yanyan; Zhan, Desong

2014-04-01

To compare the shear bond strength(SBS) of cast Co-Cr alloys and selective laser melting(SLM) Co-Cr alloys with those of dental porcelain. A dental porcelain (Vita) was applied on cast and SLM Co-Cr alloy specimens (n = 10). SBS test was conducted, and fracture mode analysis was determined. Student's t-test by SPSS 13.0 software was employed to analyze the data. The SLM Co-Cr alloy specimens had lower SBS values than the cast Co-Cr alloy specimens (P > 0.05). The metal-porcelain bond strength value of the cast group was (33.11 +/- 4.98) MPa, and that of the SLM group was (30.94 +/- 5.98) MPa. The specimens in both test groups exhibited mixed failure. The metal-porcelain system processed by SLM exhibit a bond strength that is similar to that of the cast group. This system also display a high precision.

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

NASA Astrophysics Data System (ADS)

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

2017-04-01

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

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.

Transmutation Fuel Fabrication-Fiscal Year 2016

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

Fielding, Randall Sidney; Grover, Blair Kenneth

ABSTRACT Nearly all of the metallic fuel that has been irradiated and characterized by the Advanced Fuel Campaign, and its earlier predecessors, has been arc cast. Arc casting is a very flexible method of casting lab scale quantities of materials. Although the method offers flexibility, it is an operator dependent process. Small changes in parameter space or alloy composition may affect how the material is cast. This report provides a historical insight in how the casting process has been modified over the history of the advanced fuels campaign as well as the physical parameters of the fuels cast in fiscalmore » year 2016.« less

Development of an expert system for the simulation model for casting metal substructure of a metal-ceramic crown design.

PubMed

Matin, Ivan; Hadzistevic, Miodrag; Vukelic, Djordje; Potran, Michal; Brajlih, Tomaz

2017-07-01

Nowadays, the integrated CAD/CAE systems are favored solutions for the design of simulation models for casting metal substructures of metal-ceramic crowns. The worldwide authors have used different approaches to solve the problems using an expert system. Despite substantial research progress in the design of experts systems for the simulation model design and manufacturing have insufficiently considered the specifics of casting in dentistry, especially the need for further CAD, RE, CAE for the estimation of casting parameters and the control of the casting machine. The novel expert system performs the following: CAD modeling of the simulation model for casting, fast modeling of gate design, CAD eligibility and cast ability check of the model, estimation and running of the program code for the casting machine, as well as manufacturing time reduction of the metal substructure. The authors propose an integration method using common data model approach, blackboard architecture, rule-based reasoning and iterative redesign method. Arithmetic mean roughness values was determinated with constant Gauss low-pass filter (cut-off length of 2.5mm) according to ISO 4287 using Mahr MARSURF PS1. Dimensional deviation between the designed model and manufactured cast was determined using the coordinate measuring machine Zeiss Contura G2 and GOM Inspect software. The ES allows for obtaining the castings derived roughness grade number N7. The dimensional deviation between the simulation model of the metal substructure and the manufactured cast is 0.018mm. The arithmetic mean roughness values measured on the casting substructure are from 1.935µm to 2.778µm. The realized developed expert system with the integrated database is fully applicable for the observed hardware and software. Values of the arithmetic mean roughness and dimensional deviation indicate that casting substructures are surface quality, which is more than enough and useful for direct porcelain veneering. The manufacture of the substructure shows that the proposed ES allows the improvement of the design process while reducing the manufacturing time. Copyright © 2017 Elsevier B.V. All rights reserved.

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

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

Robert D. Pehlke; John T. Berry

2005-12-16

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

Strain Rate Dependency of Bronze Metal Matrix Composite Mechanical Properties as a Function of Casting Technique

NASA Astrophysics Data System (ADS)

Brown, Lloyd; Joyce, Peter; Radice, Joshua; Gregorian, Dro; Gobble, Michael

2012-07-01

Strain rate dependency of mechanical properties of tungsten carbide (WC)-filled bronze castings fabricated by centrifugal and sedimentation-casting techniques are examined, in this study. Both casting techniques are an attempt to produce a functionally graded material with high wear resistance at a chosen surface. Potential applications of such materials include shaft bushings, electrical contact surfaces, and brake rotors. Knowledge of strain rate-dependent mechanical properties is recommended for predicting component response due to dynamic loading or impact events. A brief overview of the casting techniques for the materials considered in this study is followed by an explanation of the test matrix and testing techniques. Hardness testing, density measurement, and determination of the volume fraction of WC particles are performed throughout the castings using both image analysis and optical microscopy. The effects of particle filling on mechanical properties are first evaluated through a microhardness survey of the castings. The volume fraction of WC particles is validated using a thorough density survey and a rule-of-mixtures model. Split Hopkinson Pressure Bar (SHPB) testing of various volume fraction specimens is conducted to determine strain dependence of mechanical properties and to compare the process-property relationships between the two casting techniques. The baseline performances of C95400 bronze are provided for comparison. The results show that the addition of WC particles improves microhardness significantly for the centrifugally cast specimens, and, to a lesser extent, in the sedimentation-cast specimens, largely because the WC particles are more concentrated as a result of the centrifugal-casting process. Both metal matrix composites (MMCs) demonstrate strain rate dependency, with sedimentation casting having a greater, but variable, effects on material response. This difference is attributed to legacy effects from the casting process, namely, porosity and localized WC particle grouping.

A Process for Manufacturing Metal-Ceramic Cellular Materials with Designed Mesostructure

NASA Astrophysics Data System (ADS)

Snelling, Dean Andrew, Jr.

The goal of this work is to develop and characterize a manufacturing process that is able to create metal matrix composites with complex cellular geometries. The novel manufacturing method uses two distinct additive manufacturing processes: i) fabrication of patternless molds for cellular metal castings and ii) printing an advanced cellular ceramic for embedding in a metal matrix. However, while the use of AM greatly improves the freedom in the design of MMCs, it is important to identify the constraints imposed by the process and its process relationships. First, the author investigates potential differences in material properties (microstructure, porosity, mechanical strength) of A356 - T6 castings resulting from two different commercially available Binder Jetting media and traditional "no-bake" silica sand. It was determined that they yielded statistically equivalent results in four of the seven tests performed: dendrite arm spacing, porosity, surface roughness, and tensile strength. They differed in sand tensile strength, hardness, and density. Additionally, two critical sources of process constraints on part geometry are examined: (i) depowdering unbound material from intricate casting channels and (ii) metal flow and solidification distances through complex mold geometries. A Taguchi Design of Experiments is used to determine the relationships of important independent variables of each constraint. For depowdering, a minimum cleaning diameter of 3 mm was determined along with an equation relating cleaning distance as a function of channel diameter. Furthermore, for metal flow, choke diameter was found to be significantly significant variable. Finally, the author presents methods to process complex ceramic structure from precursor powders via Binder Jetting AM technology to incorporate into a bonded sand mold and the subsequently casted metal matrix. Through sintering experiments, a sintering temperature of 1375°C was established for the ceramic insert (78% cordierite). Upon printing and sintering the iii ceramic, three point bend tests showed the MMCs had less strength than the matrix material likely due to the relatively high porosity developed in the body. Additionally, it was found that the ceramic metal interface had minimal mechanical interlocking and chemical bonding limiting the strength of the final MMCs.

Optimization of Squeeze Casting for Aluminum Alloy Parts

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

David Schwam; John F. Wallace; Qingming Chang

2002-07-30

This study was initiated with the installation of a new production size UBE 350 Ton VSC Squeeze Casting system in the Metal Casting Laboratory at Case Western University. A Lindberg 75k W electrical melting furnace was installed alongside. The challenge of installation and operation of such industrial-size equipment in an academic environment was met successfully. Subsequently, a Sterling oil die heater and a Visi-Track shot monitoring system were added. A significant number of inserts were designed and fabricated over the span of the project, primarily for squeeze casting different configurations of test bars and plates. A spiral ''ribbon insert'' formore » evaluation of molten metal fluidity was also fabricated. These inserts were used to generate a broad range of processing conditions and determine their effect on the quality of the squeeze cast parts. This investigation has studied the influence of the various casting variables on the quality of indirect squeeze castings primarily of aluminum alloys. The variables studied include gating design, fill time and fill patter, metal pressure and die temperature variations. The quality of the die casting was assessed by an analysis of both their surface condition and internal soundness. The primary metal tested was an aluminum 356 alloy. In addition to determining the effect of these casting variables on casting quality as measured by a flat plate die of various thickness, a number of test bar inserts with different gating designs have been inserted in the squeeze casting machine. The mechanical properties of these test bars produced under different squeeze casting conditions were measured and reported. The investigation of the resulting properties also included an analysis of the microstructure of the squeeze castings and the effect of the various structural constituents on the resulting properties. The main conclusions from this investigation are as follows: The ingate size and shape are very important since it must remain open until the casting is solidified and pressure is maintained on the solidifying casting. Fanned gates, particularly on the smaller section castings avoid jetting effects at the ingate end. The fan type ingate helps accomplish a rapid fill without high velocities. The molten metal has to fill the cavity before localized solidification occurs. This is best accomplished with a larger ingate to attain rapid filling without excessive velocity or jetting that occurs at high metal velocities. Straight gates are prone to case jetting of the metal stream even a low velocities. Fanned gates allow use of higher fill velocity without excessive jetting. A higher metal pressure provides a more complete fill of the die including improved compensation for solidification shrinkage. With the proper filling pattern, ingates, overflows and die temperature for a given die, very good tensile properties can be attained in squeeze casting. In general, the smaller squeeze castings require higher die temperatures. Computer models using the UES Procast and MagmaSoft finite element software can, after suitable adjustments, predict the flow pattern in the die cavity.« less

Gas turbine blade with intra-span snubber

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

Merrill, Gary B.; Mayer, Clinton

2014-07-29

A gas turbine blade (10) including a hollow mid-span snubber (16). The snubber is affixed to the airfoil portion (14) of the blade by a fastener (20) passing through an opening (24) cast into the surface (22) of the blade. The opening is defined during an investment casting process by a ceramic pedestal (38) which is positioned between a ceramic core (32) and a surrounding ceramic casting shell (48). The pedestal provides mechanical support for the ceramic core during both wax and molten metal injection steps of the investment casting process.

Method and apparatus for improved melt flow during continuous strip casting

DOEpatents

Follstaedt, Donald W.; King, Edward L.; Schneider, Ken C.

1991-11-12

The continuous casting of metal strip using the melt overflow process is improved by controlling the weir conditions in the nozzle to provide a more uniform flow of molten metal across the width of the nozzle and reducing the tendency for freezing of metal along the interface with refractory surfaces. A weir design having a sloped rear wall and tapered sidewalls and critical gap controls beneath the weir has resulted in the drastic reduction in edge tearing and a significant improvement in strip uniformity. The floor of the container vessel is preferably sloped and the gap between the nozzle and the rotating substrate is critically controlled. The resulting flow patterns observed with the improved casting process have reduced thermal gradients in the bath, contained surface slag and eliminated undesirable solidification near the discharge area by increasing the flow rates at those points.

Method and apparatus for improved melt flow during continuous strip casting

DOEpatents

Follstaedt, D.W.; King, E.L.; Schneider, K.C.

1991-11-12

The continuous casting of metal strip using the melt overflow process is improved by controlling the weir conditions in the nozzle to provide a more uniform flow of molten metal across the width of the nozzle and reducing the tendency for freezing of metal along the interface with refractory surfaces. A weir design having a sloped rear wall and tapered sidewalls and critical gap controls beneath the weir has resulted in the drastic reduction in edge tearing and a significant improvement in strip uniformity. The floor of the container vessel is preferably sloped and the gap between the nozzle and the rotating substrate is critically controlled. The resulting flow patterns observed with the improved casting process have reduced thermal gradients in the bath, contained surface slag and eliminated undesirable solidification near the discharge area by increasing the flow rates at those points. 8 figures.

Crucible cast from beryllium oxide and refractory cement is impervious to flux and molten metal

NASA Technical Reports Server (NTRS)

Jastrzebski, Z. D.

1966-01-01

Crucible from a mixture of a beryllium oxide aggregate and hydraulic refractory cement, and coated with an impervious refractory oxide will not deteriorate in the presence of fused salt- molten metal mixtures such as uranium- magnesium-zinc-halide salt systems. Vessels cast by this process are used in the flux reduction of oxides of thorium and uranium.

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

NASA Technical Reports Server (NTRS)

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

1994-01-01

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

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

EPA Science Inventory

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

On-Line Control of Metal Processing. Report of the Committee on On-Line Control of Metal Processing

DTIC Science & Technology

1989-02-01

Materials Engineering. His work has concentrated on the electroprocessing of metals in molten salts . He is a member of TMS, AIME, ES, Canadian Institute...continuous ingot casting process with three 32 discrete control loops Figure 4-2 Controller incorporating process model 36 Figure 4-3 Real-time molten ...and others while providing a controlled macrostructure and solidification substructure. In this process, molten metal continuously flows from a

Characterization and Evaluation of Incorporation the Casting Sand in Mortar

NASA Astrophysics Data System (ADS)

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

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

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

PubMed

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

2016-02-01

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

Effect of electric arc, gas oxygen torch and induction melting techniques on the marginal accuracy of cast base-metal and noble metal-ceramic crowns.

PubMed

Gómez-Cogolludo, Pablo; Castillo-Oyagüe, Raquel; Lynch, Christopher D; Suárez-García, María-Jesús

2013-09-01

The aim of this study was to identify the most appropriate alloy composition and melting technique by evaluating the marginal accuracy of cast metal-ceramic crowns. Seventy standardised stainless-steel abutments were prepared to receive metal-ceramic crowns and were randomly divided into four alloy groups: Group 1: palladium-gold (Pd-Au), Group 2: nickel-chromium-titanium (Ni-Cr-Ti), Group 3: nickel-chromium (Ni-Cr) and Group 4: titanium (Ti). Groups 1, 2 and 3 were in turn subdivided to be melted and cast using: (a) gas oxygen torch and centrifugal casting machine (TC) or (b) induction and centrifugal casting machine (IC). Group 4 was melted and cast using electric arc and vacuum/pressure machine (EV). All of the metal-ceramic crowns were luted with glass-ionomer cement. The marginal fit was measured under an optical microscope before and after cementation using image analysis software. All data was subjected to two-way analysis of variance (ANOVA). Duncan's multiple range test was run for post-hoc comparisons. The Student's t-test was used to investigate the influence of cementation (α=0.05). Uncemented Pd-Au/TC samples achieved the best marginal adaptation, while the worst fit corresponded to the luted Ti/EV crowns. Pd-Au/TC, Ni-Cr and Ti restorations demonstrated significantly increased misfit after cementation. The Ni-Cr-Ti alloy was the most predictable in terms of differences in misfit when either torch or induction was applied before or after cementation. Cemented titanium crowns exceeded the clinically acceptable limit of 120μm. The combination of alloy composition, melting technique, casting method and luting process influences the vertical seal of cast metal-ceramic crowns. An accurate use of the gas oxygen torch may overcome the results attained with the induction system concerning the marginal adaptation of fixed dental prostheses. Copyright © 2013 Elsevier Ltd. All rights reserved.

Improved Sand-Compaction Method for Lost-Foam Metal Casting

NASA Technical Reports Server (NTRS)

Bakhtiyarov, Sayavur I.; Overfelt, Ruel A.

2008-01-01

An improved method of filling a molding flask with sand and compacting the sand around a refractory-coated foam mold pattern has been developed for incorporation into the lost-foam metal-casting process. In comparison with the conventional method of sand filling and compaction, this method affords more nearly complete filling of the space around the refractory-coated foam mold pattern and more thorough compaction of the sand. In so doing, this method enables the sand to better support the refractory coat under metallostatic pressure during filling of the mold with molten metal.

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

NASA Technical Reports Server (NTRS)

Barr, Francis A.; Page, Russell J.

1987-01-01

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

The 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).

40 CFR 421.1 - Applicability.

Code of Federal Regulations, 2010 CFR

2010-07-01

... to alloying or casting of nonferrous metals is limited to alloying or casting of hot metal directly... cooling is included in the aluminum forming, nonferrous metals forming, or metal molding and casting point...

Casting fine grained, fully dense, strong inorganic materials

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

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

2015-11-24

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

Improvements in Fabrication of Sand/Binder Cores for Casting

NASA Technical Reports Server (NTRS)

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

2005-01-01

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

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

NASA Technical Reports Server (NTRS)

2003-01-01

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

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.

The Tensile and Shear Bond Strengths of Poly (Methyl Methacrylate) Processed on Electrolytically Etched Ticonium.

DTIC Science & Technology

1986-05-01

METHYL NETHACRYLATE) PROCESSED ON ELECTROLYTICALLY ETCHED TICONIUM A THESIS Presented to the Faculty of The University of Texas Graduate School of...were cast utilizing the manufacturer’s directions for investment, burnout , and casting. Two groups of metal specimens were prepared: 20 for...STRENGTHS OF POLY (METHYL METHACRYLATE) PROCESSED ON ELECTROLYTICALLY ETCHED TICONIUM JOHN EDWARD ZURASKY, M.S. The University of Texas Graduate School

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.

Silica coatings formed on noble dental casting alloy by the sol-gel dipping process.

PubMed

Yoshida, K; Tanagawa, M; Kamada, K; Hatada, R; Baba, K; Inoi, T; Atsuta, M

1999-08-01

The sol-gel dipping process, in which liquid silicon alkoxide is transformed into the solid silicon-oxygen network, can produce a thin film coating of silica (SiO2). The features of this method are high homogeneity and purity of the thin SiO2 film and a low sinter temperature, which are important in preparation of coating films that can protect from metallic ion release from the metal substrate and prevent attachment of dental plaque. We evaluated the surface characteristics of the dental casting silver-palladium-copper-gold (Ag-Pd-Cu-Au) alloy coated with a thin SiO2 film by the sol-gel dipping process. The SiO2 film bonded strongly (over 40 MPa) to Ti-implanted Ag-Pd-Cu-Au alloy substrate as demonstrated by a pull test. Hydrophobilization of Ti-implanted/SiO2-coated surfaces resulted in a significant increase of the contact angle of water (80.5 degrees) compared with that of the noncoated alloy specimens (59.3 degrees). Ti-implanted/SiO2-coated specimens showed the release of many fewer metallic ions (192 ppb/cm2) from the substrate than did noncoated specimens (2,089 ppb/cm2). The formation of a thin SiO2 film by the sol-gel dipping process on the surface of Ti-implanted Ag-Pd-Cu-Au alloy after casting clinically may be useful for minimizing the possibilities of the accumulation of dental plaque and metal allergies caused by intraoral metal restorations.

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

NASA Astrophysics Data System (ADS)

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

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

Analysis of Dependence of the Properties of Alloy V95 on the Pressure Applied to Crystallizing Metal

NASA Astrophysics Data System (ADS)

Korostelev, V. F.; Khromova, L. P.; Denisov, M. S.

2017-05-01

Results of a study aimed at formation of a single-phase fine-grained structure in pistons from aluminum alloy V95 in the process of their fabrication, which involves isostatic pressing of liquid metal before the start of crystallization, application of pressure to the crystallizing metal, and holding under pressure in the process of cooling to the shop temperature, are presented. The ultimate strength and the structure of alloy V95 after casting with imposition of pressure are determined. An example of application of the method suggested for fabricating cast billets ∅ 82 × 70 mm in size with a uniform dense structure without gas shrinkage defects, volume and dendritic segregation is considered.

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

NASA Astrophysics Data System (ADS)

Sobek, M.; Baier, A.; Grabowski, Ł.

2018-01-01

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

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

PubMed

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

2010-01-01

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

Progress on high-performance rapid prototype aluminum mirrors

NASA Astrophysics Data System (ADS)

Woodard, Kenneth S.; Myrick, Bruce H.

2017-05-01

Near net shape parts can be produced using some very old processes (investment casting) and the relatively new direct metal laser sintering (DMLS) process. These processes have significant advantages for complex blank lightweighting and costs but are not inherently suited for producing high performance mirrors. The DMLS process can provide extremely complex lightweight structures but the high residual stresses left in the material results in unstable mirror figure retention. Although not to the extreme intricacy of DMLS, investment casting can also provide complex lightweight structures at considerably lower costs than DMLS and even conventional wrought mirror blanks but the less than 100% density for casting (and also DMLS) limits finishing quality. This paper will cover the progress that has been made to make both the DMLS and investment casting processes into viable near net shape blank options for high performance aluminum mirrors. Finish and figure results will be presented to show performance commensurate with existing conventional processes.

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

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

Diran Apelian

2012-08-15

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

Method and mold for casting thin metal objects

DOEpatents

Pehrson, Brandon P; Moore, Alan F

2014-04-29

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

Method for casting thin metal objects

DOEpatents

Pehrson, Brandon P; Moore, Alan F

2015-04-14

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

Development of the Electromagnetic Continuous Casting Technology for of Magnesium Alloys

NASA Astrophysics Data System (ADS)

Park, Joon-Pyo; Kim, Myoung-Gyun; Kim, Jong-Ho; Lee, Gyu-Chang

Currently, magnesium billets produced by ingot casting or direct chill casting process, result in low-quality surfaces and low productivity, Continuous casting technology to solve these problem has not only high-quality surface billets with fine-grained and homogeneous microstructure but also cost down. The latent heat of fusion per weight (J/g) of magnesium is similar to other metals, however, considering the heat emitted to the mold surface during continuous casting in meniscus region and converting it to the latent heat of fusion per volume, magnesium will be rapidly solidified in the mold during continuous casting, which induces subsequent surface defect formation. In this study, electromagnetic casting and stirring (EMC and EMS) techniques are proposed to control solidification process conveniently by compensating the low latent heat of solidification by volume and to fabricate magnesium billet with high-quality surface. This technique was extended to large scale billets up to 300 mm diameter and continuous casting was successfully conducted. Then magnesium billet was used for the fabrication of prototype automobile pulley.

Method of making metal matrix composites reinforced with ceramic particulates

DOEpatents

Cornie, James A.; Kattamis, Theodoulos; Chambers, Brent V.; Bond, Bruce E.; Varela, Raul H.

1989-01-01

Composite materials and methods for making such materials are disclosed in which dispersed ceramic particles are at chemical equilibrium with a base metal matrix, thereby permitting such materials to be remelted and subsequently cast or otherwise processed to form net weight parts and other finished (or semi-finished) articles while maintaining the microstructure and mechanical properties (e.g. wear resistance or hardness) of the original composite. The composite materials of the present invention are composed of ceramic particles in a base metal matrix. The ceramics are preferably carbides of titanium, zirconium, tungsten, molybdenum or other refractory metals. The base metal can be iron, nickel, cobalt, chromium or other high temperature metal and alloys thereof. For ferrous matrices, alloys suitable for use as the base metal include cast iron, carbon steels, stainless steels and iron-based superalloys.

Method of making metal matrix composites reinforced with ceramic particulates

DOEpatents

Cornie, J.A.; Kattamis, T.; Chambers, B.V.; Bond, B.E.; Varela, R.H.

1989-08-01

Composite materials and methods for making such materials are disclosed in which dispersed ceramic particles are at chemical equilibrium with a base metal matrix, thereby permitting such materials to be remelted and subsequently cast or otherwise processed to form net weight parts and other finished (or semi-finished) articles while maintaining the microstructure and mechanical properties (e.g. wear resistance or hardness) of the original composite. The composite materials of the present invention are composed of ceramic particles in a base metal matrix. The ceramics are preferably carbides of titanium, zirconium, tungsten, molybdenum or other refractory metals. The base metal can be iron, nickel, cobalt, chromium or other high temperature metal and alloys thereof. For ferrous matrices, alloys suitable for use as the base metal include cast iron, carbon steels, stainless steels and iron-based superalloys. 2 figs.

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.

The Particle Distribution in Liquid Metal with Ceramic Particles Mould Filling Process

NASA Astrophysics Data System (ADS)

Dong, Qi; Xing, Shu-ming

2017-09-01

Adding ceramic particles in the plate hammer is an effective method to increase the wear resistance of the hammer. The liquid phase method is based on the “with the flow of mixed liquid forging composite preparation of ZTA ceramic particle reinforced high chromium cast iron hammer. Preparation method for this system is using CFD simulation analysis the particles distribution of flow mixing and filling process. Taking the 30% volume fraction of ZTA ceramic composite of high chromium cast iron hammer as example, by changing the speed of liquid metal viscosity to control and make reasonable predictions of particles distribution before solidification.

Liquid Metal Infiltration Processing of Metallic Composites: A Critical Review

NASA Astrophysics Data System (ADS)

Sree Manu, K. M.; Ajay Raag, L.; Rajan, T. P. D.; Gupta, Manoj; Pai, B. C.

2016-10-01

Metal matrix composites (MMC) are one of the advanced materials widely used for aerospace, automotive, defense, and general engineering applications. MMC can be tailored to have superior properties such as enhanced high-temperature performance, high specific strength and stiffness, increased wear resistance, better thermal and mechanical fatigue, and creep resistance than those of unreinforced alloys. To fabricate such composites with ideal properties, the processing technique has to ensure high volume fraction of reinforcement incorporation, uniform distribution of the reinforcement, and acceptable adhesion between the matrix and the reinforcing phase without unwanted interfacial reactions which degrades the mechanical properties. A number of processing techniques such as stir casting/vortex method, powder metallurgy, infiltration, casting etc. have been developed to synthesize MMC employing a variety of alloy and the reinforcement's combinations. Among these, infiltration process is widely used for making MMC with high volume fraction of reinforcements and offers many more advantages compared to other conventional manufacturing processes. The present paper critically reviews the various infiltration techniques used for making the MMC, their process parameters, characteristics, and selected studies carried out worldwide and by authors on the development of metal ceramic composites by squeeze infiltration process.

Horizontal electromagnetic casting of thin metal sheets

DOEpatents

Hull, John R.; Lari, Robert J.; Praeg, Walter F.; Turner, Larry R.

1987-01-01

Thin metal sheets are cast by magnetically suspending molten metal deposited within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled to form a solid metal sheet. Magnetic flux increases as the molten metal sheet moves downward and decreases as the molten metal sheet moves upward to stabilize the sheet and maintain it in equilibrium as it is linearly displaced and solidified by cooling gases. A conducting shield is electrically coupled to the molten metal sheet by means of either metal sheet engaging rollers or brushes on the solidified metal, and by means of an electrode in the vessel containing the molten metal thereby providing a return path for the eddy currents induced in the metal sheet by the AC coil generated magnetic flux. Variation in the geometry of the conducting shield allows the magnetic flux between the metal sheet and the conducting shield to be varied and the thickness in surface quality of the metal sheet to be controlled. Side guards provide lateral containment for the molten metal sheet and stabilize and shape the magnetic field while a leader sheet having electromagnetic characteristics similar to those of the metal sheet is used to start the casting process and precedes the molten metal sheet through the magnet and forms a continuous sheet therewith. The magnet may be either U-shaped with a single racetrack coil or may be rectangular with a pair of facing bedstead coils.

Horizontal electromagnetic casting of thin metal sheets

DOEpatents

Hull, John R.; Lari, Robert J.; Praeg, Walter F.; Turner, Larry R.

1988-01-01

Thin metal sheets are cast by magnetically suspending molten metal deposited within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled to form a solid metal sheet. Magnetic flux increases as the molten metal sheet moves downward and decreases as the molten metal sheet moves upward to stabilize the sheet and maintain it in equilibrium as it is linearly displaced and solidified by cooling gases. A conducting shield is electrically coupled to the molten metal sheet by means of either metal sheet engaging rollers or brushes on the solidified metal, and by means of an electrode in the vessel containing the molten metal thereby providing a return path for the eddy currents induced in the metal sheet by the AC coil generated magnetic flux. Variation in the geometry of the conducting shield allows the magnetic flux between the metal sheet and the conducting shield to be varied and the thickness in surface quality of the metal sheet to be controlled. Side guards provide lateral containment for the molten metal sheet and stabilize and shape the magnetic field while a leader sheet having electromagnetic characteristics similar to those of the metal sheet is used to start the casting process and precedes the molten metal sheet through the magnet and forms a continuous sheet therewith. The magnet may be either U-shaped with a single racetrack coil or may be rectangular with a pair of facing bedstead coils.

40 CFR 467.02 - General definitions.

Code of Federal Regulations, 2010 CFR

2010-07-01

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

40 CFR 467.02 - General definitions.

Code of Federal Regulations, 2011 CFR

2011-07-01

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

Removable partial denture alloys processed by laser-sintering technique.

PubMed

Alageel, Omar; Abdallah, Mohamed-Nur; Alsheghri, Ammar; Song, Jun; Caron, Eric; Tamimi, Faleh

2018-04-01

Removable partial dentures (RPDs) are traditionally made using a casting technique. New additive manufacturing processes based on laser sintering has been developed for quick fabrication of RPDs metal frameworks at low cost. The objective of this study was to characterize the mechanical, physical, and biocompatibility properties of RPD cobalt-chromium (Co-Cr) alloys produced by two laser-sintering systems and compare them to those prepared using traditional casting methods. The laser-sintered Co-Cr alloys were processed by the selective laser-sintering method (SLS) and the direct metal laser-sintering (DMLS) method using the Phenix system (L-1) and EOS system (L-2), respectively. L-1 and L-2 techniques were 8 and 3.5 times more precise than the casting (CC) technique (p < 0.05). Co-Cr alloys processed by L-1 and L-2 showed higher (p < 0.05) hardness (14-19%), yield strength (10-13%), and fatigue resistance (71-72%) compared to CC alloys. This was probably due to their smaller grain size and higher microstructural homogeneity. All Co-Cr alloys exhibited low porosity (2.1-3.3%); however, pore distribution was more homogenous in L-1 and L-2 alloys when compared to CC alloys. Both laser-sintered and cast alloys were biocompatible. In conclusion, laser-sintered alloys are more precise and present better mechanical and fatigue properties than cast alloys for RPDs. © 2017 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 106B: 1174-1185, 2018. © 2017 Wiley Periodicals, Inc.

Arrays of hollow out-of-plane microneedles made by metal electrodeposition onto solvent cast conductive polymer structures

NASA Astrophysics Data System (ADS)

Mansoor, I.; Liu, Y.; Häfeli, U. O.; Stoeber, B.

2013-08-01

Transdermal drug delivery using microneedles is a technique to potentially replace hypodermic needles for injection of many vaccines and drugs. Fabrication of hollow metallic microneedles so far has been associated with time-consuming steps that restrict batch production of these devices. Here, we are presenting a novel method for making metallic microneedles with any desired height, spacing, and lumen size. In our process, we use solvent casting to coat a mold, which contains an array of pillars, with a conductive polymer composite layer. The conductive layer is then used as a seed layer in a metal electrodeposition process. To characterize the process, the conductivity of the polymer composite with respect to different filler concentrations was investigated. In addition, plasma etching of the polymer was characterized. The electroplating process was also studied further to control the thickness of the microneedle array plate. The strength of the microneedle devices was evaluated through a series of compression tests, while their performance for transdermal drug delivery was tested by injection of 2.28 µm fluorescent microspheres into animal skin. The fabricated metallic microneedles seem appropriate for subcutaneous delivery of drugs and microspheres.

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.

Strip casting apparatus and method

DOEpatents

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

1988-09-20

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

Strip casting apparatus and method

DOEpatents

Williams, Robert S.; Baker, Donald F.

1988-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-06-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-09-01

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

Ultra-high vacuum compatible induction-heated rod casting furnace

NASA Astrophysics Data System (ADS)

Bauer, A.; Neubauer, A.; Münzer, W.; Regnat, A.; Benka, G.; Meven, M.; Pedersen, B.; Pfleiderer, C.

2016-06-01

We report the design of a radio-frequency induction-heated rod casting furnace that permits the preparation of polycrystalline ingots of intermetallic compounds under ultra-high vacuum compatible conditions. The central part of the system is a bespoke water-cooled Hukin crucible supporting a casting mold. Depending on the choice of the mold, typical rods have a diameter between 6 mm and 10 mm and a length up to 90 mm, suitable for single-crystal growth by means of float-zoning. The setup is all-metal sealed and may be baked out. We find that the resulting ultra-high vacuum represents an important precondition for processing compounds with high vapor pressures under a high-purity argon atmosphere up to 3 bars. Using the rod casting furnace, we succeeded to prepare large high-quality single crystals of two half-Heusler compounds, namely, the itinerant antiferromagnet CuMnSb and the half-metallic ferromagnet NiMnSb.

Ultra-high vacuum compatible induction-heated rod casting furnace.

PubMed

Bauer, A; Neubauer, A; Münzer, W; Regnat, A; Benka, G; Meven, M; Pedersen, B; Pfleiderer, C

2016-06-01

We report the design of a radio-frequency induction-heated rod casting furnace that permits the preparation of polycrystalline ingots of intermetallic compounds under ultra-high vacuum compatible conditions. The central part of the system is a bespoke water-cooled Hukin crucible supporting a casting mold. Depending on the choice of the mold, typical rods have a diameter between 6 mm and 10 mm and a length up to 90 mm, suitable for single-crystal growth by means of float-zoning. The setup is all-metal sealed and may be baked out. We find that the resulting ultra-high vacuum represents an important precondition for processing compounds with high vapor pressures under a high-purity argon atmosphere up to 3 bars. Using the rod casting furnace, we succeeded to prepare large high-quality single crystals of two half-Heusler compounds, namely, the itinerant antiferromagnet CuMnSb and the half-metallic ferromagnet NiMnSb.

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.

Development and Implementation of the Casting of Rods Made of Refractory Cast Alloys

NASA Astrophysics Data System (ADS)

Kabanov, I. V.; Urin, S. L.; Ivanyuk, A. S.; Nesterov, A. N.; Bogdanov, S. V.

2017-12-01

The problems of the production of a so-called casting rod blank made of a refractory casting alloy in the vacuum induction furnaces of AO Metallurgical Plant Electrostal are considered. A unique technology of casting and subsequent treatment of as-cast rod blanks made of refractory alloys is developed, tested, and optimized. As a result of the developed and performed measures for the production of metal products in the Consarc furnace, the ingot-to-product yield increases by 15% as compared to metal casting in an ISV-1.0 furnace. As a result, we have widened the range of cast alloy grades and are going to cast metals for the manufacture of blanks of other sizes and ranges of alloy an steel grades.

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

PubMed

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

1989-01-01

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

Increasing the reliability and quality of important cast products made of chemically active metals and alloys

NASA Astrophysics Data System (ADS)

Varfolomeev, M. S.; Moiseev, V. S.; Shcherbakova, G. I.

2017-01-01

A technology is developed to produce highly thermoresistant ceramic monoxide corundum molds using investment casting and an aluminum-organic binder. This technology is a promising trend in creating ceramic molds for precision complex-shape casting of important ingots made of high-alloy steels, high-temperature and titanium alloys, and refractory metals. The use of the casting molds that have a high thermal and chemical resistance to chemically active metals and alloys under high-temperature casting minimizes the physicochemical interaction and substantially decreases the depth of the hard-to-remove metal oxide layer on important products, which increases their service properties.

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

NASA Technical Reports Server (NTRS)

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

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

NASA Technical Reports Server (NTRS)

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

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

NASA Technical Reports Server (NTRS)

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

Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting

PubMed Central

Mun, Jiwon; Ju, Jaehyung; Thurman, James

2016-01-01

One of the typical methods to manufacture 3D lattice metals is the direct-metal additive manufacturing (AM) process such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM). In spite of its potential processing capability, the direct AM method has several disadvantages such as high cost, poor surface finish of final products, limitation in material selection, high thermal stress, and anisotropic properties of parts. We propose a cost-effective method to manufacture 3D lattice metals. The objective of this study is to provide a detailed protocol on fabrication of 3D lattice metals having a complex shape and a thin wall thickness; e.g., octet truss made of Al and Cu alloys having a unit cell length of 5 mm and a cell wall thickness of 0.5 mm. An overall experimental procedure is divided into eight sections: (a) 3D printing of sacrificial patterns (b) melt-out of support materials (c) removal of residue of support materials (d) pattern assembly (e) investment (f) burn-out of sacrificial patterns (g) centrifugal casting (h) post-processing for final products. The suggested indirect AM technique provides the potential to manufacture ultra-lightweight lattice metals; e.g., lattice structures with Al alloys. It appears that the process parameters should be properly controlled depending on materials and lattice geometry, observing the final products of octet truss metals by the indirect AM technique. PMID:27214495

Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting.

PubMed

Mun, Jiwon; Ju, Jaehyung; Thurman, James

2016-05-14

One of the typical methods to manufacture 3D lattice metals is the direct-metal additive manufacturing (AM) process such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM). In spite of its potential processing capability, the direct AM method has several disadvantages such as high cost, poor surface finish of final products, limitation in material selection, high thermal stress, and anisotropic properties of parts. We propose a cost-effective method to manufacture 3D lattice metals. The objective of this study is to provide a detailed protocol on fabrication of 3D lattice metals having a complex shape and a thin wall thickness; e.g., octet truss made of Al and Cu alloys having a unit cell length of 5 mm and a cell wall thickness of 0.5 mm. An overall experimental procedure is divided into eight sections: (a) 3D printing of sacrificial patterns (b) melt-out of support materials (c) removal of residue of support materials (d) pattern assembly (e) investment (f) burn-out of sacrificial patterns (g) centrifugal casting (h) post-processing for final products. The suggested indirect AM technique provides the potential to manufacture ultra-lightweight lattice metals; e.g., lattice structures with Al alloys. It appears that the process parameters should be properly controlled depending on materials and lattice geometry, observing the final products of octet truss metals by the indirect AM technique.

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

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

Weiss, David; Purgert, Robert; Rhudy, Richard

1999-04-21

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

Casting Apparatus Including A Gas Driven Molten Metal Injector And Method

DOEpatents

Meyer, Thomas N.

2004-06-01

The casting apparatus (50) includes a holding vessel (10) for containing a supply of molten metal (12) and a casting mold (52) located above the holding vessel (10) and having a casting cavity (54). A molten metal injector (14) extends into the holding vessel (10) and is at least partially immersed in the molten metal (12) in the holding vessel (10). The molten metal injector (14) is in fluid communication with the casting cavity (54). The molten metal injector (14) has an injector body (16) defining an inlet opening (24) for receiving molten metal into the injector body (16). A gas pressurization source (38) is in fluid communication with the injector body (16) for cyclically pressurizing the injector body (16) and inducing molten metal to flow from the injector body (16) to the casting cavity (54). An inlet valve (42) is located in the inlet opening (24) in the injector body (16) for filling molten metal into the injector body (16). The inlet valve (42) is configured to prevent outflow of molten metal from the injector body (16) during pressurization and permit inflow of molten metal into the injector body (16) after pressurization. The inlet valve (42) has an inlet valve actuator (44) located above the surface of the supply of molten metal (12) and is operatively connected to the inlet valve (42) for operating the inlet valve (42) between open and closed positions.

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Fabricating Superior NiAl Bronze Components through Wire Arc Additive Manufacturing.

PubMed

Ding, Donghong; Pan, Zengxi; van Duin, Stephen; Li, Huijun; Shen, Chen

2016-08-03

Cast nickel aluminum bronze (NAB) alloy is widely used for large engineering components in marine applications due to its excellent mechanical properties and corrosion resistance. Casting porosity, as well as coarse microstructure, however, are accompanied by a decrease in mechanical properties of cast NAB components. Although heat treatment, friction stir processing, and fusion welding were implemented to eliminate porosity, improve mechanical properties, and refine the microstructure of as-cast metal, their applications are limited to either surface modification or component repair. Instead of traditional casting techniques, this study focuses on developing NAB components using recently expanded wire arc additive manufacturing (WAAM). Consumable welding wire is melted and deposited layer-by-layer on substrates producing near-net shaped NAB components. Additively-manufactured NAB components without post-processing are fully dense, and exhibit fine microstructure, as well as comparable mechanical properties, to as-cast NAB alloy. The effects of heat input from the welding process and post-weld-heat-treatment (PWHT) are shown to give uniform NAB alloys with superior mechanical properties revealing potential marine applications of the WAAM technique in NAB production.

Fabricating Superior NiAl Bronze Components through Wire Arc Additive Manufacturing

PubMed Central

Ding, Donghong; Pan, Zengxi; van Duin, Stephen; Li, Huijun; Shen, Chen

2016-01-01

Cast nickel aluminum bronze (NAB) alloy is widely used for large engineering components in marine applications due to its excellent mechanical properties and corrosion resistance. Casting porosity, as well as coarse microstructure, however, are accompanied by a decrease in mechanical properties of cast NAB components. Although heat treatment, friction stir processing, and fusion welding were implemented to eliminate porosity, improve mechanical properties, and refine the microstructure of as-cast metal, their applications are limited to either surface modification or component repair. Instead of traditional casting techniques, this study focuses on developing NAB components using recently expanded wire arc additive manufacturing (WAAM). Consumable welding wire is melted and deposited layer-by-layer on substrates producing near-net shaped NAB components. Additively-manufactured NAB components without post-processing are fully dense, and exhibit fine microstructure, as well as comparable mechanical properties, to as-cast NAB alloy. The effects of heat input from the welding process and post-weld-heat-treatment (PWHT) are shown to give uniform NAB alloys with superior mechanical properties revealing potential marine applications of the WAAM technique in NAB production. PMID:28773774

The effect of high energy concentration source irradiation on structure and properties of Fe-based bulk metallic glass

NASA Astrophysics Data System (ADS)

Pilarczyk, Wirginia

2016-06-01

Metallic glasses exhibit metastable structure and maintain this relatively stable amorphous state within certain temperature range. High intensity laser beam was used for the surface irradiation of Fe-Co-B-Si-Nb bulk metallic glasses. The variable parameter was laser beam pulse energy. For the analysis of structure and properties of bulk metallic glasses and their surface after laser remelting the X-ray analysis, microscopic observation and test of mechanical properties were carried out. Examination of the nanostructure of amorphous materials obtained by high pressure copper mold casting method and the irradiated with the use of TITAN 80-300 HRTEM was carried out. Nanohardness and reduced Young's modulus of particular amorphous and amorphous-crystalline material zone of the laser beam were examined with the use of Hysitron TI950 Triboindenter nanoindenter and with the use of Berkovich's indenter. The XRD and microscopic analysis showed that the test material is amorphous in its structure before irradiation. Microstructure observation with electron transmission microscopy gave information about alloy crystallization in the irradiated process. Identification of given crystal phases allows to determine the kind of crystal phases created in the first place and also further changes of phase composition of alloy. The main value of the nanohardness of the surface prepared by laser beam has the order of magnitude similar to bulk metallic glasses formed by casting process irrespective of the laser beam energy used. Research results analysis showed that the area between parent material and fusion zone is characterized by extraordinarily interesting structure which is and will be the subject of further analysis in the scope of bulk metallic glasses amorphous structure and high energy concentration source. The main goal of this work is the results' presentation of structure and chosen properties of the selected bulk metallic glasses after casting process and after irradiation process employing the high energy concentration sources.

Bond strength of luting cement to casting and soldering alloy.

PubMed

Kumbuloglu, O; Lassila, L V J; User, A; Toksavul, S; Vallittu, P K

2006-03-01

Adjustment of metal alloy framework of the porcelain-fused-to-metal crown by soldering minor marginal deficiences prior insertion may sometimes be needed. The aim of this study was to compare shear bond strengths of four luting cements to casting metal alloy and soldering metal alloy. A total of 64 flame cast non-precious metal alloy and flame soldered metal alloy samples were used. Durelon, Panavia F, RelyX Unicem Applicap and RelyX ARC stubs were bonded to the alloy substrate surface. After stored in water at 37 degrees C for 1 week, shear bond strength of the cement to the alloy was measured. Differences were analyzed using one way ANOVA (p<0.05). There were no difference between the cast metal alloy and soldering metal alloy substrate.

Casting technology for manufacturing metal rods from simulated metallic spent fuels

NASA Astrophysics Data System (ADS)

Leeand, Y. S.; Lee, D. B.; Kim, C. K.; Shin, Y. J.; Lee, J. H.

2000-09-01

A uranium metal rod 13.5 mm in diameter and 1,150 mm long was produced from simulated metallic spent fuels with advanced casting equipment using the directional-solidification method. A vacuum casting furnace equipped with a four-zone heater to prevent surface oxidation and the formation of surface shrinkage holes was designed. By controlling the axial temperature gradient of the casting furnace, deformation by the surface shrinkage phenomena was diminished, and a sound rod was manufactured. The cooling behavior of the molten uranium was analyzed using the computer software package MAGMAsoft.

A Brief History of Physics in China,

DTIC Science & Technology

1982-07-29

not attracted by magnets. Chang Hua noticed that a static charge was produced in combing hair and in undressing with silk and wool garments. He...after the expiration of the greenish white gas. It is at this moment that casting can be performed’. For the process of smelting and casting, since there...orange, then yellow, and appears white at about 1000°C. In the process of heating pottery and metals, the ancient Chinese mastered the knowledge of

Influence of Ni Interlayer on Microstructure and Mechanical Properties of Mg/Al Bimetallic Castings

NASA Astrophysics Data System (ADS)

Liu, Ning; Liu, Canchun; Liang, Chunyong; Zhang, Yongguang

2018-05-01

Dissimilar joining of magnesium and aluminum using a compound casting process was investigated in the present work. For the first time, a Ni interlayer prepared by plasma spraying was inserted between the two base metals to improve the interfacial characteristics. Examination of the interfacial regions using scanning electron microscopy, energy-dispersive X-ray spectroscopy, electron probe microanalysis, and X-ray diffraction revealed the formation of a three-layered interface between Mg and Al without the interlayer. The thickness of the interface was approximately 600 μm when the casting was performed at 700 °C and increased with increasing casting temperature. However, with the addition of the Ni interlayer, the Al-Mg reaction was successfully prevented, and metallurgical bonding between the Ni interlayer and two base metals was achieved at a casting temperature of 700 °C. Upon increasing this temperature, Mg-Ni and Al-Ni intermetallics were generated at the separate interfaces. The shear strength of the Mg/Al bimetallic castings with the Ni interlayer was substantially improved compared with that of the direct Mg/Al joint, with a maximum value of 25.4 MPa achieved at 700 °C. Fracture occurred mainly along the Mg/Ni interface for the Mg/Ni/Al multilayer structure castings.

Enhancing Manufacturing Process Education via Computer Simulation and Visualization

ERIC Educational Resources Information Center

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

2014-01-01

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

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

NASA Technical Reports Server (NTRS)

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

2000-01-01

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

Viscosity Meaurement Technique for Metal Fuels

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

Ban, Heng; Kennedy, Rory

2015-02-09

Metallic fuels have exceptional transient behavior, excellent thermal conductivity, and a more straightforward reprocessing path, which does not separate out pure plutonium from the process stream. Fabrication of fuel containing minor actinides and rare earth (RE) elements for irradiation tests, for instance, U-20Pu-3Am-2Np-1.0RE-15Zr samples at the Idaho National Laboratory, is generally done by melt casting in an inert atmosphere. For the design of a casting system and further scale up development, computational modeling of the casting process is needed to provide information on melt flow and solidification for process optimization. Therefore, there is a need for melt viscosity data, themore » most important melt property that controls the melt flow. The goal of the project was to develop a measurement technique that uses fully sealed melt sample with no Americium vapor loss to determine the viscosity of metallic melts and at temperatures relevant to the casting process. The specific objectives of the project were to: develop mathematical models to establish the principle of the measurement method, design and build a viscosity measurement prototype system based on the established principle, and calibrate the system and quantify the uncertainty range. The result of the project indicates that the oscillation cup technique is applicable for melt viscosity measurement. Detailed mathematical models of innovative sample ampoule designs were developed to not only determine melt viscosity, but also melt density under certain designs. Measurement uncertainties were analyzed and quantified. The result of this project can be used as the initial step toward the eventual goal of establishing a viscosity measurement system for radioactive melts.« less

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

PubMed

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

2017-01-01

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

Influence of S. mutans on base-metal dental casting alloy toxicity.

PubMed

McGinley, E L; Dowling, A H; Moran, G P; Fleming, G J P

2013-01-01

We have highlighted that exposure of base-metal dental casting alloys to the acidogenic bacterium Streptococcus mutans significantly increases cellular toxicity following exposure to immortalized human TR146 oral keratinocytes. With Inductively Coupled Plasma-Mass Spectrometry (ICP-MS), S. mutans-treated nickel-based (Ni-based) and cobalt-chromium-based (Co-Cr-based) dental casting alloys were shown to leach elevated levels of metal ions compared with untreated dental casting alloys. We targeted several biological parameters: cell morphology, viable cell counts, cell metabolic activity, cell toxicity, and inflammatory cytokine expression. S. mutans-treated dental casting alloys disrupted cell morphology, elicited significantly decreased viable cell counts (p < 0.0001) and cell metabolic activity (p < 0.0001), and significantly increased cell toxicity (p < 0.0001) and inflammatory cytokine expression (p < 0.0001). S. mutans-treated Ni-based dental casting alloys induced elevated levels of cellular toxicity compared with S. mutans-treated Co-Cr-based dental casting alloys. While our findings indicated that the exacerbated release of metal ions from S. mutans-treated base-metal dental casting alloys was the likely result of the pH reduction during S. mutans growth, the exact nature of mechanisms leading to accelerated dissolution of alloy-discs is not yet fully understood. Given the predominance of S. mutans oral carriage and the exacerbated cytotoxicity observed in TR146 cells following exposure to S. mutans-treated base-metal dental casting alloys, the implications for the long-term stability of base-metal dental restorations in the oral cavity are a cause for concern.

INTERIOR VIEW, LOOKING EAST, TOWARD BASE OF CUPOLA WITH AN ...

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

INTERIOR VIEW, LOOKING EAST, TOWARD BASE OF CUPOLA WITH AN IRON POUR IN PROCESS AS CUPOLA TENDERS, BENNY GOODMAN AND ALAN REVER, USING A ROD TO CLEAN OUT THE TAP HOLE ('RODDING THE HOLE') TO KEEP THE MOLTEN METAL FLOWING FREELY FROM THE IRON BOXES AT THE CUPOLA BASE INTO THE IRON TROUGH FOR LADLE TRANSFER TO THE MIXER AND PIPE CASTING OPERATIONS. ACIPCO'S CUPOLA (150 INCH IN DIAMETER AND 72 FEET IN HEIGHT) PRODUCED IRON THAT IS FURTHER REFINED FOR CASTING OPERATIONS. NATURAL GAS IS USED TO RESTART THE CUPOLA AFTER WHICH IT RUNS CONTINUOUSLY USING FURNACE GASES, PRODUCING AN AVERAGE OF 100 TONS OF MOLTEN METAL PER HOUR. - American Cast Iron Pipe Company, Cupola Area, 1501 Thirty-first Avenue North, Birmingham, Jefferson County, AL

Cause and Prevention of Explosions Involving DC Casting of Aluminum Sheet Ingot

NASA Astrophysics Data System (ADS)

Richter, Ray T.; Ekenes, J. Martin

The casting of aluminum alloy sheet ingot and T-bar presents the potential for some of the most volatile situations that can occur in DC (direct chill) and EMC (Electromagnetic) casting processes. Aluminum Association explosion incident data from over 300 explosions spanning a twenty-year period were reviewed and analyzed looking for common factors and repetitive reasons for explosions. Analysis of explosions occurring during the three stages of sheet ingot casting, `start of cast', `steady state' and `end of cast', were examined and prioritized. Case studies illustrate the need for understanding both technical and non-technical factors contributing to explosions involving molten metal. This paper identifies the major causes of explosions involving DC casting of aluminum alloy sheet ingot and makes recommendations for how to prevent the recurrence of such events and minimize the risk of injury.

A Review of Permanent Magnet Stirring During Metal Solidification

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Structure-processing correlations and mechanical properties in freeze-cast Ti-6Al-4V with highly aligned porosity and a lightweight Ti-6Al-4V-PMMA composite with excellent energy absorption capability

DOE PAGES

Weaver, Jordan S.; Kalidindi, Surya R.; Wegst, Ulrike G. K.

2017-02-12

In contrast to freeze-cast ceramics and polymers, few freeze-cast metals have been described, to date. This systematic study on structure-processing correlations in freeze-cast Ti-6Al-4V scaffolds reports how processing parameters determine the architecture formed during the directional solidification of water-based metal slurries and after sintering. Additionally, sedimentation in the slurry during freezing and volume shrinkage during burnout and sintering were found to significantly affect both structure and properties of the scaffolds. In using two freezing rates, 1 and 10 °C min -1, two water-based polymer solutions as binders (chitosan and carboxymethyl cellulose) and two different metal volume fractions in the slurry,more » 20 and 30 vol%, Ti-6Al-4V scaffolds could be prepared with pore length, width, and porosity ranging from 41 to 523 μm, 14.5–76.5 μm, and 65 to 34%, respectively. Their compressive strength, stiffness, and toughness (work to 20% strain) fall in the range of 83–412 MPa, 7–29 GPa, and 14–122 MJ m -3, respectively. In order to improve the properties a select composition was infiltrated with poly(methyl methacrylate). This increased the average yield strength by a factor of 2.3 from 83 to 193 MPa and the average toughness (work to 50% strain) by a factor of 2.7 from 28.1 to 76.8 MJ m -3.« less

Structure-processing correlations and mechanical properties in freeze-cast Ti-6Al-4V with highly aligned porosity and a lightweight Ti-6Al-4V-PMMA composite with excellent energy absorption capability

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

Weaver, Jordan S.; Kalidindi, Surya R.; Wegst, Ulrike G. K.

In contrast to freeze-cast ceramics and polymers, few freeze-cast metals have been described, to date. This systematic study on structure-processing correlations in freeze-cast Ti-6Al-4V scaffolds reports how processing parameters determine the architecture formed during the directional solidification of water-based metal slurries and after sintering. Additionally, sedimentation in the slurry during freezing and volume shrinkage during burnout and sintering were found to significantly affect both structure and properties of the scaffolds. In using two freezing rates, 1 and 10 °C min -1, two water-based polymer solutions as binders (chitosan and carboxymethyl cellulose) and two different metal volume fractions in the slurry,more » 20 and 30 vol%, Ti-6Al-4V scaffolds could be prepared with pore length, width, and porosity ranging from 41 to 523 μm, 14.5–76.5 μm, and 65 to 34%, respectively. Their compressive strength, stiffness, and toughness (work to 20% strain) fall in the range of 83–412 MPa, 7–29 GPa, and 14–122 MJ m -3, respectively. In order to improve the properties a select composition was infiltrated with poly(methyl methacrylate). This increased the average yield strength by a factor of 2.3 from 83 to 193 MPa and the average toughness (work to 50% strain) by a factor of 2.7 from 28.1 to 76.8 MJ m -3.« less

Fabrication of Mechanically Tunable and Bioactive Metal Scaffolds for Biomedical Applications

PubMed Central

Jung, Hyun-Do; Lee, Hyun; Kim, Hyoun-Ee; Koh, Young-Hag; Song, Juha

2015-01-01

Biometal systems have been widely used for biomedical applications, in particular, as load-bearing materials. However, major challenges are high stiffness and low bioactivity of metals. In this study, we have developed a new method towards fabricating a new type of bioactive and mechanically reliable porous metal scaffolds-densified porous Ti scaffolds. The method consists of two fabrication processes, 1) the fabrication of porous Ti scaffolds by dynamic freeze casting, and 2) coating and densification of the porous scaffolds. The dynamic freeze casting method to fabricate porous Ti scaffolds allowed the densification of porous scaffolds by minimizing the chemical contamination and structural defects. The densification process is distinctive for three reasons. First, the densification process is simple, because it requires a control of only one parameter (degree of densification). Second, it is effective, as it achieves mechanical enhancement and sustainable release of biomolecules from porous scaffolds. Third, it has broad applications, as it is also applicable to the fabrication of functionally graded porous scaffolds by spatially varied strain during densification. PMID:26709604

Interfacial and capillary phenomena in solidification processing of metal-matrix composites

NASA Technical Reports Server (NTRS)

Asthana, R.; Tewari, S. N.

1993-01-01

Chemical and hydrodynamic aspects of wetting and interfacial phenomena during the solidification processing of metal-matrix composites are reviewed. Significant experimental results on fiber-matrix interactions and wetting under equilibrium and non-equilibrium conditions in composites of engineering interest have been compiled, based on a survey of the recent literature. Finally, certain aspects of wetting relevant to stir-casting and infiltration processing of composites are discussed.

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

DOEpatents

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.

Oxidation feature and diffusion mechanism of Zr-based metallic glasses near the glass transition point

NASA Astrophysics Data System (ADS)

Hu, Zheng; Lei, Xianqi; Wang, Yang; Zhang, Kun

2018-03-01

The oxidation behaviors of as-cast, pre-deformed, and crystallized Zr47.9Ti0.3Ni3.1Cu39.3Al9.4 metallic glasses (MGs) were studied near the glass transition point. The oxidation kinetics of the crystallized MGs followed a parabolic-rate law, and the as-cast and pre-deformed MGs exerted a typical two-stage behavior above the glass transition temperature (T g). Most interesting, pre-deformed treatment can significantly improve the oxidation rate of MGs, as the initial oxidation appeared earlier than for the as-cast MGs, and was accompanied by much thicker oxide scale. The EDS and XPS results showed that the metal Al acted as the preferred scavenger that absorbed intrinsic oxygen in the near-surface region of as-cast MGs. However, a homogeneous mixed layer without Al was observed in the pre-deformed MGs. We speculated the accelerated diffusion of other elements in the MGs was due to the local increase in the free volume and significant shear-induced dilation of the local structure. The results from this study demonstrate that MGs exhibit controllable atomic diffusion during the oxidation process, which can facilitate use in super-cooled liquid region applications.

One-step Tape Casting of Composites via Slurry on Fiber

NASA Technical Reports Server (NTRS)

deGroh, Henry C., III

2001-01-01

A process by which metal matrix composites can be made was presented. The process involves putting a powder slurry on fibers to make a precursor green tape. These green tapes are cut, stacked and hot pressed to form the fully dense composite. A computer program was presented which enables complete quantification and control of the process. Once some easily obtained properties of the slurry and its behavior are determined (such as the shrinkage from the wet to green state, and the density of the green tape) modification of the fiber spacing and blade height give the maker precise control of fiber volume fraction, and fiber architecture in the composite. The process was shown to be accurate and flexible through the production of a wide variety of volume fraction fiber composites made from a wide variety of fibers and powders. The most time consuming step of the tape casting process (other than hot pressing) was winding the fiber on the drum. The tape casting techniques developed resulted in high quality metal matrix composites, with ultimate tensile strength in the range of 215 ksi (1477 MPa), a strain at failure of 1.15 percent, and in fatigue at room temperature 0 to 120 ksi, n = 0.3 Hz, a 4-ply Ti-24Al-11Nb/SCS-6, 32 vol% fiber tape cast composite lasted 202,205 cycles with a maximum strain on the 100th cycle of 0.43 percent.

Method of reducing the green density of a slip cast article

DOEpatents

Mangels, John A.; Dickie, Ray A.

1985-01-01

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

Electromagnetic confinement for vertical casting or containing molten metal

DOEpatents

Lari, Robert J.; Praeg, Walter F.; Turner, Larry R.

1991-01-01

An apparatus and method adapted to confine a molten metal to a region by means of an alternating electromagnetic field. As adapted for use in the present invention, the alternating electromagnetic field given by B.sub.y =(2.mu..sub.o .rho.gy).sup.1/2 (where B.sub.y is the vertical component of the magnetic field generated by the magnet at the boundary of the region; y is the distance measured downward form the top of the region, .rho. is the metal density, g is the acceleration of gravity and .mu..sub.o is the permeability of free space) induces eddy currents in the molten metal which interact with the magnetic field to retain the molten metal with a vertical boudnary. As applied to an apparatus for the continuous casting of metal sheets or rods, metal in liquid form can be continuously introduced into the region defined by the magnetic field, solidified and conveyed away from the magnetic field in solid form in a continuous process.

Space Processing Applications Rocket project, SPAR 2

NASA Technical Reports Server (NTRS)

1977-01-01

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

Simulation for grinding balls production using sand mold-gravity casting

NASA Astrophysics Data System (ADS)

Nurjaman, F.; Shofi, A.; Herlina, U.; Prilitasari, N. M.; Triapriani, Y.

2018-01-01

In this present work, the grinding balls from high chromium white cast iron (ASTM A-532) were produced by using sand mold-gravity casting. The simulation casting process was conducted before making these grinding balls by using SOLIDCast™ version 8.2.0. The gating system design and the pouring temperature of hot metal were investigated clearly to obtain grinding balls with no-defect. The sound casting of grinding balls was resulted by using the proper gating system with the addition of vent air on the top of each grinding ball’s mold. The dimension of vent air was reduced by the increasing of pouring temperature, thus it resulted on the increasing of the yield production of grinding balls.

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.

A Comparison between Shear Bond Strength of VMK Master Porcelain with Three Base-metal Alloys (Ni-cr-T3, VeraBond, Super Cast) and One Noble Alloy (X-33) in Metal-ceramic Restorations

PubMed Central

Ahmadzadeh, A; Neshati, A; Mousavi, N; Epakchi, S; Dabaghi Tabriz, F; Sarbazi, AH

2013-01-01

Statement of Problem: The increase in the use of metal-ceramic restorations and a high prevalence of porcelain chipping entails introducing an alloy which is more compatible with porcelain and causes a stronger bond between the two. This study is to compare shear bond strength of three base-metal alloys and one noble alloy with the commonly used VMK Master Porcelain. Materials and Method: Three different groups of base-metal alloys (Ni-cr-T3, Super Cast, and VeraBond) and one group of noble alloy (X-33) were selected. Each group consisted of 15 alloy samples. All groups went through the casting process and change from wax pattern into metal disks. The VMK Master Porcelain was then fired on each group. All the specimens were put in the UTM; a shear force was loaded until a fracture occurred and the fracture force was consequently recorded. The data were analyzed by SPSS Version 16 and One-Way ANOVA was run to compare the shear strength between the groups. Furthermore, the groups were compared two-by-two by adopting Tukey test. Results: The findings of this study revealed shear bond strength of Ni-Cr-T3 alloy was higher than the three other alloys (94 MPa or 330 N). Super Cast alloy had the second greatest shear bond strength (80. 87Mpa or 283.87 N). Both VeraBond (69.66 MPa or 245 N) and x-33 alloys (66.53 MPa or 234 N) took the third place. Conclusion: Ni-Cr-T3 with VMK Master Porcelain has the greatest shear bond strength. Therefore, employment of this low-cost alloy is recommended in metal-ceramic restorations. PMID:24724144

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

PubMed Central

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

2017-01-01

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

[Evaluation method with radiographic image quality indicator for internal defects of dental casting metallic restoration].

PubMed

Li, Y; Zheng, G; Lin, H

2014-12-18

To develop a new kind of dental radiographic image quality indicator (IQI) for internal quality of casting metallic restoration to influence on its usage life. Radiographic image quality indicator method was used to evaluate the depth of the defects region and internal quality of 127 casting metallic restoration and the accuracy was compared with that of conventional callipers method. In the 127 cases of casting metallic restoration, 9 were found the thickness less than 0.7 mm and the thinnest thickness only 0.2 mm in 26 casting metallic crowns or bridges' occlusal defects region. The data measured by image quality indicator were consistent with those measured by conventional gauging. Two metal inner crowns were found the thickness less than 0.3 mm in 56 porcelain crowns or bridges. The thickness of casting removable partial denture was more than 1.0 mm, but thinner regions were not found. It was found that in a titanium partial denture, the X-ray image of clasp was not uniform and there were internal porosity defects in the clasp. Special dental image quality indicator can solve the visual error problems caused by different observing backgrounds and estimate the depth of the defects region in the casting.

A thermodynamic approach to obtain materials properties for engineering applications

NASA Technical Reports Server (NTRS)

Chang, Y. Austin

1993-01-01

With the ever increases in the capabilities of computers for numerical computations, we are on the verge of using these tools to model manufacturing processes for improving the efficiency of these processes as well as the quality of the products. One such process is casting for the production of metals. However, in order to model metal casting processes in a meaningful way it is essential to have the basic properties of these materials in their molten state, solid state as well as in the mixed state of solid and liquid. Some of the properties needed may be considered as intrinsic such as the density, heat capacity or enthalpy of freezing of a pure metal, while others are not. For instance, the enthalpy of solidification of an alloy is not a defined thermodynamic quantity. Its value depends on the micro-segregation of the phases during the course of solidification. The objective of the present study is to present a thermodynamic approach to obtain some of the intrinsic properties and combining thermodynamics with kinetic models to estimate such quantities as the enthalpy of solidification of an alloy.

Comparative assessment of marginal accuracy of grade II titanium and Ni–Cr alloy before and after ceramic firing: An in vitro study

PubMed Central

Patil, Abhijit; Singh, Kishan; Sahoo, Sukant; Suvarna, Suraj; Kumar, Prince; Singh, Anupam

2013-01-01

Objective: The aims of the study are to assess the marginal accuracy of base metal and titanium alloy casting and to evaluate the effect of repeated ceramic firing on the marginal accuracy of base metal and titanium alloy castings. Materials and Methods: Twenty metal copings were fabricated with each casting material. Specimens were divided into 4 groups of 10 each representing base metal alloys castings without (Group A) and with metal shoulder margin (Group B), titanium castings without (Group C) and with metal shoulder margin (Group D). The measurement of fit of the metal copings was carried out before the ceramic firing at four different points and the same was followed after porcelain build-up. Results: Significant difference was found when Ni–Cr alloy samples were compared with Grade II titanium samples both before and after ceramic firings. The titanium castings with metal shoulder margin showed highest microgap among all the materials tested. Conclusions: Based on the results that were found and within the limitations of the study design, it can be concluded that there is marginal discrepancy in the copings made from Ni–Cr and Grade II titanium. This marginal discrepancy increased after ceramic firing cycles for both Ni–Cr and Grade II titanium. The comparative statistical analysis for copings with metal-collar showed maximum discrepancy for Group D. The comparative statistical analysis for copings without metal-collar showed maximum discrepancy for Group C. PMID:24926205

Experimental Procedure for Warm Spinning of Cast Aluminum Components.

PubMed

Roy, Matthew J; Maijer, Daan M

2017-02-01

High performance, cast aluminum automotive wheels are increasingly being incrementally formed via flow forming/metal spinning at elevated temperatures to improve material properties. With a wide array of processing parameters which can affect both the shape attained and resulting material properties, this type of processing is notoriously difficult to commission. A simplified, light-duty version of the process has been designed and implemented for full-size automotive wheels. The apparatus is intended to assist in understanding the deformation mechanisms and the material response to this type of processing. An experimental protocol has been developed to prepare for, and subsequently perform forming trials and is described for as-cast A356 wheel blanks. The thermal profile attained, along with instrumentation details are provided. Similitude with full-scale forming operations which impart significantly more deformation at faster rates is discussed.

Experimental Procedure for Warm Spinning of Cast Aluminum Components

PubMed Central

Roy, Matthew J.; Maijer, Daan M.

2017-01-01

High performance, cast aluminum automotive wheels are increasingly being incrementally formed via flow forming/metal spinning at elevated temperatures to improve material properties. With a wide array of processing parameters which can affect both the shape attained and resulting material properties, this type of processing is notoriously difficult to commission. A simplified, light-duty version of the process has been designed and implemented for full-size automotive wheels. The apparatus is intended to assist in understanding the deformation mechanisms and the material response to this type of processing. An experimental protocol has been developed to prepare for, and subsequently perform forming trials and is described for as-cast A356 wheel blanks. The thermal profile attained, along with instrumentation details are provided. Similitude with full-scale forming operations which impart significantly more deformation at faster rates is discussed. PMID:28190063

Filler metal alloy for welding cast nickel aluminide alloys

DOEpatents

Santella, M.L.; Sikka, V.K.

1998-03-10

A filler metal alloy used as a filler for welding cast nickel aluminide alloys contains from about 15 to about 17 wt. % chromium, from about 4 to about 5 wt. % aluminum, equal to or less than about 1.5 wt. % molybdenum, from about 1 to about 4.5 wt. % zirconium, equal to or less than about 0.01 wt. % yttrium, equal to or less than about 0.01 wt. % boron and the balance nickel. The filler metal alloy is made by melting and casting techniques such as are melting the components of the filler metal alloy and cast in copper chill molds. 3 figs.

Manufacturing Processes for Long-Life Gas Turbines

NASA Astrophysics Data System (ADS)

Hoppin, G. S.; Danesi, W. P.

1986-07-01

Dual-alloy turbine wheels produced by solid-state diffusion bonding of vacuum investment cast blade rings of one superalloy to preconsolidated powder metal hubs of a second superalloy have the long cyclic lives characteristic of wrought or powder superalloys combined with the high creep strength and net-shape blades characteristic of cast superalloys. A wide variety of superalloys and turbine configurations are compatible with this technology. Improved temperature capability turbine blades and vanes of the MAR-M 247 alloy made by directional solidification casting processes are now in volume production for Garrett gas turbines. Single-crystal alloys derivative to MAR-M 247 further extend the temperature capability of turbine blades and have been successfully engine tested. These blades are produced by a relatively simple modification of the processes used to manufacture directionally solidified blades.

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)

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

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

Littleton, Harry; Griffin, John

2011-07-31

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

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

PubMed

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

2015-01-01

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

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

PubMed

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

2003-03-01

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

Report on results of current and future metal casting

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

Unal, Cetin; Carlson, Neil N.

2015-09-28

New modeling capabilities needed to simulate the casting of metallic fuels are added to Truchas code. In this report we summarize improvements we made in FY2015 in three areas; (1) Analysis of new casting experiments conducted with BCS and EFL designs, (2) the simulation of INL’s U-Zr casting experiments with Flow3D computer program, (3) the implementation of surface tension model into Truchas for unstructured mesh required to run U-Zr casting.

Development of Metallic Fuels for Actinide Transmutation

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

Hayes, Steven Lowe; Fielding, Randall Sidney; Benson, Michael Timothy

Research and development activities on metallic fuels are focused on their potential use for actinide transmutation in future sodium fast reactors. As part of this application, there is also a need for a near zero-loss fabrication process and a desire to demonstrate a multifold increase in burnup potential. The incorporation of Am and Np into the traditional U-20Pu-10Zr metallic fuel alloy was demonstrated in the US during the Integral Fast Reactor Program of the 1980’s and early 1990’s. However, the conventional counter gravity injection casting method performed under vacuum, previously used to fabricate these metallic fuel alloys, was not optimizedmore » for mitigating loss of the volatile Am constituent in the casting charge; as a result, approximately 40% of the Am casting charge failed to be incorporated into the as-cast fuel alloys. Fabrication development efforts of the past few years have pursued an optimized bottom-pour casting method to increase utilization of the melted charge to near 100%, and a differential pressure casting approach, performed under an argon overpressure, has been demonstrated to result in essentially no loss of Am due to volatilization during fabrication. In short, a path toward zero-loss fabrication of metallic fuels including minor actinides has been shown to be feasible. Irradiation testing of advanced metallic fuel alloys in the Advanced Test Reactor (ATR) has been underway since 2003. Testing in the ATR is performed inside of cadmium-shrouded positions to remove >99% of the thermal flux incident on the test fuels, resulting in an epi-thermal driven fuel test that is free from gross flux depression and producing an essentially prototypic radial temperature profile inside the fuel rodlets. To date, three irradiation test series (AFC-1,2,3) have been completed. Over 20 different metallic fuel alloys have been tested to burnups as high as 30% with constituent compositions of Pu up to 30%, Am up to 12%, Np up to 10%, and Zr between 10 and 60%. In general, the performance of all of these substantially disparate metallic fuel alloys has been observed to be excellent, and their irradiation behaviors are generally consistent with historic norms for metallic fuels without minor actinide additions and having lower Pu or Zr contents. Future work is being undertaken with a view toward increasing the burnup potential of metallic fuels even more. Design innovations under investigation include: 1) lowering the fuel smear density in order to accommodate more swelling, 2) annular fuel geometry to eliminate the need for a sodium bond, 3) minor alloy additions to stabilize lanthanide fission products inside the fuel and prevent their transport to the cladding where they can participate in fuel-cladding chemical interaction (FCCI), and 4) coatings/liners on the cladding inner surface to mitigate FCCI and enable higher temperature operation. This paper will present the current state of development of metallic fuels for actinide transmutation in the US. Highlights will include recent results from metallic fuel casting experiments, experiments to identify alloy additions to immobilize lanthanide fission products, and postirradiation examinations of annular metallic fuels at low burnup.« less

Castable Amorphous Metal Mirrors and Mirror Assemblies

NASA Technical Reports Server (NTRS)

Hofmann, Douglas C.; Davis, Gregory L.; Agnes, Gregory S.; Shapiro, Andrew A.

2013-01-01

A revolutionary way to produce a mirror and mirror assembly is to cast the entire part at once from a metal alloy that combines all of the desired features into the final part: optical smoothness, curvature, flexures, tabs, isogrids, low CTE, and toughness. In this work, it has been demonstrated that castable mirrors are possible using bulk metallic glasses (BMGs, also called amorphous metals) and BMG matrix composites (BMGMCs). These novel alloys have all of the desired mechanical and thermal properties to fabricate an entire mirror assembly without machining, bonding, brazing, welding, or epoxy. BMGs are multi-component metal alloys that have been cooled in such a manner as to avoid crystallization leading to an amorphous (non-crystalline) microstructure. This lack of crystal structure and the fact that these alloys are glasses, leads to a wide assortment of mechanical and thermal properties that are unlike those observed in crystalline metals. Among these are high yield strength, carbide-like hardness, low melting temperatures (making them castable like aluminum), a thermoplastic processing region (for improving smoothness), low stiffness, high strength-to-weight ratios, relatively low CTE, density similar to titanium alloys, high elasticity and ultra-smooth cast parts (as low as 0.2-nm surface roughness has been demonstrated in cast BMGs). BMGMCs are composite alloys that consist of a BMG matrix with crystalline dendrites embedded throughout. BMGMCs are used to overcome the typically brittle failure observed in monolithic BMGs by adding a soft phase that arrests the formation of cracks in the BMG matrix. In some cases, BMGMCs offer superior castability, toughness, and fatigue resistance, if not as good a surface finish as BMGs. This work has demonstrated that BMGs and BMGMCs can be cast into prototype mirrors and mirror assemblies without difficulty.

Directly susceptible, noncarbon metal ceramic composite crucible

DOEpatents

Holcombe, Jr., Cressie E.; Kiggans, Jr., James O.; Morrow, S. Marvin; Rexford, Donald

1999-01-01

A sintered metal ceramic crucible suitable for high temperature induction melting of reactive metals without appreciable carbon or silicon contamination of the melt. The crucible comprises a cast matrix of a thermally conductive ceramic material; a perforated metal sleeve, which serves as a susceptor for induction heating of the crucible, embedded within the ceramic cast matrix; and a thermal-shock-absorber barrier interposed between the metal sleeve and the ceramic cast matrix to allow for differential thermal expansions between the matrix and the metal sleeve and to act as a thermal-shock-absorber which moderates the effects of rapid changes of sleeve temperature on the matrix.

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

USGS Publications Warehouse

Spencer, J.E.

1999-01-01

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

Semisolid Metal Processing Consortium

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

Apelian,Diran

Mathematical modeling and simulations of semisolid filling processes remains a critical issue in understanding and optimizing the process. Semisolid slurries are non-Newtonian materials that exhibit complex rheological behavior. There the way these slurries flow in cavities is very different from the way liquid in classical casting fills cavities. Actually filling in semisolid processing is often counter intuitive

APPARATUS AND METHOD FOR INJECTION CASTING

DOEpatents

Shuck, A.B.

1960-09-13

S>A single-chamber metal casting apparatus is described wherein molten metal in a vertically movable container can be brought directly into contact with molds. By increasing the gas pressure within the chamber the metal is forced upward into the molds.

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. Copyright © 2014 Elsevier B.V. All rights reserved.

High-Temperature Oxidation Behavior of Two Nickel-Based Superalloys Produced by Metal Injection Molding for Aero Engine Applications

NASA Astrophysics Data System (ADS)

Albert, Benedikt; Völkl, Rainer; Glatzel, Uwe

2014-09-01

For different high-temperature applications like aero engines or turbochargers, metal injection molding (MIM) of superalloys is an interesting processing alternative. For operation at high temperatures, oxidation behavior of superalloys produced by MIM needs to match the standard of cast or forged material. The oxidation behavior of nickel-based superalloys Inconel 713 and MAR-M247 in the temperature interval from 1073 K to 1373 K (800 °C to 1100 °C) is investigated and compared to cast material. Weight gain is measured discontinuously at different oxidation temperatures and times. Analysis of oxidized samples is done via SEM and EDX-measurements. MIM samples exhibit homogeneous oxide layers with a thickness up to 4 µm. After processing by MIM, Inconel 713 exhibits lower weight gain and thinner oxide layers than MAR-M247.

Development in corrosion resistance by microstructural refinement in Zr-16 SS 304 alloy using suction casting technique

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

Das, N., E-mail: nirupamd@barc.gov.in; Sengupta, P.; Abraham, G.

Highlights: • Grain refinement was made in Zr–16 wt.% SS alloy while prepared by suction casting process. • Distribution of Laves phase, e.g., Zr{sub 2}(Fe, Cr) was raised in suction cast (SC) Zr–16 wt.% SS. • Corrosion resistance was improved in SC alloy compared to that of arc-melt-cast alloy. • Grain refinement in SC alloy assisted for an increase in its corrosion resistance. - Abstract: Zirconium (Zr)-stainless steel (SS) hybrid alloys are being considered as baseline alloys for developing metallic-waste-form (MWF) with the motivation of disposing of Zr and SS base nuclear metallic wastes. Zr–16 wt.% SS, a MWF alloymore » optimized from previous studies, exhibit significant grain refinement and changes in phase assemblages (soft phase: Zr{sub 2}(Fe, Cr)/α-Zr vs. hard phase: Zr{sub 3}(Fe, Ni)) when prepared by suction casting (SC) technique in comparison to arc-cast-melt (AMC) route. Variation in Cr-distribution among different phases are found to be low in suction cast alloy, which along with grain refinement restricted Cr-depletion at the Zr{sub 2}(Fe, Cr)/Zr interfaces, prone to localized attack. Hence, SC alloy, compared to AMC alloy, showed lower current density, higher potential at the breakdown of passivity and higher corrosion potential during polarization experiments (carried out under possible geological repository environments, viz., pH 8, 5 and 1) indicating its superior corrosion resistance.« less

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.

Spall behavior of cast iron with varying microstructures

NASA Astrophysics Data System (ADS)

Plume, Gifford; Rousseau, Carl-Ernst

2014-07-01

The spall strength of cast iron with varying microstructures has been investigated using plate impact at moderate speed. Stress history measurements were made with manganin stress gauges embedded between the back face of the specimen and a low impedance polycarbonate backing. Five separate cast irons were tested. Four of these consisted of gray cast iron with graphite in flake form, with three classified as Type VII A2 and the fourth containing a bimodal distribution of Types VII A4 and VII D8. The fifth casting consisted of ductile cast iron with graphite in nodular form, classified as Type I, size class 5. The spall strength for the Type VII A2 gray cast irons varied between 40 and 370 MPa, and that of the additional gray cast iron, between 410 and 490 MPa. The spall strength of the ductile cast iron fell within the range of 0.94-1.2 GPa. It is shown that the spall strength is linked to the damage level at the spall plane, where an increased level of tensile stress is required to generate higher levels of damage. Post mortem analysis was performed on the recovered samples, revealing the graphite phase to be the primary factor governing the spall fracture of cast irons, where crack nucleation is directly correlated to the debonding of graphite from the metal matrix. The average length of graphite found within a casting is linked to the material's strength, where strength increases as a function of decreasing length. The morphology and mean free path of graphite precipitates further govern the subsequent coalescence of initiated cracks to form a complete fracture plane. In cases where graphite spacing is large, increased energy level is required to complete the fracture process. A secondary factor governing the spall fracture of cast irons has also been linked to the microstructure of the metal matrix, with pearlite yielding higher spall strengths than free ferrite.

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

NASA Astrophysics Data System (ADS)

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

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

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

PubMed

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

2017-08-30

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

Developments in metallic materials for aerospace applications

NASA Astrophysics Data System (ADS)

Wadsworth, J.; Froes, F. H.

1989-05-01

High-performance aerospace systems are creating a demand for new materials, not only for airframe and engine applications, but for missile and space systems as well. Recently, advances have been made in metallic materials systems based on magnesium, aluminum, titanium and niobium using a variety of processing methods, including ingot casting, powder metallurgy, rapid solidification and composite technology.

Marginal discrepancy of noble metal-ceramic fixed dental prosthesis frameworks fabricated by conventional and digital technologies.

PubMed

Afify, Ahmed; Haney, Stephan; Verrett, Ronald; Mansueto, Michael; Cray, James; Johnson, Russell

2018-02-01

Studies evaluating the marginal adaptation of available computer-aided design and computer-aided manufacturing (CAD-CAM) noble alloys for metal-ceramic prostheses are lacking. The purpose of this in vitro study was to evaluate the vertical marginal adaptation of cast, milled, and direct metal laser sintered (DMLS) noble metal-ceramic 3-unit fixed partial denture (FDP) frameworks before and after fit adjustments. Two typodont teeth were prepared for metal-ceramic FDP abutments. An acrylic resin pattern of the prepared teeth was fabricated and cast in nickel-chromium (Ni-Cr) alloy. Each specimen group (cast, milled, DMLS) was composed of 12 casts made from 12 impressions (n=12). A single design for the FDP substructure was created on a laboratory scanner and used for designing the specimens in the 3 groups. Each specimen was fitted to its corresponding cast by using up to 5 adjustment cycles, and marginal discrepancies were measured on the master Ni-Cr model before and after laboratory fit adjustments. The milled and DMLS groups had smaller marginal discrepancy measurements than those of the cast group (P<.001). Significant differences were found in the number of adjustments among the groups, with the milled group requiring the minimum number of adjustments, followed by the DMLS and cast groups (F=30.643, P<.001). Metal-ceramic noble alloy frameworks fabricated by using a CAD-CAM workflow had significantly smaller marginal discrepancies compared with those with a traditional cast workflow, with the milled group demonstrating the best marginal fit among the 3 test groups. Manual refining significantly enhanced the marginal fit of all groups. All 3 groups demonstrated marginal discrepancies within the range of clinical acceptability. Copyright © 2017 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

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

PubMed Central

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

2015-01-01

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

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

NASA Astrophysics Data System (ADS)

Witantyo; Setyawan, David

2018-03-01

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

Influence of tool pin in friction stir welding on activated carbon reinforced aluminium metal matrix composite

NASA Astrophysics Data System (ADS)

DijuSamuel, G.; Raja Dhas, J. Edwin

2017-10-01

This paper focus on impact of tool pin in friction stir welding on activated carbon reinforced aluminium metal matrix composite. For fabrication of metal matrix composite AA6061 is used as matrix and activated carbon is used as reinforcement and it is casted using modified stir casting technique. After casting metal matrix composite has undergone various microstructure tests like SEM,EDAX and XRD. FSW is carried out in this metal matrix composite by choosing various tool pin profile like square,round,Threaded round, hexagon and taper. The quality of welded plates is measured in terms of ultimate tensile strength and hardness.

[Exposure to metals in dental laboratories].

PubMed

Apostoli, P; Ferioli, A; Crippa, M; Redaelli, P; Braga Marcazzan, G; Alessio, L

1988-11-01

Dental care includes handling of different types of metal alloys usually classified as "noble" and "base" in relation to the presence or absence of either gold or other precious metals. It must be born in mind that exposure to metals in this activities is due not only to those metals present in the alloys but also to those contained in the other materials used during the processes of casting and finishing. The most important metals are the following: Al, Be, Cd, Cr, Co, Cu, Au, In, Hg, Mo, Ni, Pd, Pt, Si, Ag, Sn, Ti, W, Zn. In this paper we investigated the environmental exposure to metals in dental laboratories studying the environmental air concentration of metals in casting and finishing processes estimating the "quality" of the elements present by Particle Induces X-ray Emission (PIXE) and the "quantity" of the elements by electro thermic atomic absorption spectrophotometry (ET-AAS) and the concentration of the main metals in the blood and in the urine of exposed technicians by ET-AAS. These analyses permitted to detect all the metals present in the work environment and to quantify their concentration, which always resulted to be low (except some metals during short time operations). The biological monitoring revealed the existence of moderate absorption of these metals in the exposed workers but it is not possible for us to affirm if this phenomenon represents a real risk for the health of the technicians. Hence further epidemiological and health surveillance investigations are needed to verify morbidity and mortality of the subjects employed in this activity.

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

ERIC Educational Resources Information Center

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

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

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

Chandler, H.E.

The predictions of a special Metal Progress round table spanning the next 20 years in materials and process engineering in North America are given. Subjects discussed include the energy crunch, impact of computer technology, new roles for testing and inspection, happenings in non ferrous technology, materials substitution, composites and non metallics, people aspects of technology, materials availability, powder metallurgy changes, casting, welding and joining, heat treatments, carbon and alloy steels, new and improved materials, forming, coatings and conservation, and metal production. (FS)

Study on erosion behaviour of hybrid aluminium composite

NASA Astrophysics Data System (ADS)

Vishwas, D. K.; Chandrappa, C. N.; Venkatesh, Shreyas

2018-04-01

The origin of the light metals, as compared to other metals in this century, is noticeable and an exciting area of expansion for innovation. Light metals, are need of the day in engineering, among them application of aluminium and its alloys is enormous. we observe that these metals tend to have a progressive loss of metal from having contact surface with other metals. Erosion is one such wear process, where damage occurs by the repeated application of high localised stresses. Erosion due to impact of solid particle, is a significant problem. In the present work, the erosion behaviour of hybrid aluminium composite is studied. AL 6061 is used as the base alloy. AL 6061 alloy has excellent corrosion resistance but poor wear resistance. So, in order to have improved properties, it is reinforced with Tungsten Chromium Nickel powder in varied proportions by the method of stir casting. The results are compared with the as-cast Al-alloy to determine the improvement in mechanical properties. The tests were conducted in ASTM G76 setup, to determine solid particle erosion behaviour and the results of the hybrid composite were compared with that of as-cast AL 6061 alloy. It was evident that mass loss was maximum at 300 inclinations, which is a characteristic of ductile materials. It was observed that upon increasing the percentages of reinforcement (wt.%), the wear resistance of the hybrid composite increased significantly. It was also observed that the inclusion of tungsten-chromium-nickel powder increased the hardness of the hybrid composite significantly.

Method of forming a relatively stable slip of silicon metal particles and yttrium containing particles

DOEpatents

Dickie, Ray A.; Mangels, John A.

1984-01-01

The method concerns forming a relatively stable slip of silicon metal particles and yttrium containing particles. In one embodiment, a casting slip of silicon metal particles is formed in water. Particles of a yttrium containing sintering aid are added to the casting slip. The yttrium containing sintering aid is a compound which has at least some solubility in water to form Y.sup.+3 ions which have a high potential for totally flocculating the silicon metal particles into a semiporous solid. A small amount of a fluoride salt is added to the casting slip which contains the yttrium containing sintering aid. The fluoride salt is one which will produce fluoride anions when dissolved in water. The small amount of the fluoride anions produced are effective to suppress the flocculation of the silicon metal particles by the Y.sup.+3 ions so that all particles remain in suspension in the casting slip and the casting slip has both an increased shelf life and can be used to cast articles having a relatively thick cross-section. The pH of the casting slip is maintained in a range from 7.5 to 9. Preferably, the fluoride salt used is one which is based on a monovalent cation such as sodium or ammonia. The steps of adding the yttrium containing sintering aid and the fluoride salt may be interchanged if desired, and the salt may be added to a solution containing the sintering aid prior to addition of the silicon metal particles.

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

NASA Astrophysics Data System (ADS)

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

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

Method for uniformly distributing carbon flakes in a positive electrode, the electrode made thereby and compositions

DOEpatents

Mrazek, Franklin C.; Smaga, John A.; Battles, James E.

1983-01-01

A positive electrode for a secondary electrochemical cell wherein an electrically conductive current collector is in electrical contact with a particulate mixture of gray cast iron and an alkali metal sulfide and an electrolyte including alkali metal halides or alkaline earth metal halides. Also present may be a transition metal sulfide and graphite flakes from the conversion of gray cast iron to iron sulfide. Also disclosed is a method of distributing carbon flakes in a cell wherein there is formed an electrochemical cell of a positive electrode structure of the type described and a suitable electrolyte and a second electrode containing a material capable of alloying with alkali metal ions. The cell is connected to a source of electrical potential to electrochemically convert gray cast iron to an iron sulfide and uniformly to distribute carbon flakes formerly in the gray cast iron throughout the positive electrode while forming an alkali metal alloy in the negative electrode. Also disclosed are compositions useful in preparing positive electrodes.

Influence of time of placement of investments for burnout and the type of rings being used on the casting accuracy.

PubMed

Shah, Shabir A; Naqash, Talib Amin; Padmanabhan, T V; Subramanium; Lambodaran; Nazir, Shazana

2014-03-01

The sole objective of casting procedure is to provide a metallic duplication of missing tooth structure, with as great accuracy as possible. The ability to produce well fitting castings require strict adherence to certain fundamentals. A study was undertaken to comparatively evaluate the effect on casting accuracy by subjecting the invested wax patterns to burnout after different time intervals. The effect on casting accuracy using metal ring into a pre heated burnout furnace and using split ring was also carried. The readings obtained were tabulated and subjected to statistical analysis.

Food equipment manufacturer takes a slice out of its scrap rate

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

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

1996-09-01

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

Location, location & size: defects close to surfaces dominate fatigue crack initiation

NASA Astrophysics Data System (ADS)

Serrano-Munoz, Itziar; Buffiere, Jean-Yves; Mokso, Rajmund; Verdu, Catherine; Nadot, Yves

2017-03-01

Metallic cast components inevitably contain defects such as shrinkage cavities which are inherent to the solidification process. Those defects are known to significantly alter the fatigue life of components. Yet very little is known, quantitatively, on the dangerosity of internal casting defects compared to surface ones. In this study, fatigue specimens containing controlled internal defects (shrinkage pores) are used to foster internal cracking. In situ fatigue tests monitored by X ray synchrotron tomography revealed that the internal nucleation and propagation of cracks was systematically overran by surface cracking initiated at castings defects up to ten times smaller than the internal ones. These findings indicate that the presence of internal defects in cast components can be tolerated to a larger extent than is allowed by nowadays standards

On the damping capacity of cast irons

NASA Astrophysics Data System (ADS)

Golovin, S. A.

2012-07-01

The treatment of experimental data on the amplitude-dependent internal friction (ADIF) in terms of various theoretical models has revealed a staged character and the main mechanisms of the processes of energy dissipation in graphite with increasing amplitude of vibrations upon cyclic loading. It is shown that the level of the damping capacity of lamellar cast iron depends on the relationship between the elastic and strength characteristics of graphite and the matrix phase. In cast irons with a rigid matrix structure (pearlite, martensite), the energy dissipation is determined by the volume fraction and morphology of the initial graphite phase. In cast irons with a softer metallic phase (ferrite), the contact interaction of graphite inclusions with the matrix and the properties of the matrix introduce additional sources of high damping.

Location, location &size: defects close to surfaces dominate fatigue crack initiation.

PubMed

Serrano-Munoz, Itziar; Buffiere, Jean-Yves; Mokso, Rajmund; Verdu, Catherine; Nadot, Yves

2017-03-27

Metallic cast components inevitably contain defects such as shrinkage cavities which are inherent to the solidification process. Those defects are known to significantly alter the fatigue life of components. Yet very little is known, quantitatively, on the dangerosity of internal casting defects compared to surface ones. In this study, fatigue specimens containing controlled internal defects (shrinkage pores) are used to foster internal cracking. In situ fatigue tests monitored by X ray synchrotron tomography revealed that the internal nucleation and propagation of cracks was systematically overran by surface cracking initiated at castings defects up to ten times smaller than the internal ones. These findings indicate that the presence of internal defects in cast components can be tolerated to a larger extent than is allowed by nowadays standards.

Location, location & size: defects close to surfaces dominate fatigue crack initiation

PubMed Central

Serrano-Munoz, Itziar; Buffiere, Jean-Yves; Mokso, Rajmund; Verdu, Catherine; Nadot, Yves

2017-01-01

Metallic cast components inevitably contain defects such as shrinkage cavities which are inherent to the solidification process. Those defects are known to significantly alter the fatigue life of components. Yet very little is known, quantitatively, on the dangerosity of internal casting defects compared to surface ones. In this study, fatigue specimens containing controlled internal defects (shrinkage pores) are used to foster internal cracking. In situ fatigue tests monitored by X ray synchrotron tomography revealed that the internal nucleation and propagation of cracks was systematically overran by surface cracking initiated at castings defects up to ten times smaller than the internal ones. These findings indicate that the presence of internal defects in cast components can be tolerated to a larger extent than is allowed by nowadays standards PMID:28345599

Silicon-based Porous Ceramics via Freeze Casting of Preceramic Polymers

NASA Astrophysics Data System (ADS)

Naviroj, Maninpat

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

Optimization of heat treatment parameters for additive manufacturing and gravity casting AlSi10Mg alloy

NASA Astrophysics Data System (ADS)

Girelli, L.; Tocci, M.; Montesano, L.; Gelfi, M.; Pola, A.

2017-11-01

Additive manufacturing of metals is a production process developed in the last few years to realize net shape components with complex geometry and high performance. AlSi10Mg is one of the most widely used aluminium alloys, both in this field and in conventional foundry processes, for its significant mechanical properties combined with good corrosion resistance. In this paper the effect of heat treatment on AlSi10Mg alloy was investigated. Solution and ageing treatments were carried out with different temperatures and times on samples obtained by direct metal laser sintering and gravity casting in order to compare their performance. Microstructural analyses and hardness tests were performed to investigate the effectiveness of the heat treatment. The results were correlated to the sample microstructure and porosity, analysed by means of optical microscopy and density measurements. It was found that, in the additive manufactured samples, the heat treatment can reduce significantly the performance of the alloy also because of the increase of porosity due to entrapped gas during the deposition technique and that the higher the solution temperature the higher the increase of such defects. A so remarkable effect was not found in the conventional cast alloy.

Software Computes Tape-Casting Parameters

NASA Technical Reports Server (NTRS)

deGroh, Henry C., III

2003-01-01

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

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

Code of Federal Regulations, 2010 CFR

2010-07-01

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

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2011 CFR

2011-07-01

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

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2010 CFR

2010-07-01

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

Clinical marginal and internal fit of metal ceramic crowns fabricated with a selective laser melting technology.

PubMed

Huang, Zhuoli; Zhang, Lu; Zhu, Jingwei; Zhang, Xiuyin

2015-06-01

Selective laser melting (SLM) technology has been introduced to fabricate dental restorations. However, the fit of these restorations still needs further study. The purpose of this in vivo investigation was to compare the marginal and internal fit of SLM metal ceramic crowns with 2 lost-wax cast metal ceramic crowns and to evaluate the influence of tooth type on the marginal and internal fit of these crowns. A total of 330 metal ceramic crowns were evaluated. The metal copings were fabricated with SLM Co-Cr, cast Au-Pt, and cast Co-Cr alloy (n=110). The marginal and internal gaps of crowns were recorded by using a replica technique. The anterior and premolar replicas were sectioned 2 times, and molar replicas were sectioned 4 times. The marginal and internal gap width of each cross section was examined by stereomicroscope at ×30 magnification. Two-way analysis of variance was performed to identify the statistical difference among the groups. The marginal fit of the SLM Co-Cr group (75.6 ±32.6 μm) was not different from the cast Au-Pt group (76.8 ±32.1 μm) (P>.05) but was better than the cast Co-Cr group (91.0 ±36.3 μm) (P<.01). No significant difference was found among the SLM Co-Cr group (127.3 ±45.8 μm), cast Au-Pt group (129.9 ±61.1 μm). and cast Co-Cr group (142.5 ±63.7 μm) (P>.05). The mean occlusal gap width of the SLM Co-Cr group (309.8 ±106.6 μm) was significantly higher than that of the cast Au-Pt group (254.6 ±109.6 μm) and the cast Co-Cr group (249.6 ±110.4 μm) (P<.005). No significant difference was found in the marginal fit among the anterior group (84.4 ±35.1 μm), the premolar group (80.6 ±26.3 μm), and the molar group (82.7 ±38.0 μm) (P>.05). Also, no significant difference was found in the axial fit among the anterior group (138.3 ±52.5 μm), the premolar group (132.9 ±50.4 μm), and the molar group (134.4 ±52.5 μm) (P>.05). The anterior group (267.6 ±110.2 μm) did not differ from the premolar group (270.2 ±112.8 μm) and the molar group (268.6 ±110.5 μm) in occlusal fit (P>.05). The marginal fit of SLM Co-Cr metal ceramic crowns was similar to that of the cast Au-Pt metal ceramic crowns and was better than that of the cast Co-Cr metal ceramic crowns. The SLM Co-Cr metal ceramic crowns were not significantly different from the 2 cast metal ceramic crowns in axial fit but were less accurate in occlusal fit. Tooth type did not influence the marginal and internal fit of the metal ceramic crowns. Copyright © 2015 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

Method for the preparation of thin-skinned asymmetric reverse osmosis membranes and products thereof

NASA Technical Reports Server (NTRS)

Wydeven, T. J. (Inventor); Katz, M. G.

1984-01-01

A method for preparing water insoluble asymmetric membranes from water soluble polymers is discussed. The process involves casting a film of the polymer, partially drying it, and then contacting it with a concentrated solution of a transition metal salt. The transition metal ions render the polymer insoluable and are believed to form a complex with it. Optionally, the polymer is crosslinked with heat or radiation. The most preferred polymer is poly(vinyl alcohol). The most preferred complexing salt is copper sulfate. The process and the metal ion linked membranes are discussed. The membranes are reverse osmosis membranes.

X-ray tomography studies on porosity and particle size distribution in cast in-situ Al-Cu-TiB{sub 2} semi-solid forged composites

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

Mathew, James; Mandal, Animesh

X-ray computed tomography (XCT) was used to characterise the internal microstructure and clustering behaviour of TiB{sub 2} particles in in-situ processed Al-Cu metal matrix composites prepared by casting method. Forging was used in semi-solid state to reduce the porosity and to uniformly disperse TiB{sub 2} particles in the composite. Quantification of porosity and clustering of TiB{sub 2} particles was evaluated for different forging reductions (30% and 50% reductions) and compared with an as-cast sample using XCT. Results show that the porosity content was decreased by about 40% due to semi-solid forging as compared to the as-cast condition. Further, XCT resultsmore » show that the 30% forging reduction resulted in greater uniformity in distribution of TiB{sub 2} particles within the composite compared to as-cast and the 50% forge reduction in semi-solid state. These results show that the application of forging in semi-solid state enhances particle distribution and reduces porosity formation in cast in-situ Al-Cu-TiB{sub 2} metal matrix composites. - Highlights: •XCT was used to visualise 3D internal structure of Al-Cu-TiB{sub 2} MMCs. •Al-Cu-TiB{sub 2} MMC was prepared by casting using flux assisted synthesis method. •TiB{sub 2} particles and porosity size distribution were evaluated. •Results show that forging in semi-solid condition decreases the porosity content and improve the particle dispersion in MMCs.« less

Internal fit of single crowns produced by CAD-CAM and lost-wax metal casting technique assessed by the triple-scan protocol.

PubMed

Dahl, Bjørn Einar; Rønold, Hans Jacob; Dahl, Jon E

2017-03-01

Whether single crowns produced by computer-aided design and computer-aided manufacturing (CAD-CAM) have an internal fit comparable to crowns made by lost-wax metal casting technique is unknown. The purpose of this in vitro study was to compare the internal fit of single crowns produced with the lost-wax and metal casting technique with that of single crowns produced with the CAD-CAM technique. The internal fit of 5 groups of single crowns produced with the CAD-CAM technique was compared with that of single crowns produced in cobalt-chromium with the conventional lost-wax and metal casting technique. Comparison was performed using the triple-scan protocol; scans of the master model, the crown on the master model, and the intaglio of the crown were superimposed and analyzed with computer software. The 5 groups were milled presintered zirconia, milled hot isostatic pressed zirconia, milled lithium disilicate, milled cobalt-chromium, and laser-sintered cobalt-chromium. The cement space in both the mesiodistal and buccopalatal directions was statistically smaller (P<.05) for crowns made by the conventional lost-wax and metal casting technique compared with that of crowns produced by the CAD-CAM technique. Single crowns made using the conventional lost-wax and metal casting technique have better internal fit than crowns produced using the CAD-CAM technique. Copyright © 2016 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

Modeling metal droplet sprays in spray forming

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

Muoio, N.G.; Crowe, C.T.; Fritsching, U.

1995-12-31

Spray casting is a process whereby a molten metal stream is atomized and deposited on a substrate. The rapid solidification of the metal droplets gives rise to a fine grain structure and improved material properties. This paper presents a simulation for the fluid and thermal interaction of the fluid and droplets in the spray and the effect on the droplet spray pattern. Good agreement is obtained between the measured and predicted droplet mass flux distribution in the spray.

Coal gasification plant

DOEpatents

Wood, Andrew

1978-01-01

A removable annular hearth member, shaped to fit over the slag outlet of a slagging gasifier, comprises a cast body of high thermal conductivity having integral coolant passageways, said passageways being formed by shaping a metal tube into a coil having an inlet and an outlet, and casting metal to the desired shape around the coil such that the inlet and outlet communicate exteriorly of the cast body.

An application of powder metallurgy to dentistry.

PubMed

Oda, Y; Ueno, S; Kudoh, Y

1995-11-01

Generally, the dental casting method is used to fabricate dental prostheses made with metal. The method of fabricating dental prostheses from sintered titanium alloy has certain advantages: the elimination of casting defects, a sintering temperature that is lower than the melting point, and a shorter processing time. By examining (1) the properties of green, sintered compacts of titanium powder, (2) the effects of adding aluminum powder on the properties of green, sintered compacts of Ti-Al compound, and (3) the effects of adding copper powder on the properties of green, sintered compacts of Ti-Al-Cu compound, the authors developed a sintered titanium alloy on a trial basis. Because the properties satisfied the requirements of dental restorations, a powder metallurgical method of making dental restorations from this sintered titanium alloy was devised. Applications of such sintered titanium alloys for the metal coping of metal-ceramic crowns and denture base plates were discussed.

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

PubMed

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

2016-03-01

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

A Solid Case for Microgravity Processing

NASA Technical Reports Server (NTRS)

Grugel, Richard N.

2000-01-01

Solidification of metals, particularly alloys, is a complicated process. At some sufficiently high temperature, the components comprising an alloy fully mix, producing a single homogeneous liquid. Unfortunately, after this liquid is cast into a mold and allowed to freeze, the resulting solid is usually very inhomogeneous. In most cases the first solid to "freeze out" of the liquid has a composition very close to one of the pure metals. This initially solidifying metal usually comprises microscopic, pine-tree shaped components, collectively referred to as a dendritic array, whose distribution, alignment, and scale directly influence a materials strength and docility. During dendrite growth the adjacent liquid becomes enriched, and consequently, solidifies a much lower temperature and considerably later time. Thus, in the course of solidification, both the solid and the enriched liquid can have compositions (and local temperatures) significantly different from those of the bulk liquid. Different compositions and temperatures imply different densities that, in Earth's gravity, induce motion in the liquid. Such motion promotes formation of a casting that is denser at the bottom and lighter at the top. This condition known as macrosegregation, precludes optimized, uniform material properties.

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Changes in metal properties after thermal and electric impulse processing

NASA Astrophysics Data System (ADS)

Shaburova, N. A.

2015-04-01

The results of the experiments on processing metal melts by powerful electromagnetic impulses are given. The generator used in the experiments has the following characteristics: pulse height - 10KV, duration - 1ns, leading edge - 0.1ns, repetition rate - 1KHz, the output - 100KWt. The duration of the processing is 10-15min. The comparative analysis of the processed and unprocessed samples results in the changes of structure, increase of density, solidity, plasticity and resilience of cast metal. The result analysis of different external physical processing methods on alloys shows full agreement with the results of the ultrasonic processing of metals. The hypothesis of ultrasonic shock wave formation at the pulse front was adopted as the main mechanism of the electromagnetic impulse impact on alloys. The theoretical part of the research describes the transformation process of electromagnetic impulses into acoustic ones.

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

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

Dr. Von L. Richards

2011-09-30

This project addresses improvements in metal casting processes by reducing scrap and reducing the cost of production, due to scrap reduction from investment casting and yield improvement offered by lost foam casting as compared to no-bake or green sand molding. The objectives for the investment casting portion of the subtask are to improve knowledge of fracture toughness of mold shells and the sources of strength limiting flaws and to understand the effects of wax reclamation procedures on wax properties. Applying 'clean steel' approaches to pouring technology and cleanliness in investment casting of steel are anticipated to improve incoming materials inspectionmore » procedures as they affect the microstructure and toughness of the shell. This project focused on two areas of study in the production of steel castings to reduce scrap and save energy: (1) Reducing the amount of shell cracking in investment cast steel production; (2) Investigate the potential of lost foam steel casting The basic findings regarding investment casting shell cracking were: (1) In the case of post pouring cracking, this could be related to phase changes in silica upon cooling and could be delayed by pouring arrangement strategies that maintained the shell surface at temperature for longer time. Employing this delay resulted in less adherent oxidation of castings since the casting was cooler at the time o fair exposure. (2) A model for heat transfer through water saturated shell materials under steam pressure was developed. (3) Initial modeling result of autoclave de-waxing indicated the higher pressure and temperature in the autoclave would impose a steeper temperature gradient on the wax pattern, causing some melt flow prior to bulk expansion and decreasing the stress on the green shell. Basic findings regarding lost foam casting of steel at atmospheric pressure: (1) EPS foam generally decomposes by the collapse mode in steel casting. (2) There is an accumulation of carbon pick-up at the end of the casting opposite the gate. (3) It is recommended that lost foam castings in steel be gated for a quiescent fill in an empty cavity mold to prevent foam occlusion defects from the collapse mode. The energy benefit is primarily in yield savings and lower casting weight per function due to elimination of draft and parting lines for the larger lost foam castings. For the smaller investment casting, scrap losses due to shell cracking will be reduced. Both of these effects will reduce the metal melted per good ton of castings. There will also be less machine stock required per casting which is a yield savings and a small additional energy savings in machining. Downstream savings will come from heavy truck and railroad applications. Application of these processes to heavy truck castings will lighten the heavy truck fleet by about ten pounds per truck. Using ten years to achieve full penetration of the truck fleet at linear rate this will result in a fuel savings of 131 trillion BTU over ten years.« less

Effect of surface contamination on adhesive bonding of cast pure titanium and Ti-6Al-4V alloy.

PubMed

Watanabe, I; Watanabe, E; Yoshida, K; Okabe, T

1999-03-01

There is little information regarding bond strengths of resin cements to cast titanium surfaces contaminated by investment material. This study examined the effect of surface contamination on the shear bond strength of resin cements to cast titanium and Ti-6Al-4V alloy. Two types of disks were cast from commercially pure titanium (CP-Ti) and Ti-6Al-4V alloy ingots using an argon-arc pressure casting unit and a phosphate-bonded Al2 O3 /LiAlSiO6 investment. After casting, disks were subjected to 3 surface treatments: (1) cast surface sandblasted (50 microm-sized Al2 O3 ) for 30 seconds; (2) metal surface sanded with silicon-carbide paper (600 grit) after grinding the contaminated cast surface (approximately 200 microm in thickness); and (3) metal surface sandblasted for 30 seconds after treatment 2. Surface structures were examined after each treatment with SEM and optical microscopy. Each type of disk was then bonded with 2 types of luting materials. Bonded specimens were subjected to thermocycling for up to 50,000 cycles, and shear bond strengths were determined after 0 (baseline) and 50,000 thermocycles. Results were statistically analyzed with 3-way ANOVA (P <.05). Microscopic observation of cast CP-Ti and Ti-6Al-4V exhibited noticeable structures on the cast surfaces apparently contaminated with investment material. However, there were no statistical differences (P >.05) in the bond strengths of both cements between contaminated (treatment 1) and uncontaminated surfaces (treatment 3) for both metals at baseline and after 50,000 thermocycles. The bond strength of specimens sanded with silicon-carbide paper (treatment 2) deteriorated dramatically after 50,000 thermocycles. Contamination of the cast metal surfaces by elements of the investment during casting did not affect bond strengths of the luting materials to CP-Ti and Ti-6Al-4V.

Chrysler Upset Protrusion Joining Techniques for Joining Dissimilar Metals

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

Logan, Stephen

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

Ceramic-metal composites prepared via tape casting and melt infiltration methods

NASA Astrophysics Data System (ADS)

Kim, Hyun Jun

Melt infiltration of preforms prepared by tape casting and lamination has been accomplished using a short-time infiltration process that significantly suppresses reaction product formation. For layered materials produced via infiltration of laminated ceramic tapes, of particular interest is the effect that a large change in microstructure has on infiltration, phase formation, and mechanical properties. Hardness of the fine scale composite layers is approximately three times higher than coarse scale layers, due to greater strength of the fine B4C network. Fractography showed that crack propagation occurred by brittle fracture of the carbide and ductile extension of the metal. Despite large differences in hardness, the fracture mode of the fine and coarse scale microstructures appears identical. Fluid flow modeling for tape casting was conducted with a Newtonian slurry under a parallel blade, and the effect of beveling the blade based on a one dimensional flow model is shown. The discussion on slurry deformation after the blade exit suggests that the mode of slurry deformation depends on the relative importance of the pressure gradient and wall shear and that the existence of zero shear plane might have a negative effect on particle alignment in the tape. The analysis of the flow under a beveled blade predicts that this configuration is more advantageous than the parallel blade for productivity and parallel blade is better for producing uniform particle alignment and thinner tape. Also, the one dimensional flow model for the beveled blade is shown to be a valid approximation of the fluid behavior below a blade angle of 45 degrees. The flow visualization study on tape casting was conducted with a transparent apparatus and model slurry. Most investigators have concluded that the shear stress between the doctor blade and moving carrier causes the particle alignment, but, according to the result of visualization experiment, some degree of particle alignment is already established in the reservoir. The fluid flow concept of tape casting is incorporated with a metal infiltration technique to prepare the ceramic-metal composites with tailored porosity and pore orientation. Boron carbide-aluminum system was used to prepare the composites, and its stiffness constants were investigated. The aligned metal ligaments rarely affect the stiffness constant anisotropy which appears to be caused by tape casting operation.

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

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

Aikin, Jr., Robert M.

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

INTERIOR VIEW, LOOKING NORTH, TOWARDS CUPOLA WHERE SCRAP METAL AND ...

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

INTERIOR VIEW, LOOKING NORTH, TOWARDS CUPOLA WHERE SCRAP METAL AND OTHER COMPONENTS ARE MELTED TO CREATE DUCTILE IRON. BRIGHT FLASH IN BACKGROUND RESULTS FROM MOLTEN METAL (DUCTILE IRON) BEING POURED FROM CUPOLA INTO TRANSFER LADLE. - McWane Cast Iron Pipe Company, Pipe Casting Area, 1201 Vanderbilt Road, Birmingham, Jefferson County, AL

40 CFR 464.25 - Pretreatment standards for existing sources.

Code of Federal Regulations, 2011 CFR

2011-07-01

...) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Copper Casting... Maximum for monthly average kg/1000 kkg (pounds per million pounds) of metal poured Copper (T) 0.0307 0... any 1 day Maximum for monthly average kg/1,000 kkg (pounds per million pounds) of metal poured Copper...

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2014 CFR

2014-07-01

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

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2012 CFR

2012-07-01

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

40 CFR 464.02 - General definitions.

Code of Federal Regulations, 2013 CFR

2013-07-01

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

Method for uniformly distributing carbon flakes in a positive electrode, the electrode made thereby and compositions. [Patent application

DOEpatents

Mrazek, F.C.; Smaga, J.A.; Battles, J.E.

1981-01-19

A positive electrode for a secondary electrochemical cell is described wherein an electrically conductive current collector is in electrical contact with a particulate mixture of gray cast iron and an alkali metal sulfide and an electrolyte including alkali metal halides or alkaline earth metal halides. Also present may be a transition metal sulfide and graphite flakes from the conversion of gray cast iron to iron sulfide. Also disclosed is a method of distributing carbon flakes in a cell wherein there is formed an electrochemical cell of a positive electrode structure of the type described and a suitable electrolyte and a second electrode containing a material capable of alloying with alkali metal ions. The cell is connected to a source of electrical potential to electrochemically convert gray cast iron to an iron sulfide and uniformly to distribute carbon flakes formerly in the gray cast iron throughout the positive electrode while forming an alkali metal alloy in the negative electrode. Also disclosed are compositions useful in preparing positive electrodes.

Metal casts showing the three-dimensional structure of the human inner ear were converted into jewelry.

PubMed

Heywood, Peter

2015-06-01

This article describes a straightforward method for making metal casts of the human inner ear developed in 1937 by M. Wharton Young of Howard University College of Medicine. These casts were used to study anatomy, but there do not appear to be any published photographs of the casts. Inner ear casts converted into jewelry provide the only known images of this work. Later, Young studied the inner ear in living rhesus monkeys by injecting mercury into their membranous labyrinths. Young's investigations indicated a blind-ending perilymphatic sac that was not in continuity with the subarachnoid space.

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

PubMed

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

2002-09-01

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

Sidewall containment of liquid metal with vertical alternating magnetic fields

DOEpatents

Lari, Robert J.; Praeg, Walter F.; Turner, Larry R.; Battles, James E.; Hull, John R.; Rote, Donald M.

1990-01-01

An apparatus for containing molten metal using a magnet producing vertical alternating magnetic field positioned adjacent the area in which the molten metal is to be confined. This invention can be adapted particularly to the casting of metal between counter-rotating rollers with the vertical alternating magnetic field used to confine the molten metal at the edges of the rollers. Alternately, the vertical alternating magnetic field can be used as a flow regulator in casting molten metal from an opening in a channel.

Mold with improved core for metal casting operation

DOEpatents

Gritzner, Verne B.; Hackett, Donald W.

1977-01-01

The present invention is directed to a mold containing an improved core for use in casting hollow, metallic articles. The core is formed of, or covered with, a layer of cellular material which possesses sufficient strength to maintain its structural integrity during casting, but will crush to alleviate the internal stresses that build up if the normal contraction during solidification and cooling is restricted.

Evaluation of metal-ceramic bond characteristics of three dental Co-Cr alloys prepared with different fabrication techniques.

PubMed

Wang, Hongmei; Feng, Qing; Li, Ning; Xu, Sheng

2016-12-01

Limited information is available regarding the metal-ceramic bond strength of dental Co-Cr alloys fabricated by casting (CAST), computer numerical control (CNC) milling, and selective laser melting (SLM). The purpose of this in vitro study was to evaluate the metal-ceramic bond characteristics of 3 dental Co-Cr alloys fabricated by casting, computer numerical control milling, and selective laser melting techniques using the 3-point bend test (International Organization for Standardization [ISO] standard 9693). Forty-five specimens (25×3×0.5 mm) made of dental Co-Cr alloys were prepared by CAST, CNC milling, and SLM techniques. The morphology of the oxidation surface of metal specimens was evaluated by scanning electron microscopy (SEM). After porcelain application, the interfacial characterization was evaluated by SEM equipped with energy-dispersive spectrometry (EDS) analysis, and the metal-ceramic bond strength was assessed with the 3-point bend test. Failure type and elemental composition on the debonding interface were assessed by SEM/EDS. The bond strength was statistically analyzed by 1-way ANOVA and Tukey honest significant difference test (α=.05). The oxidation surfaces of the CAST, CNC, and SLM groups were different. They were porous in the CAST group but compact and irregular in the CNC and SLM groups. The metal-ceramic interfaces of the SLM and CNC groups showed excellent combination compared with those of the CAST group. The bond strength was 37.7 ±6.5 MPa for CAST, 43.3 ±9.2 MPa for CNC, and 46.8 ±5.1 MPa for the SLM group. Statistically significant differences were found among the 3 groups tested (P=.028). The debonding surfaces of all specimens exhibited cohesive failure mode. The oxidation surface morphologies and thicknesses of dental Co-Cr alloys are dependent on the different fabrication techniques used. The bond strength of all 3 groups exceed the minimum acceptable value of 25 MPa recommended by ISO 9693; hence, dental Co-Cr alloy fabricated with the SLM techniques could be a promising alternative for metal ceramic restorations. Copyright © 2016 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

[Studies on high temperature oxidation of noble metal alloys for dental use. (III) On high temperature oxidation resistance of noble metal alloys by adding small amounts of alloying elements. (author's transl)].

PubMed

Ohno, H

1976-11-01

The previous report pointed out the undesirable effects of high temperature oxidation on the casting. The influence of small separate additions of Zn, Mg, Si, Be and Al on the high temperature oxidation of the noble metal alloys was examined. These alloying elements were chosen because their oxide have a high electrical resistivity and they have much higher affinity for oxygen than Cu. The casting were oxidized at 700 degrees C for 1 hour in air. The results obtained were as follows: 1. The Cu oxides are not observed on the as-cast surface of noble metal alloys containing small amounts of Zn, Mg, Si, Be, and Al. The castings have gold- or silver-colored surface. 2. After heating of the unpolished and polished castings, the additions of Si, Be and Al are effective in preventing oxidation of Cu in the 18 carats gold alloys. Especially the golden surface is obtained by adding Be and Al. But there is no oxidation-resistance on the polished castings in the alloys containing Zn and Mg. 3. The zinc oxide film formed on the as-cast specimen is effective in preventing of oxidation Cu in 18 carats gold alloys. 4. It seems that the addition of Al is most available in dental application.

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

NASA Technical Reports Server (NTRS)

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

1986-01-01

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

Materials

NASA Technical Reports Server (NTRS)

Glaessgen, Edward H.; Schoeppner, Gregory A.

2006-01-01

NASA Langley Research Center has successfully developed an electron beam freeform fabrication (EBF3) process, a rapid metal deposition process that works efficiently with a variety of weldable alloys. The EBF3 process can be used to build a complex, unitized part in a layer-additive fashion, although the more immediate payoff is for use as a manufacturing process for adding details to components fabricated from simplified castings and forgings or plate products. The EBF3 process produces structural metallic parts with strengths comparable to that of wrought product forms and has been demonstrated on aluminum, titanium, and nickel-based alloys to date. The EBF3 process introduces metal wire feedstock into a molten pool that is created and sustained using a focused electron beam in a vacuum environment. Operation in a vacuum ensures a clean process environment and eliminates the need for a consumable shield gas. Advanced metal manufacturing methods such as EBF3 are being explored for fabrication and repair of aerospace structures, offering potential for improvements in cost, weight, and performance to enhance mission success for aircraft, launch vehicles, and spacecraft. Near-term applications of the EBF3 process are most likely to be implemented for cost reduction and lead time reduction through addition of details onto simplified preforms (casting or forging). This is particularly attractive for components with protruding details that would require a significantly large volume of material to be machined away from an oversized forging, offering significant reductions to the buy-to-fly ratio. Future far-term applications promise improved structural efficiency through reduced weight and improved performance by exploiting the layer-additive nature of the EBF3 process to fabricate tailored unitized structures with functionally graded microstructures and compositions.

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

Kervick, R.; Blue, C. A.; Kadolkar, P. B.

Forging is a manufacturing process in which metal is pressed, pounded or squeezed under great pressure and, often, under high strain rates into high-strength parts known as forgings. The process is typically performed hot by preheating the metal to a desired temperature before it is worked. The forging process can create parts that are stronger than those manufactured by any other metal working process. Forgings are almost always used where reliability and human safety are critical. Forgings are normally component parts contained inside assembled items such airplanes, automobiles, tractors, ships, oil drilling equipment, engines missiles, and all kinds of capitalmore » equipment Forgings are stronger than castings and surpass them in predictable strength properties, producing superior strength that is assured, part to part.« less

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

EPA Pesticide Factsheets

Human exposure to heavy metals occurs through food contamination due to industrial processes, vehicle emissions and farming methods. Specific toxicity endpoints have been associated with metal exposures, e.g. lead and neurotoxicity; however, numerous varieties of heavy metals have not been systematically examined for potential toxicities. We describe results from testing a large set of heavy metal-containing compounds in extensive suites of in vitro assays to suggest possible molecular initiating events in toxicity pathways. A broad definition of heavy metals that includes As, Se and organometallics or inorganic salts containing metals in Group III or higher (MW > 40) was used to identify 75 different compounds tested in the EPA’s ToxCast assays encompassing biochemical, cellular and model organism assays. These 75, plus an additional 100 metal-containing compounds, were tested in Tox21 quantitative high-throughput screening (qHTS) assays covering nuclear receptor and stress pathways. Known activities were confirmed such as activation of stress pathways and nuclear receptors (RXR, PPARg) as well as overt cytotoxicity. Specifically, organotin and organomercury were among the most potent of over 8K chemicals tested. The HTS results support known toxicities, including promiscuous GPCR activity for mercury compounds consistent with the neuropsychiatric effects seen in mercury poisoning (Mad Hatter’s Syndrome). As such, HTS approaches provide an efficient method

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

PubMed Central

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

2017-01-01

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

Process for the fabrication of aluminum metallized pyrolytic graphite sputtering targets

DOEpatents

Makowiecki, Daniel M.; Ramsey, Philip B.; Juntz, Robert S.

1995-01-01

An improved method for fabricating pyrolytic graphite sputtering targets with superior heat transfer ability, longer life, and maximum energy transmission. Anisotropic pyrolytic graphite is contoured and/or segmented to match the erosion profile of the sputter target and then oriented such that the graphite's high thermal conductivity planes are in maximum contact with a thermally conductive metal backing. The graphite contact surface is metallized, using high rate physical vapor deposition (HRPVD), with an aluminum coating and the thermally conductive metal backing is joined to the metallized graphite target by one of four low-temperature bonding methods; liquid-metal casting, powder metallurgy compaction, eutectic brazing, and laser welding.

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

Casting evaluation of U-Zr alloy system fuel slug for SFR prepared by injection casting method

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

Song, Hoon; Kim, Jong-Hwan; Kim, Ki-Hwan

2013-07-01

Metal fuel slugs of U-Pu-Zr alloys for Sodium-cooled Fast Reactor (SFR) have conventionally been fabricated by a vacuum injection casting method. Recently, management of minor actinides (MA) became an important issue because direct disposal of the long-lived MA can be a long-term burden for a tentative repository up to several hundreds of thousand years. In order to recycle transuranic elements (TRU) retained in spent nuclear fuel, remote fabrication capability in a shielded hot cell should be prepared. Moreover, generation of long-lived radioactive wastes and loss of volatile species should be minimized during the recycled fuel fabrication step. In order tomore » prevent the evaporation of volatile elements such as Am, alternative fabrication methods of metal fuel slugs have been studied applying gravity casting, and improved injection casting in KAERI, including melting under inert atmosphere. And then, metal fuel slugs were examined with casting soundness, density, chemical analysis, particle size distribution and microstructural characteristics. Based on these results there is a high level of confidence that Am losses will also be effectively controlled by application of a modest amount of overpressure. A surrogate fuel slug was generally soundly cast by improved injection casting method, melted fuel material under inert atmosphere.« less

Evaluation of marginal and internal gaps of metal ceramic crowns obtained from conventional impressions and casting techniques with those obtained from digital techniques.

PubMed

Rai, Rathika; Kumar, S Arun; Prabhu, R; Govindan, Ranjani Thillai; Tanveer, Faiz Mohamed

2017-01-01

Accuracy in fit of cast metal restoration has always remained as one of the primary factors in determining the success of the restoration. A well-fitting restoration needs to be accurate both along its margin and with regard to its internal surface. The aim of the study is to evaluate the marginal fit of metal ceramic crowns obtained by conventional inlay casting wax pattern using conventional impression with the metal ceramic crowns obtained by computer-aided design and computer-aided manufacturing (CAD/CAM) technique using direct and indirect optical scanning. This in vitro study on preformed custom-made stainless steel models with former assembly that resembles prepared tooth surfaces of standardized dimensions comprised three groups: the first group included ten samples of metal ceramic crowns fabricated with conventional technique, the second group included CAD/CAM-milled direct metal laser sintering (DMLS) crowns using indirect scanning, and the third group included DMLS crowns fabricated by direct scanning of the stainless steel model. The vertical marginal gap and the internal gap were evaluated with the stereomicroscope (Zoomstar 4); post hoc Turkey's test was used for statistical analysis. One-way analysis of variance method was used to compare the mean values. Metal ceramic crowns obtained from direct optical scanning showed the least marginal and internal gap when compared to the castings obtained from inlay casting wax and indirect optical scanning. Indirect and direct optical scanning had yielded results within clinically acceptable range.

Comparison of the electrochemical properties of various orthopedic porous metals.

PubMed

Warren, L D; Chowdhary, P R

1992-01-01

The electrochemical properties of various porous metal coatings used in reconstructive orthopedic prosthetics were examined. Potentiodynamic corrosion testing was used to evaluate the behavior of the following porous metals; CSTi on Cast CoCr, CSTi on Ti-6Al-4V, CoCr beads on Cast CoCr, CoCr beads on Ti-6Al-4V, CP Ti beads on Cast CoCr, and CP Ti beads on Ti-6Al-4V. Analysis of the resultant corrosion scans showed that these materials behave similarly to one another. No corrosion-related anomalies were noted.

An oxide dispersion strengthened Ni-W-Al alloy with superior high temperature strength

NASA Technical Reports Server (NTRS)

Glasgow, T. K.

1976-01-01

An experimental oxide dispersion strengthened (ODS) alloy, WAZ-D, derived from the WAZ-20 composition was produced by the mechanical alloying process. Cast WAZ-20 is strengthened by both a high refractory metal content, and 70 volume percent of gamma prime. The ODS alloy WAZ-D was responsive to variables of alloy content, of attritor processing, of consolidation by extrusion, and of heat treatment. The best material produced had large highly elongated grains. It exhibited tensile strengths generally superior to a comparable cast alloy. The ODS alloy exhibited high temperature stress rupture life considerably superior to any known cast superalloy. Tensile and rupture ductility were low, as was intermediate temperature rupture life. Very low creep rates were noted and some specimens failed with essentially no third stage creep. Also the benefit derived from the oxide dispersion, far out-weighed that from the elongated microstructure alone.

40 CFR 421.56 - Pretreatment standards for new sources.

Code of Federal Regulations, 2011 CFR

2011-07-01

... GUIDELINES AND STANDARDS NONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY Primary Electrolytic Copper.... The mass of wastewater pollutants in primary electrolytic copper refining process wastewater... pounds) of copper cast Arsenic .692 .309 Copper .638 .304 Nickel .274 .184 (b) Subpart E—Anode and...

40 CFR 421.56 - Pretreatment standards for new sources.

Code of Federal Regulations, 2010 CFR

2010-07-01

... GUIDELINES AND STANDARDS NONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY Primary Electrolytic Copper.... The mass of wastewater pollutants in primary electrolytic copper refining process wastewater... pounds) of copper cast Arsenic .692 .309 Copper .638 .304 Nickel .274 .184 (b) Subpart E—Anode and...

Mathematical Model of Solidification During Electroslag Casting of Pilger Roll

NASA Astrophysics Data System (ADS)

Liu, Fubin; Li, Huabing; Jiang, Zhouhua; Dong, Yanwu; Chen, Xu; Geng, Xin; Zang, Ximin

A mathematical model for describing the interaction of multiple physical fields in slag bath and solidification process in ingot during pilger roll casting with variable cross-section which is produced by the electroslag casting (ESC) process was developed. The commercial software ANSYS was applied to calculate the electromagnetic field, magnetic driven fluid flow, buoyancy-driven flow and heat transfer. The transportation phenomenon in slag bath and solidification characteristic of ingots are analyzed for variable cross-section with variable input power under the conditions of 9Cr3NiMo steel and 70%CaF2 - 30%Al2O3 slag system. The calculated results show that characteristic of current density distribution, velocity patterns and temperature profiles in the slag bath and metal pool profiles in ingot have distinct difference at variable cross-sections due to difference of input power and cooling condition. The pool shape and the local solidification time (LST) during Pilger roll ESC process are analyzed.

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

PubMed

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

2014-02-01

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

Sidewall containment of liquid metal with vertical alternating magnetic fields

DOEpatents

Lari, R.J.; Praeg, W.F.; Turner, L.R.; Battles, J.E.; Hull, J.R.; Rote, D.M.

1990-12-04

An apparatus is disclosed for containing molten metal using a magnet producing vertical alternating magnetic field positioned adjacent the area in which the molten metal is to be confined. This invention can be adapted particularly to the casting of metal between counter-rotating rollers with the vertical alternating magnetic field used to confine the molten metal at the edges of the rollers. Alternately, the vertical alternating magnetic field can be used as a flow regulator in casting molten metal from an opening in a channel. 9 figs.

Sidewall containment of liquid metal with vertical alternating magnetic fields

DOEpatents

Lari, R.J.; Praeg, W.F.; Turner, L.R.; Battles, J.E.; Hull, J.R.; Rote, D.M.

1988-06-17

An apparatus for containing molten metal using a magnet producing vertical alternating magnetic field positioned adjacent to the area in which the molten metal is to be confined. This invention can be adapted particularly to the casting of metal between counter-rotating rollers with the vertical alternating magnetic field used to confine the molten metal at the edges of the rollers. Alternately, the vertical alternating magnetic field can be used as a flow regulator in casting molten metal from an opening in a channel. 8 figs.

Electromagnetic augmentation for casting of thin metal sheets

DOEpatents

Hull, John R.

1989-01-01

Thin metal sheets are cast by magnetically levitating molten metal deposited in a mold within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled by the water-cooled walls of the mold to form a solid metal sheet. A conducting shield is electrically coupled to the molten metal sheet to provide a return path for eddy currents induced in the metal sheet by the current in the AC conducting coils. In another embodiment, a DC conducting coil is coupled to the metal sheet for providing a direct current therein which interacts with the magnetic field to levitate the moving metal sheet. Levitation of the metal sheet in both molten and solid forms reduces its contact pressure with the mold walls while maintaining sufficient engagement therebetween to permit efficient conductive cooling by the mold through which a coolant fluid may be circulated. The magnetic fields associated with the currents in the aforementioned coils levitate the molten metal sheet while the mold provides for its lateral and vertical confinement. A leader sheet having electromagnetic characteristics similar to those of the molten metal sheet is used to start the casing process and precedes the molten metal sheet through the yoke/coil arrangement and mold and forms a continuous sheet therewith. The yoke/coil arrangement may be either U-shaped with a single racetrack coil or may be rectangular with a pair of spaced, facing bedstead coils.

Coupled thermal-fluid-mechanics analysis of twin roll casting of A7075 aluminum alloy

NASA Astrophysics Data System (ADS)

Lee, Yun-Soo; Kim, Hyoung-Wook; Cho, Jae-Hyung; Chun, Se-Hwan

2017-09-01

Better understanding of temperature distribution and roll separation force during twin roll casting of aluminum alloys is critical to successfully fabricate good quality of aluminum strips. Therefore, the simulation techniques are widely applied to understand the twin roll casting process in a comprehensive way and to reduce the experimental time and cost of trial and error. However, most of the conventional approaches are considered thermally coupled flow, or thermally coupled mechanical behaviors. In this study, a fully coupled thermal-fluid-mechanical analysis of twin roll casting of A7075 aluminum strips was carried out using the finite element method. Temperature profile, liquid fraction and metal flow of aluminum strips with different thickness were predicted. Roll separation force and roll temperatures were experimentally obtained from a pilot-scale twin roll caster, and those results were compared with model predictions. Coupling the fluid of the liquid melt to the thermal and mechanical modeling reasonably predicted roll temperature distribution and roll separation force during twin roll casting.

Feasibility of producing cast-refractory metal-fiber superalloy composites

NASA Technical Reports Server (NTRS)

Mcintyre, R. D.

1973-01-01

A study was conducted to evaluate the feasibility of direct casting as a practical method for producing cast superalloy tungsten or columbium alloy fiber composites while retaining a high percentage of fiber strength. Fourteen nickel base, four cobalt, and three iron based matrices were surveyed for their degree of reaction with the metal fibers. Some stress-rupture results were obtained at temperatures of 760, 816, 871, and 1093 C for a few composite systems. The feasibility of producing acceptable composites of some cast nickel, cobalt, and iron matrix alloys with tungsten or columbium alloy fibers was demonstrated.

Non-Magnetic, Tough, Corrosion- and Wear-Resistant Knives From Bulk Metallic Glasses and Composites

NASA Technical Reports Server (NTRS)

Hoffman, Douglas C.; Potter, Benjamin

2013-01-01

Quality knives are typically fabricated from high-strength steel alloys. Depending on the application, there are different requirements for mechanical and physical properties that cause problems for steel alloys. For example, diver's knives are generally used in salt water, which causes rust in steel knives. Titanium diver's knives are a popular alternative due to their salt water corrosion resistance, but are too soft to maintain a sharp cutting edge. Steel knives are also magnetic, which is undesirable for military applications where the knives are used as a tactical tool for diffusing magnetic mines. Steel is also significantly denser than titanium (8 g/cu cm vs. 4.5 g/cu cm), which results in heavier knives for the same size. Steel is hard and wear-resistant, compared with titanium, and can keep a sharp edge during service. A major drawback of both steel and titanium knives is that they must be ground or machined into the final knife shape from a billet. Since most knives have a mirrored surface and a complex shape, manufacturing them is complex. It would be more desirable if the knife could be cast into a net or near-net shape in a single step. The solution to the deficiencies of titanium, steel, and ceramic knives is to fabricate them using bulk metallic glasses (or composites). These alloys can be cast into net or near-net shaped knives with a combination of properties that exceed both titanium and steel. A commercially viable BMG (bulk metallic glass) or composite knife is one that exhibits one or all of the following properties: It is based on titanium, has a self-sharpening edge, can retain an edge during service, is hard, is non-magnetic, is corrosion-resistant against a variety of corrosive environments, is tough (to allow for prying), can be cast into a net-shape with a mirror finish and a complex shape, has excellent wear resistance, and is low-density. These properties can be achieved in BMG and composites through alloy chemistry and processing. For each desired property for knife fabrication and performance, there is an alloy development strategy that optimizes behavior. Although BMG knives have been demonstrated as far back as 1995, they never found commercial success because they had to be ground (which presented problems because the alloys contained beryllium), they weren't low cost (because they weren't cast to a net-shape), they were brittle (because they were made with a low-quality commercial material), and they had extremely poor corrosion resistance (because corrosion was not well-understood in these materials). Ultimately, these shortcomings prevented the widespread commercialization. In the current work, the inventors have applied more than a decade of research on BMGs from Caltech and JPL to develop a better understanding of how to make BMG knives that exhibit an optimal combination of properties, processing and cost. Alloys have been developed based in titanium (and other metals), that exhibit high toughness, high hardness, excellent corrosion resistance, no ferromagnetism, edge-retaining selfsharpening, and the ability to be cast like a plastic using commercially available casting techniques (currently used by commercial companies such as Liquidmetal Technologies and Visser Precision Casting). The inventors argue that depending on the application (diving, military, tactical, utility, etc.) there is an optimal combination of design and alloy composition. Moreover, with new casting technologies not available at the inception of these materials, net-shaped knives can be cast into complex shapes that require no aftermarket forming, except for sharpening using water-cooled polishing wheel. These combinations of discoveries seek to make low-cost BMG knives commercially viable products that have no equal among metal or ceramic knives. Current work at JPL focuses on net-shape casting of these alloys and testing their mechanical properties versus commercially available knives to demonstrate their benefits.

[Application of sintered Ti powder to dental prostheses].

PubMed

Hikosaka, Tatsuya; Tanaka, Yoshinobu; Hoshiai, Kazumoto; Kanazawa, Takeshi; Nakamura, Yoshinori; Tsuda, Kenji; Ohasi, Hideya

2005-04-01

Powder metallurgy is a metal processing technology. Porous titanium produced from powder is widely used. The method is applied to titanium, which is not easy to cast as it sinters under melting point. In prosthetic dentistry, powder metallurgy can be applied to high fusing metal that is biocompatible. In this study, we examined the mechanical characteristics of the Ti sheet produced by sintering and discussed its application to dental prosthesis manufacturing. Ti sheets of 1-mm thickness, in which a binder was added to spherical Ti powder, were produced with the Doctor Blade Method. The sintering was carried out between 900-1150 degrees C at 6 temperatures. The sintered compact was evaluated by dimensional change rate, hardness test, bending strength, tensile strength and SEM observation. Another compact was sintered on the refractory cast. Mechanical strength significantly increased with sintering temperature. In addition, excellent mechanical strength was acquired by adding crushed powder and performing the de-binder process. In the sintering on the refractory cast, pre-baking for more than 100 minutes and sintering at over 1050 degrees C was needed for practical application. It thus seems possible to apply sintered titanium to dental prostheses. However, it will be necessary to examine the control of the shrinkage of the sintered compact in the future too.

Process and apparatus for obtaining silicon from fluosilicic acid

DOEpatents

Sanjurjo, Angel

1988-06-28

Process and apparatus for producing low cost, high purity solar grade silicon ingots in single crystal or quasi single crystal ingot form in a substantially continuous operation in a two stage reactor starting with sodium fluosilicate and a metal more electropositive than silicon (preferably sodium) in separate compartments having easy vapor transport therebetween and thermally decomposing the sodium fluosilicate to cause formation of substantially pure silicon and a metal fluoride which may be continuously separated in the melt and silicon may be directly and continuously cast from the melt.

GRINDING ROOM AT SOUTHERN DUCTILE CASTING COMPANY, BESSEMER FOUNDRY SHOWING ...

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

GRINDING ROOM AT SOUTHERN DUCTILE CASTING COMPANY, BESSEMER FOUNDRY SHOWING WHEELABORATOR THAT IMPALE SHOT AT TUMBLING CASTINGS TO REMOVE EXCESS SURFACE METALS AND SAND; ANNEALING OVENS TO HEAT CERTAIN CASTINGS TO ACHIEVE A DESIRED CHARACTERISTIC; AND GRINDING WHEELS USED TO REMOVE GATES. - Southern Ductile Casting Company, Grinding & Shipping, 2217 Carolina Avenue, Bessemer, Jefferson County, AL

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

Titanium removable denture based on a one-metal rehabilitation concept.

PubMed

Ohkubo, Chikahiro; Sato, Yohei; Nishiyama, Yuichiro; Suzuki, Yasunori

2017-09-26

The use of a single metal for all restorations would be necessary because it protects against metal corrosion caused by the contact of different metals. For this "one-metal rehabilitation" concept, non-alloyed commercially pure (CP) titanium should be used for all restorations. Titanium frameworks have been cast and used for the long term without catastrophic failure, whereas they have been fabricated recently using computer-aided design/computer-aided manufacturing (CAD/CAM). However, the milling process for the frameworks of removable partial dentures (RPDs) is not easy because they have very complicated shapes and consist of many components. Currently, the fabrication of RPD frameworks has been challenged by one-process molding using repeated laser sintering and high-speed milling. Laser welding has also been used typically for repairing and rebuilding titanium frameworks. Although laboratory and clinical problems still remain, the one-metal rehabilitation concept using CP titanium as a bioinert metal can be recommended for all restorations.

40 CFR 464.25 - Pretreatment standards for existing sources.

Code of Federal Regulations, 2010 CFR

2010-07-01

...) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Copper Casting... existing sources. (a) Casting Quench Operations. PSES Pollutant or pollutant property Maximum for any 1 day... monitoring) 1.2 0.399 (b) Direct Chill Casting Operations. PSES Pollutant or pollutant property Maximum for...

Molten metal feed system controlled with a traveling magnetic field

DOEpatents

Praeg, Walter F.

1991-01-01

A continuous metal casting system in which the feed of molten metal is controlled by means of a linear induction motor capable of producing a magnetic traveling wave in a duct that connects a reservoir of molten metal to a caster. The linear induction motor produces a traveling magnetic wave in the duct in opposition to the pressure exerted by the head of molten metal in the reservoir so that p.sub.c =p.sub.g -p.sub.m where p.sub.c is the desired pressure in the caster, p.sub.g is the gravitational pressure in the duct exerted by the force of the head of molten metal in the reservoir, and p.sub.m is the electromagnetic pressure exerted by the force of the magnetic field traveling wave produced by the linear induction motor. The invention also includes feedback loops to the linear induction motor to control the casting pressure in response to measured characteristics of the metal being cast.

Thin sheet casting with electromagnetic pressurization

DOEpatents

Walk, Steven R.; Slepian, R. Michael; Nathenson, Richard D.; Williams, Robert S.

1991-01-01

An apparatus, method and system for the casting of thin strips or strips of metal upon a moving chill block that includes an electromagnet located so that molten metal poured from a reservoir onto the chill block passes into the magnetic field produced by the electromagnet. The electromagnet produces a force on the molten metal on said chill block in the direction toward said chill block in order to enhance thermal contact between the molten metal and the chill block.

Repair welding of cast iron coated electrodes

NASA Astrophysics Data System (ADS)

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

2017-08-01

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

40 CFR 464.26 - Pretreatment standards for new sources.

Code of Federal Regulations, 2011 CFR

2011-07-01

... GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Copper Casting Subcategory § 464.26... million pounds) of metal poured Copper (T) 0.0307 0.0168 Lead (T) 0.0211 0.0104 Zinc (T) 0.0303 0.0116 TTO... kkg (pounds per million pounds) of metal poured Copper (T) 0.928 0.506 Lead (T) 0.639 0.314 Zinc (T) 0...

40 CFR 464.46 - Pretreatment standards for new sources.

Code of Federal Regulations, 2010 CFR

2010-07-01

... GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Zinc Casting Subcategory § 464.46... million pounds) of metal poured Copper (T) 0.0344 0.0187 Lead (T) 0.0237 0.0116 Zinc (T) 0.0339 0.0129 TTO... million pounds) of metal poured Copper (T) 0.0066 0.0036 Lead (T) 0.0046 0.0022 Zinc (T) 0.0066 0.0025...

40 CFR 464.46 - Pretreatment standards for new sources.

Code of Federal Regulations, 2011 CFR

2011-07-01

... GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Zinc Casting Subcategory § 464.46... million pounds) of metal poured Copper (T) 0.0344 0.0187 Lead (T) 0.0237 0.0116 Zinc (T) 0.0339 0.0129 TTO... million pounds) of metal poured Copper (T) 0.0066 0.0036 Lead (T) 0.0046 0.0022 Zinc (T) 0.0066 0.0025...

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Process for the fabrication of aluminum metallized pyrolytic graphite sputtering targets

DOEpatents

Makowiecki, D.M.; Ramsey, P.B.; Juntz, R.S.

1995-07-04

An improved method is disclosed for fabricating pyrolytic graphite sputtering targets with superior heat transfer ability, longer life, and maximum energy transmission. Anisotropic pyrolytic graphite is contoured and/or segmented to match the erosion profile of the sputter target and then oriented such that the graphite`s high thermal conductivity planes are in maximum contact with a thermally conductive metal backing. The graphite contact surface is metallized, using high rate physical vapor deposition (HRPVD), with an aluminum coating and the thermally conductive metal backing is joined to the metallized graphite target by one of four low-temperature bonding methods; liquid-metal casting, powder metallurgy compaction, eutectic brazing, and laser welding. 11 figs.

Real-Time Investigation of Solidification of Metal Matrix Composites

NASA Technical Reports Server (NTRS)

Kaukler, William; Sen, Subhayu

1999-01-01

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

The effect of casting conditions on the biaxial flexural strength of glass-ceramic materials.

PubMed

Johnson, A; Shareef, M Y; Walsh, J M; Hatton, P V; van Noort, R; Hill, R G

1998-11-01

To assess the effect of mould and glass casting temperatures on the biaxial flexural strength (BFS) of two different types of castable glass-ceramic, using existing laboratory equipment and techniques. Two castable glass-ceramic materials were evaluated. One glass (LG3) is based on SiO2-Al2O3-P2O5-CaO-CaF2, and is similar in composition to glasses used in the manufacture of glass-ionomer cements. The other glass (SG3) is based on SiO2-K2O-Na2O-CaO-CaF2, and is a canasite-based material. Both materials were used to produce discs of 12 mm diameter and 2 mm thickness using the same lost-wax casting process as used for metal castings. Mould temperatures of between 500 degrees C and 1000 degrees C and glass casting temperatures of between 1100 degrees C and 1450 degrees C were evaluated. The cast discs were cerammed and the biaxial flexural strength determined with a Lloyd 2000 R tester. A significant difference was found for the BFS in the range of mould temperatures evaluated, with the optimum investment mould temperature being 590 degrees C for LG3 and 610 degrees C for SG3 (p = 0.0002 and p = 0.019, respectively). No significant differences were seen between any of the glass casting temperatures evaluated. The mould temperature for castable glass-ceramic materials produced using the lost-wax casting process can have a significant effect on BFS. The optimum mould temperature may differ slightly depending on the type of material being used. The glass casting temperature of these materials does not appear to have a significant effect on BFS.

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

Code of Federal Regulations, 2011 CFR

2011-07-01

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

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

Code of Federal Regulations, 2010 CFR

2010-07-01

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

40 CFR 464.16 - Pretreatment standards for new sources.

Code of Federal Regulations, 2010 CFR

2010-07-01

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

40 CFR 464.26 - Pretreatment standards for new sources.

Code of Federal Regulations, 2010 CFR

2010-07-01

... GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Copper Casting Subcategory § 464.26... and achieve the following pretreatment standards for new sources. (a) Casting Quench Operations. PSNS... 0.0335 0.0109 Oil and grease (for alternate monitoring) 1.2 0.399 (b) Direct Chill Casting...

40 CFR 464.15 - Pretreatment standards for existing sources.

Code of Federal Regulations, 2010 CFR

2010-07-01

...) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Aluminum Casting... existing sources. (a) Casting Cleaning Operations. PSES Pollutant or pollutant property Maximum for any 1....0771 0.0421 Lead (T) 0.0791 0.039 Zinc (T) 0.114 0.0431 (b) Casting Quench Operation. PSES Pollutant or...

CASTING SLIPS FOR FABRICATION OF REFRACTORY METAL WARE

DOEpatents

Stoddard, S.D.; Nuckolls, D.E.; Cowan, R.E.

1962-09-01

A composition is given for slip casting tungsten metal. The composition consists essentially of tungsten metal with an average particle size of 0.9 micron, an organic vehicle such as methyl chloroform, o-xylene, n-butyl acetate, isobutyl acetate, and 1, 1, 2, 2-tetrachlorethane, and a suspending agent such as ethyl cellulose, with the approximate ratio of said vehicle to the tungsten metal being 12 cc of a solution containing from 5 to about 20 grams of said ethyl cellulose in 400 cc of said organic vehicle per 100 grams of metal. (AEC)

A versatile approach to vacuum injection casting for materials research and development.

PubMed

Xu, Donghua; Xu, Yifan

2017-03-01

Vacuum injection casting (VIC) is important for research and development (R&D) of materials that are prone to oxidation at high temperatures, particularly metals and metallic alloys (e.g., metallic glasses and high entropy alloys). VIC in R&D laboratories often involves initial melting/alloying in a prior step, transporting the sample to a dedicated vacuum chamber, re-melting the sample in a quartz tube, and finally injecting the melt with an inert gas to a dedicated mold. Here we present a new approach to laboratory VIC that requires no sample transfer (for a variety of materials), no dedicated vacuum chamber/space nor dedicated mold, and hence provides more versatility and higher efficiency and yet lowers the capital equipment cost. Our approach takes advantage of the exceptional portability, thermal and chemical stability, and thermoplastic processability of quartz glass and uses quartz tubes for all the melting, re-melting, injection casting, and molding. In addition, our approach includes oxygen gettering to remove residual oxygen for all the steps and allows for slow or fast cooling (e.g., water quenching) upon injection. This paper focuses on the design, the procedures, and the versatile features of this new approach while also demonstrating the practical implementation of this approach and computational modeling of the heat transfer and the cooling rates for two exemplary cases. The new approach is expected to bring notable expedition to sample fabrication and materials discovery, as well as wider adoption of vacuum injection casting in materials science and condensed matter physics research laboratories.

A versatile approach to vacuum injection casting for materials research and development

NASA Astrophysics Data System (ADS)

Xu, Donghua; Xu, Yifan

2017-03-01

Vacuum injection casting (VIC) is important for research and development (R&D) of materials that are prone to oxidation at high temperatures, particularly metals and metallic alloys (e.g., metallic glasses and high entropy alloys). VIC in R&D laboratories often involves initial melting/alloying in a prior step, transporting the sample to a dedicated vacuum chamber, re-melting the sample in a quartz tube, and finally injecting the melt with an inert gas to a dedicated mold. Here we present a new approach to laboratory VIC that requires no sample transfer (for a variety of materials), no dedicated vacuum chamber/space nor dedicated mold, and hence provides more versatility and higher efficiency and yet lowers the capital equipment cost. Our approach takes advantage of the exceptional portability, thermal and chemical stability, and thermoplastic processability of quartz glass and uses quartz tubes for all the melting, re-melting, injection casting, and molding. In addition, our approach includes oxygen gettering to remove residual oxygen for all the steps and allows for slow or fast cooling (e.g., water quenching) upon injection. This paper focuses on the design, the procedures, and the versatile features of this new approach while also demonstrating the practical implementation of this approach and computational modeling of the heat transfer and the cooling rates for two exemplary cases. The new approach is expected to bring notable expedition to sample fabrication and materials discovery, as well as wider adoption of vacuum injection casting in materials science and condensed matter physics research laboratories.

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

NASA Astrophysics Data System (ADS)

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

2017-08-01

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

Casting Apparatus Including A Gas Driven Molten Metal Injector And Method

DOEpatents

Trudel, David R.; Meyer, Thomas N.; Kinosz, Michael J.; Arnaud, Guy; Bigler, Nicolas

2003-06-17

The filtering molten metal injector system includes a holder furnace, a casting mold supported above the holder furnace, and at least one molten metal injector supported from a bottom side of the casting mold. The holder furnace contains a supply of molten metal. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The molten metal injector projects into the holder furnace. The molten metal injector includes a cylinder defining a piston cavity housing a reciprocating piston for pumping the molten metal upward from the holder furnace to the mold cavity. The cylinder and piston are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder or the piston includes a molten metal intake for receiving the molten metal into the piston cavity when the holder furnace contains molten metal. A conduit connects the piston cavity to the mold cavity. A molten metal filter is located in the conduit for filtering the molten metal passing through the conduit during the reciprocating movement of the piston. The molten metal intake may be a valve connected to the cylinder, a gap formed between the piston and an open end of the cylinder, an aperture defined in the sidewall of the cylinder, or a ball check valve incorporated into the piston. A second molten metal filter preferably covers the molten metal intake to the injector.

PROCESS OF PRODUCING SHAPED PLUTONIUM

DOEpatents

Anicetti, R.J.

1959-08-11

A process is presented for producing and casting high purity plutonium metal in one step from plutonium tetrafluoride. The process comprises heating a mixture of the plutonium tetrafluoride with calcium while the mixture is in contact with and defined as to shape by a material obtained by firing a mixture consisting of calcium oxide and from 2 to 10% by its weight of calcium fluoride at from 1260 to 1370 deg C.

Casting And Solidification Technology (CAST): Directional solidification phenomena in a metal model at reduced gravity

NASA Technical Reports Server (NTRS)

Mccay, M. H.

1988-01-01

The Casting and Solidification Technology (CAST) experiment will study the phenomena that occur during directional solidification of an alloy, e.g., constitutional supercooling, freckling, and dendrite coarsening. The reduced gravity environment of space will permit the individual phenomena to be examined with minimum complication from buoyancy driven flows.

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

Code of Federal Regulations, 2012 CFR

2012-07-01

... 40 Protection of Environment 31 2012-07-01 2012-07-01 false Applicability; description of the zinc casting subcategory. 464.40 Section 464.40 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS (CONTINUED) METAL MOLDING AND CASTING POINT SOURCE CATEGORY Zinc Casting Subcategory § 464.40...

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

Code of Federal Regulations, 2013 CFR

2013-07-01

... 40 Protection of Environment 31 2013-07-01 2013-07-01 false Applicability; description of the zinc casting subcategory. 464.40 Section 464.40 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS (CONTINUED) METAL MOLDING AND CASTING POINT SOURCE CATEGORY Zinc Casting Subcategory § 464.40...

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

Code of Federal Regulations, 2014 CFR

2014-07-01

... 40 Protection of Environment 30 2014-07-01 2014-07-01 false Applicability; description of the zinc casting subcategory. 464.40 Section 464.40 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS (CONTINUED) METAL MOLDING AND CASTING POINT SOURCE CATEGORY Zinc Casting Subcategory § 464.40...

Innovative forming and fabrication technologies : new opportunities.

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

Davis, B.; Hryn, J.; Energy Systems

2008-01-31

The advent of light metal alloys and advanced materials (polymer, composites, etc.) have brought the possibility of achieving important energy reductions into the full life cycle of these materials, especially in transportation applications. 1 These materials have gained acceptance in the aerospace industry but use of light metal alloys needs to gain wider acceptance in other commercial transportation areas. Among the main reasons for the relatively low use of these materials are the lack of manufacturability, insufficient mechanical properties, and increased material costs due to processing inefficiencies. Considering the enormous potential energy savings associated with the use of light metalmore » alloys and advanced materials in transportation, there is a need to identify R&D opportunities in the fields of materials fabrication and forming aimed at developing materials with high specific mechanical properties combined with energy efficient processes and good manufacturability. This report presents a literature review of the most recent developments in the areas of fabrication and metal forming focusing principally on aluminum alloys. In the first section of the document, the different sheet manufacturing technologies including direct chill (DC) casting and rolling, spray forming, spray rolling, thin slab, and strip casting are reviewed. The second section of the document presents recent research on advanced forming processes. The various forming processes reviewed are: superplastic forming, electromagnetic forming, age forming, warm forming, hydroforming, and incremental forming. Optimization of conventional forming processes is also discussed. Potentially interesting light metal alloys for high structural efficiency including aluminum-scandium, aluminum-lithium, magnesium, titanium, and amorphous metal alloys are also reviewed. This section concludes with a discussion on alloy development for manufacturability. The third section of the document reviews the latest developments in fiber-reinforced composite materials. Emerging curing processes are presented along with a discussion on the possible developments in biocomposite materials. The fourth section presents recent developments in the fabrication of bulk nanomaterials and nanoparticles reinforced materials. Advanced joining technologies are presented in the fifth section. Future research is proposed in the last section.« less

Adhesive bonding of super-elastic titanium-nickel alloy castings with a phosphate metal conditioner and an acrylic adhesive.

PubMed

Matsumura, H; Tanoue, N; Yanagida, H; Atsuta, M; Koike, M; Yoneyama, T

2003-06-01

The purpose of the current study was to evaluate the bonding characteristics of super-elastic titanium-nickel (Ti-Ni) alloy castings. Disk specimens were cast from a Ti-Ni alloy (Ti-50.85Ni mol%) using an arc centrifugal casting machine. High-purity titanium and nickel specimens were also prepared as experimental references. The specimens were air-abraded with alumina, and bonded with an adhesive resin (Super-Bond C & B). A metal conditioner containing a phosphate monomer (Cesead II Opaque Primer) was also used for priming the specimens. Post-thermocycling average bond strengths (MPa) of the primed groups were 41.5 for Ti-Ni, 30.4 for Ti and 19.5 for Ni, whereas those of the unprimed groups were 21.6 for Ti, 19.3 for Ti-Ni and 9.3 for Ni. Application of the phosphate conditioner elevated the bond strengths of all alloy/metals (P < 0.05). X-ray fluorescence analysis revealed that nickel was attached to the debonded resin surface of the resin-to-nickel bonded specimen, indicating that corrosion of high-purity nickel occurred at the resin-nickel interface. Durable bonding to super-elastic Ti-Ni alloy castings can be achieved with a combination of a phosphate metal conditioner and a tri-n-butylborane-initiated adhesive resin.

The Effect of Temperature and Rotational Speed on Structure and Mechanical Properties of Cast Cu Base Alloy (Cu-Al-Si-Fe) Welded by Semisolid Stir Joining Method

NASA Astrophysics Data System (ADS)

Ferasat, Keyvan; Aashuri, Hossein; Kokabi, Amir Hossein; Shafizadeh, Mahdi; Nikzad, Siamak

2015-12-01

Semisolid stir joining has been under deliberation as a possible method for joining of copper alloys. In this study, the effect of temperature and rotational speed of stirrer on macrostructure evaluation and mechanical properties of samples were investigated. Optical microscopy and X-ray diffraction were performed for macro and microstructural analysis. A uniform micro-hardness profile was attained by semisolid stir joining method. The ultimate shear strength and bending strength of welded samples were improved in comparison with the cast sample. There is also lower area porosity in welded samples than the cast metal. The mechanical properties were improved by increasing temperature and rotational speed of the joining process.

Rapid Model Fabrication and Testing for Aerospace Vehicles

NASA Technical Reports Server (NTRS)

Buck, Gregory M.

2000-01-01

Advanced methods for rapid fabrication and instrumentation of hypersonic wind tunnel models are being developed and evaluated at NASA Langley Research Center. Rapid aeroheating model fabrication and measurement techniques using investment casting of ceramic test models and thermographic phosphors are reviewed. More accurate model casting techniques for fabrication of benchmark metal and ceramic test models are being developed using a combination of rapid prototype patterns and investment casting. White light optical scanning is used for coordinate measurements to evaluate the fabrication process and verify model accuracy to +/- 0.002 inches. Higher-temperature (<210C) luminescent coatings are also being developed for simultaneous pressure and temperature mapping, providing global pressure as well as global aeroheating measurements. Together these techniques will provide a more rapid and complete experimental aerodynamic and aerothermodynamic database for future aerospace vehicles.

[Research progress in CoCr metal-ceramic alloy fabricated by selective laser melting].

PubMed

Yan, X; Lin, H

2018-02-09

Cobalt-chromium alloys have been applied to dental porcelain fused to metal (PFM) restorations over the past decades owing to their excellent corrosion resistance, good biocompatibility and low price. The production of CoCr metal-ceramic restorations has always been based on traditional lost-wax casting techniques. However, in recent years, selective laser melting (SLM) is becoming more and more highly valued by dental laboratories and dental practitioners due to its individuation, precision and efficiency. This paper mainly reviews the recent researches on the production process of copings, microstructure, mechanical property, metal-ceramic bond strength, fit of copings, corrosion resistance and biocompatibility of SLM CoCr metal-ceramic alloy.

Corrosion resistance of cast irons and titanium alloys as reference engineered metal barriers for use in basalt geologic storage: a literature assessment

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

Charlot, L.A.; Westerman, R.E.

A survey and assessment of the literature on the corrosion resistance of cast irons and low-alloy titanium are presented. Selected engineering properties of cast iron and titanium are briefly described; however, the corrosion resistance of cast iron and titanium in aqueous solutions or in soils and their use in a basalt repository are emphasized. In evaluating the potential use of cast iron and titanium as structural barrier materials for long-lived nuclear waste packages, it is assumed that titanium has the general corrosion resistance to be used in relatively thin cross sections whereas the cost and availability of cast iron allowsmore » its use even in very thick cross sections. Based on this assumption, the survey showed that: The uniform corrosion of low-alloy titanium in a basalt environment is expected to be extremely low. A linear extrapolation of general corrosion rates with an added corrosion allowance suggests that a 3.2- to 6.4-mm-thick wall may have a life of 1000 yr. Pitting and crevice corrosion are not likely corrosion modes in basalt ground waters. It is also unlikely that stress corrosion cracking (SCC) will occur in the commercially pure (CP) titanium alloy or in palladiumor molybdenum-alloyed titanium materials. Low-alloy cast irons may be used as barrier metals if the environment surrounding the metal keeps the alloy in the passive range. The solubility of the corrosion product and the semipermeable nature of the oxide film allow significant uniform corrosion over long time periods. A linear extrapolation of high-temperature corrosion rates on carbon steels and corrosion rates of cast irons in soils gives an estimated metal penetration of 51 to 64 mm after 1000 yr. A corrosion allowance of 3 to 5 times that suggests that an acceptable cast iron wall may be from 178 to 305 mm thick. Although they cannot be fully assessed, pitting and crevice corrosion should not affect cast iron due to the ground-water chemistry of basalt.« less

Cutting efficiency of air-turbine burs on cast titanium and dental casting alloys.

PubMed

Watanabe, I; Ohkubo, C; Ford, J P; Atsuta, M; Okabe, T

2000-11-01

The purpose of this study was to investigate the cutting efficiency of air-turbine burs on cast free-machining titanium alloy (DT2F) and to compare the results with those for cast commercially pure (CP) Ti, Ti-6Al-4V alloy, and dental casting alloys. The cast metal (DT2F, CP Ti, Ti-6Al-4V, Type IV gold alloy and Co-Cr alloy) specimens were cut with air-turbine burs (carbide burs and diamond points) at air pressures of 138 or 207 kPa and a cutting force of 0.784 N. The cutting efficiency of each bur was evaluated as volume loss calculated from the weight loss cut for 5 s and the density of each metal. The bulk microhardness was measured to correlate the machinability and the hardness of each metal. The amounts of DT2F cut with the carbide burs were significantly (p < 0.05) greater than for the other titanium specimens at either 138 or 207 kPa. The diamond points exhibited similar machining efficiency among all metals except for Type IV gold alloy. The increase in the volume loss of Co-Cr alloy (Vitallium) cut with the diamond points showed a negative value (-29%) with an increase in air pressure from 138 to 207 kPa. There was a negative correlation between the amounts of metal removed (volume loss) and the hardness (r2 = 0.689) when the carbide burs were used. The results of this study indicated that a free-machining titanium alloy (DT2F) exhibited better machinability compared to CP Ti and Ti-6Al-4V alloy when using carbide fissure burs. When machining cast CP Ti and its alloys, carbide fissure burs possessed a greater machining efficiency than the diamond points and are recommended for titanium dental prostheses.

Ultrastable Photoelectrodes for Solar Water Splitting Based on Organic Metal Halide Perovskite Fabricated by Lift-Off Process.

PubMed

Nam, SeongSik; Mai, Cuc Thi Kim; Oh, Ilwhan

2018-05-02

Herein, we report an integrated photoelectrolysis of water employing organic metal halide (OMH) perovskite material. As generic OMH perovskite material and device architecture are highly susceptible to degradation by aqueous electrolytes, we have developed a versatile mold-cast and lift-off process to fabricate and assemble multipurpose metal encapsulation onto perovskite devices. With the metal encapsulation effectively protecting the perovskite cell and also functioning as electrocatalyst, the high-performance perovskite photoelectrodes exhibit high photovoltage and photocurrent that are effectively inherited from the original solid-state solar cell. More importantly, thus-fabricated perovskite photoelectrode demonstrates record-long unprecedented stability even at highly oxidizing potential in strong alkaline electrolyte. We expect that this versatile lift-off process can be adapted in a wide variety of photoelectrochemical devices to protect the material surfaces from corroding electrolyte and facilitate various electrochemical reactions.

Effect of palatal form on movement of teeth during processing of complete denture prosthesis: An in-vitro study.

PubMed

Babu, Sumanth; Manjunath, Shaurya; Vajawat, Mayuri

2016-01-01

The aim of this in-vitro study was to assess the influence of shallow and deep palatal forms on the movement of teeth during the processing of complete denture prosthesis. Maxillary casts with shallow and deep palatal forms were selected and duplicated to make 10 casts of each palatal form. Base plates were constructed and teeth were arranged in their anatomic positions. Metal pins with true apex were placed on the central groove of the right and left first molars and one on the incisive papilla area as a reference point. Casts were scanned using i-CAT Vision Q 1.9 (i-CAT cone beam 3D dental imaging system by Imaging Sciences International, PA, USA), which has 360° rotational tomography. The distances between the apices of metallic pin inserts on the teeth and fitted point of reference were recorded in buccopalatal axes at waxed up stage, after deflasking, and after finishing and polishing. Results showed a statistically significant movement of teeth in shallow and deep palatal forms during all stages of complete denture processing. In shallow palatal form dentures, there was a significant tooth movement in palatal direction between Stages 1 and 2 (P ≤ 0.05) and buccal movement between Stages 2 and 3. In deep palatal form dentures, teeth showed a statistically significant (P ≤ 0.05) movement in buccal direction during all stages of denture processing. Teeth showed significant movement during processing of acrylic resin dentures. Overall, the movement of teeth in shallow palatal form dentures was in palatal direction, whereas in deep palatal form dentures, the movement of teeth was in buccal direction.

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

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

Brevick, Jerald R.

2014-06-13

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

Experimental Exploration of Metal Cable as Reinforcement in 3D Printed Concrete.

PubMed

Bos, Freek P; Ahmed, Zeeshan Y; Jutinov, Evgeniy R; Salet, Theo A M

2017-11-16

The Material Deposition Method (MDM) is enjoying increasing attention as an additive method to create concrete mortar structures characterised by a high degree of form-freedom, a lack of geometrical repetition, and automated construction. Several small-scale structures have been realised around the world, or are under preparation. However, the nature of this construction method is unsuitable for conventional reinforcement methods to achieve ductile failure behaviour. Sometimes, this is solved by combining printing with conventional casting and reinforcing techniques. This study, however, explores an alternative strategy, namely to directly entrain a metal cable in the concrete filament during printing to serve as reinforcement. A device is introduced to apply the reinforcement. Several options for online reinforcement media are compared for printability. Considerations specific to the manufacturing process are discussed. Subsequently, pull-out tests on cast and printed specimens provide an initial characterisation of bond behaviour. Bending tests furthermore show the potential of this reinforcement method. The bond stress of cables in printed concrete was comparable to values reported for smooth rebar but lower than that of the same cables in cast concrete. The scatter in experimental results was high. When sufficient bond length is available, ductile failure behaviour for tension parallel to the filament direction can be achieved, even though cable slip occurs. Further improvements to the process should pave the way to achieve better post-crack resistance, as the concept in itself is feasible.

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

NASA Astrophysics Data System (ADS)

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

2004-06-01

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

New Nomenclatures for Heat Treatments of Additively Manufactured Titanium Alloys

NASA Astrophysics Data System (ADS)

Baker, Andrew H.; Collins, Peter C.; Williams, James C.

2017-07-01

The heat-treatment designations and microstructure nomenclatures for many structural metallic alloys were established for traditional metals processing, such as casting, hot rolling or forging. These terms do not necessarily apply for additively manufactured (i.e., three-dimensionally printed or "3D printed") metallic structures. The heat-treatment terminology for titanium alloys generally implies the heat-treatment temperatures and their sequence relative to a thermomechanical processing step (e.g., forging, rolling). These designations include: β-processing, α + β-processing, β-annealing, duplex annealing and mill annealing. Owing to the absence of a thermomechanical processing step, these traditional designations can pose a problem when titanium alloys are first produced via additive manufacturing, and then heat-treated. This communication proposes new nomenclatures for heat treatments of additively manufactured titanium alloys, and uses the distinct microstructural features to provide a correlation between traditional nomenclature and the proposed nomenclature.

A new binder-free and conductive-additive-free TiO2/WO3-W integrative anode material produced by laser ablation

NASA Astrophysics Data System (ADS)

Su, Yibo; Zhang, Hongjun; Liang, Peng; Liu, Kai; Cai, Mingyong; Huang, Zeya; Wang, Chang-An; Zhong, Minlin

2018-02-01

Although transition metal oxides anodes have attracted lots of attention, there are still many problems to be resolved. Complicated fabrication process, high cost and poor electrochemical performances are the most important ones, together hindering transition metal oxides anodes for practical use. Herein, we provide a new approach to fabricate a binder-free and conductive-additive-free TiO2/WO3-W integrative anode material through the nanosecond laser ablation and dip-coating technology, which simplifies the entire anode preparation process with no need for a conventional tape-casting procedure. Using this method, great time cost, machine cost and labor cost related to mixing and tape-casting process can be saved on the basis of good electrochemical performances. The prepared TiO2/WO3-W integrative anode realizes a first Coulombic efficiency of 75.6% and attains to a stable capacity within the first five cycles. It can still maintain a capacity of 600 mAh g-1 in the range of 0.01-3 V vs. Li+/Li at a current rate of 0.2 C after 500 cycles. This work offers a new way to achieve a fast fabrication of the integrative anode for lithium ion battery, which is universal for other transition metals (such as Fe, Cu, Ni, Co, Mo, W etc.).

Nuclear Weapons. National Nuclear Security Administration’s Plans for Its Uranium Processing Facility Should Better Reflect Funding Estimates and Technology Readiness

DTIC Science & Technology

2010-11-01

metal. Recovery extraction centrifugal contactors A process that uses solvent to extract uranium for purposes of purification. Agile machining A...extraction centrifugal contactors 5 6 Yes 6 No Agile machining 5 5 No 6 No Chip management 5 6 Yes 6 No Special casting 3 6 Yes 6 No Source: GAO

Wear study of Al-SiC metal matrix composites processed through microwave energy

NASA Astrophysics Data System (ADS)

Honnaiah, C.; Srinath, M. S.; Prasad, S. L. Ajit

2018-04-01

Particulate reinforced metal matrix composites are finding wider acceptance in many industrial applications due to their isotropic properties and ease of manufacture. Uniform distribution of reinforcement particulates and good bonding between matrix and reinforcement phases are essential features in order to obtain metal matrix composites with improved properties. Conventional powder metallurgy technique can successfully overcome the limitation of stir casting techniques, but it is time consuming and not cost effective. Use of microwave technology for processing particulate reinforced metal matrix composites through powder metallurgy technique is being increasingly explored in recent times because of its cost effectiveness and speed of processing. The present work is an attempt to process Al-SiC metal matrix composites using microwaves irradiated at 2.45 GHz frequency and 900 W power for 10 minutes. Further, dry sliding wear studies were conducted at different loads at constant velocity of 2 m/s for various sliding distances using pin-on-disc equipment. Analysis of the obtained results show that the microwave processed Al-SiC composite material shows around 34 % of resistance to wear than the aluminium alloy.

Magnetically assisted slip casting of bioinspired heterogeneous composites

NASA Astrophysics Data System (ADS)

Le Ferrand, Hortense; Bouville, Florian; Niebel, Tobias P.; Studart, André R.

2015-11-01

Natural composites are often heterogeneous to fulfil functional demands. Manufacturing analogous materials remains difficult, however, owing to the lack of adequate and easily accessible processing tools. Here, we report an additive manufacturing platform able to fabricate complex-shaped parts exhibiting bioinspired heterogeneous microstructures with locally tunable texture, composition and properties, as well as unprecedentedly high volume fractions of inorganic phase (up to 100%). The technology combines an aqueous-based slip-casting process with magnetically directed particle assembly to create programmed microstructural designs using anisotropic stiff platelets in a ceramic, metal or polymer functional matrix. Using quantitative tools to control the casting kinetics and the temporal pattern of the applied magnetic fields, we demonstrate that this approach is robust and can be exploited to design and fabricate heterogeneous composites with thus far inaccessible microstructures. Proof-of-concept examples include bulk composites with periodic patterns of microreinforcement orientation, and tooth-like bilayer parts with intricate shapes exhibiting site-specific composition and texture.

Systems and Methods for Fabricating Structures Including Metallic Glass-Based Materials Using Low Pressure Casting

NASA Technical Reports Server (NTRS)

Hofmann, Douglas C. (Inventor); Kennett, Andrew (Inventor)

2018-01-01

Systems and methods to fabricate objects including metallic glass-based materials using low-pressure casting techniques are described. In one embodiment, a method of fabricating an object that includes a metallic glass-based material includes: introducing molten alloy into a mold cavity defined by a mold using a low enough pressure such that the molten alloy does not conform to features of the mold cavity that are smaller than 100 microns; and cooling the molten alloy such that it solidifies, the solid including a metallic glass-based material.

Azimuthal MHD stirring of metal in vessels with cross-sections of different configuration

NASA Astrophysics Data System (ADS)

Siraev, R. R.; Khripchenko, S. Yu

2017-11-01

Continuous casting of cylindrical ingots from aluminum and preparation of aluminum-based alloys and composites require intensive mixing of liquid metal phase in the crystallization area of the melt. It is evident that the topology of the flow in the liquid phase of an ingot should influence the processes occurring during crystallization. Contemporary continuous casting machines use MHD-stirrers that generate an azimuthal motion in a crystallizer with a warm top of circular cross-section in the presence of rotating magnetic field. The flow of metal in the liquid phase of an ingot is similar to its rotation in a solid state, and transport processes are most intensively carried out in the near near-wall region and near the ingot solidification front, where shear flows are essential. In this work, we consider the possibility of amplifying transport processes in the entire volume of a stirred metal by making the cross-section shape of the warm top of the crystallizer different from a circle. It has been found numerically that the total energy of the flow in a crucible of square cross-section is twice as lower as that in a crucible with circular cross-section at the same inductor current. Turbulent pulsations in the square crucible, as well as in the circular one, are concentrated mainly in the near-wall region. The energy of pulsations in the square crucible also reduces, but the time of stirring of the passive impurity introduced into the volume of the metal is less than in the circular crucible. The effect of MHD stirring on the vertical temperature distribution on the square crucible is higher than in the “round crucible”.

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

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

Liu, Yongning; Chen, Yiqing; Yang, Chunhui, E-mail: r.yang@uws.edu.au

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 andmore » 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.« less

Influence of friction stir processing on the room temperature fatigue cracking mechanisms of A356 aluminum alloy

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

Nelaturu, Phalgun; Jana, Saumyadeep; Mishra, Rajiv S.

Here, failure by fatigue is a common problem associated with cast aluminum alloys due to defects like shrinkage porosities, non-metallic inclusions, etc. Friction stir processing (FSP) has recently emerged as an effective technique for local modification of microstructure. This study investigates the fatigue crack initiation and growth mechanisms in cast and FSPed A356 aluminum alloy. Two sets of parameters were used to friction stir the cast alloy resulting in the complete modification the cast microstructure to a wrought microstructure. Both the FSPed microstructures exhibited severe abnormal grain growth (AGG) after heat treatment leading to a multimodal grain size distribution –more » the grain sizes ranging from a few microns to a few millimeters. One of the FSP conditions displayed an excellent improvement in fatigue life by an order of magnitude, while the other condition displayed an unexpectedly large scatter in fatigue lives. Detailed study of the fractured fatigue specimens by electron back scattered diffraction (EBSD) revealed that both, fatigue crack initiation and propagation, were intimately tied to the grain size as well as the grain misorientations in the microstructure.« less

Influence of friction stir processing on the room temperature fatigue cracking mechanisms of A356 aluminum alloy

DOE PAGES

Nelaturu, Phalgun; Jana, Saumyadeep; Mishra, Rajiv S.; ...

2018-01-11

Here, failure by fatigue is a common problem associated with cast aluminum alloys due to defects like shrinkage porosities, non-metallic inclusions, etc. Friction stir processing (FSP) has recently emerged as an effective technique for local modification of microstructure. This study investigates the fatigue crack initiation and growth mechanisms in cast and FSPed A356 aluminum alloy. Two sets of parameters were used to friction stir the cast alloy resulting in the complete modification the cast microstructure to a wrought microstructure. Both the FSPed microstructures exhibited severe abnormal grain growth (AGG) after heat treatment leading to a multimodal grain size distribution –more » the grain sizes ranging from a few microns to a few millimeters. One of the FSP conditions displayed an excellent improvement in fatigue life by an order of magnitude, while the other condition displayed an unexpectedly large scatter in fatigue lives. Detailed study of the fractured fatigue specimens by electron back scattered diffraction (EBSD) revealed that both, fatigue crack initiation and propagation, were intimately tied to the grain size as well as the grain misorientations in the microstructure.« less

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Porosity and environment

NASA Technical Reports Server (NTRS)

Piwonka, T. S.

1984-01-01

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

Cavitation During Superplastic Forming

PubMed Central

Campbell, John

2011-01-01

Cavitation is the opening of pores during superplastic forming, typically at grain boundary triple points or on second phase grain boundary particles during slip of grain boundaries. Theories for the initiation of cavitation are reviewed. It seems that cavitation is unlikely to occur by processes intrinsic to metals such as dislocation mechanisms or point defect condensation. It is proposed that cavitation can only occur at non-bonded interfaces such as those introduced extrinsically (i.e., from the outside) during the original casting of the metal. These defects, known as oxide bifilms, are naturally introduced during pouring of the liquid metal, and are frozen into the solid, often pushed by dendritic growth into grain boundaries where they are difficult to detect because of their extreme thinness, often measured in nanometres. Their unbonded central interface acts as a crack and can initiate cavitation. Second phase precipitates probably do not nucleate and grow on grain boundaries but grow on bifilms in the boundaries, explaining the apparent association between boundaries, second phase particles and failure initiation. Improved melting and casting techniques can provide metal with reduced or zero bifilm population for which cavitation would not be possible, promising significant improvements in superplastic behaviour. PMID:28824142

Cavitation During Superplastic Forming.

PubMed

Campbell, John

2011-07-08

Cavitation is the opening of pores during superplastic forming, typically at grain boundary triple points or on second phase grain boundary particles during slip of grain boundaries. Theories for the initiation of cavitation are reviewed. It seems that cavitation is unlikely to occur by processes intrinsic to metals such as dislocation mechanisms or point defect condensation. It is proposed that cavitation can only occur at non-bonded interfaces such as those introduced extrinsically (i.e., from the outside) during the original casting of the metal. These defects, known as oxide bifilms, are naturally introduced during pouring of the liquid metal, and are frozen into the solid, often pushed by dendritic growth into grain boundaries where they are difficult to detect because of their extreme thinness, often measured in nanometres. Their unbonded central interface acts as a crack and can initiate cavitation. Second phase precipitates probably do not nucleate and grow on grain boundaries but grow on bifilms in the boundaries, explaining the apparent association between boundaries, second phase particles and failure initiation. Improved melting and casting techniques can provide metal with reduced or zero bifilm population for which cavitation would not be possible, promising significant improvements in superplastic behaviour.

Help for the Steel Industry

NASA Technical Reports Server (NTRS)

1991-01-01

A collaboration between NASA Lewis Research Center (LRC) and Gladwin Engineering resulted in the adaptation of aerospace high temperature metal technology to the continuous casting of steel. The continuous process is more efficient because it takes less time and labor. A high temperature material, once used on the X-15 research plane, was applied to metal rollers by a LRC developed spraying technique. Lewis Research Center also supplied mold prototype of metal composites, reducing erosion and promoting thermal conductivity. Rollers that previously cracked due to thermal fatigue, lasted longer. Gladwin's sales have increased, and additional NASA-developed innovations are anticipated.

Crystallography of in-situ transformations of the M 7C3 carbide in the cast Fe-Cr-Ni alloy

NASA Astrophysics Data System (ADS)

Kraposhin, V. S.; Kondrat'ev, S. Yu.; Talis, A. L.; Anastasiadi, G. P.

2017-03-01

In the process of holding of the cast heat-resistant Fe-Cr-Ni (0.45C-25Cr-35Ni) alloy at 1150°C, the eutectic chromium carbide present in its structure undergoes a gradual transition M 7C3 → M 23C6. The gradual formation of domains of the M 23C6 carbide inside the particles of the M 7C3 carbide makes it possible to assume that the observed phase transition is the well-known carbide transformation of the in situ type. The mechanism of the in situ transformation of the crystal structure of the carbide from M 7C3 into M 23C6 with a change in the number of nearest metal neighbors of carbon atoms is explained within the previously developed combinatory model of polymorphic transitions in the metals.

Development of Metal Matrix Composites for NASA'S Advanced Propulsion Systems

NASA Technical Reports Server (NTRS)

Lee, Jonathan A.

2000-01-01

The state-of-the-art development of several aluminum and copper based Metal Matrix Composites (MMC) for NASA's advanced propulsion systems will be presented. The presentation's goal is to provide an overview of NASA-Marshall Space Flight Center's planned and on-going activities in MMC for advanced liquid rocket engines such as the X-33 vehicle's Aerospike and X-34 Fastrac engine. The focus will be on lightweight and environmental compatibility with oxygen and hydrogen of key MMC materials, within each NASA's new propulsion application, that will provide a high payoff for NASA's reusable launch vehicle systems and space access vehicles. Advanced MMC processing techniques such as plasma spray, centrifugal casting, pressure infiltration casting will be discussed. Development of a novel 3D printing method for low cost production of composite preform, and functional gradient MMC to enhanced rocket engine's dimensional stability will be presented.

Field isotopic study of lead fate and compartmentalization in earthworm-soil-metal particle systems for highly polluted soil near Pb recycling factory.

PubMed

Goix, Sylvaine; Mombo, Stéphane; Schreck, Eva; Pierart, Antoine; Lévêque, Thibaut; Deola, Frédéric; Dumat, Camille

2015-11-01

Earthworms are important organisms in soil macrofauna and play a key role in soil functionality, and consequently in terrestrial ecotoxicological risk assessments. Because they are frequently observed in soils strongly polluted by metals, the influence of earthworm bioturbation on Pb fate could therefore be studied through the use of Pb isotopes. Total Pb concentrations and isotopic composition ((206)Pb, (207)Pb and (208)Pb) were then measured in earthworms, casts and bulk soils sampled at different distance from a lead recycling factory. Results showed decreasing Pb concentrations with the distance from the factory whatever the considered matrix (bulk soils, earthworm bodies or cast samples) with higher concentrations in bulk soils than in cast samples. The bivariate plot (208)Pb/(206)Pb ratios versus (206)Pb/(207)Pb ratios showed that all samples can be considered as a linear mixing between metallic process particulate matter (PM) and geochemical Pb background. Calculated anthropogenic fraction of Pb varied between approximately 84% and 100%. Based on Pb isotopic signatures, the comparison between casts, earthworms and bulk soils allowed to conclude that earthworms preferentially ingest the anthropogenic lead fraction associated with coarse soil organic matter. Actually, soil organic matter was better correlated with Pb isotopic ratios than with Pb content in soils. The proposed hypothesis is therefore a decrease of soil organic matter turnover due to Pb pollution with consequences on Pb distribution in soils and earthworm exposure. Finally, Pb isotopes analysis constitutes an efficient tool to study the influence of earthworm bioturbation on Pb cycle in polluted soils. Copyright © 2015 Elsevier Ltd. All rights reserved.

Method for determining molten metal pool level in twin-belt continuous casting machines

DOEpatents

Kaiser, Timothy D.; Daniel, Sabah S.; Dykes, Charles D.

1989-03-21

A method for determining level of molten metal in the input of a continuous metal casting machine having at least one endless, flexible, revolving casting belt with a surface which engages the molten metal to be cast and a reverse, cooled surface along which is directed high velocity liquid coolant includes the steps of predetermining the desired range of positions of the molten metal pool and positioning at least seven heat-sensing transducers in bearing contact with the moving reverse belt surface and spaced in upstream-downstream relationship relative to belt travel spanning the desired pool levels. A predetermined temperature threshold is set, somewhat above coolant temperature and the output signals of the transducer sensors are scanned regarding their output signals indicative of temperatures of the moving reverse belt surface. Position of the molten pool is determined using temperature interpolation between any successive pair of upstream-downstream spaced sensors, which follows confirmation that two succeeding downstream sensors are at temperature levels exceeding threshold temperature. The method accordingly provides high resolution for determining pool position, and verifies the determined position by utilizing full-strength signals from two succeeding downstream sensors. In addition, dual sensors are used at each position spanning the desired range of molten metal pool levels to provide redundancy, wherein only the higher temperature of each pair of sensors at a station is utilized.

DIRECT INGOT PROCESS FOR PRODUCING URANIUM

DOEpatents

Leaders, W.M.; Knecht, W.S.

1960-11-15

A process is given in which uranium tetrafluoride is reduced to the metal with magnesium and in the same step the uranium metal formed is cast into an ingot. For this purpose a mold is arranged under and connected with the reaction bomb, and both are filled with the reaction mixture. The entire mixture is first heated to just below reaction temperature, and thereafter heating is restricted to the mixture in the mold. The reaction starts in the mold whereby heat is released which brings the rest of the mixture to reaction temperature. Pure uranium metal settles in the mold while the magnesium fluoride slag floats on top of it. After cooling, the uranium is separated from the slag by mechanical means.

Metal Alloy Compositions And Process Background Of The Invention

DOEpatents

Flemings, Merton C.; Martinez-Ayers, Raul A.; de Figueredo, Anacleto M.; Yurko, James A.

2003-11-11

A skinless metal alloy composition free of entrapped gas and comprising primary solid discrete degenerate dendrites homogeneously dispersed within a secondary phase is formed by a process wherein the metal alloy is heated in a vessel to render it a liquid. The liquid is then rapidly cooled while vigorously agitating it under conditions to avoid entrapment of gas while forming solid nuclei homogeneously distributed in the liquid. Agitation then is ceased when the liquid contains a small fraction solid or the liquid-solid alloy is removed from the source of agitation while cooling is continued to form the primary solid discrete degenerate dendrites in liquid secondary phase. The solid-liquid mixture then can be formed such as by casting.

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.

40 CFR 464.23 - Effluent limitations guidelines representing the degree of effluent reduction attainable by the...

Code of Federal Regulations, 2011 CFR

2011-07-01

... (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Copper Casting... copper, lead, zinc, and total phenols. For non-continuous discharges, annual average mass limitations and... for monthly average kg/1,000 kkg (pounds per million pounds) of metal poured Copper (T) 0.0307 .0168...

40 CFR 464.23 - Effluent limitations guidelines representing the degree of effluent reduction attainable by the...

Code of Federal Regulations, 2010 CFR

2010-07-01

... (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Copper Casting... copper, lead, zinc, and total phenols. For non-continuous discharges, annual average mass limitations and... for monthly average kg/1,000 kkg (pounds per million pounds) of metal poured Copper (T) 0.0307 .0168...

Manufacturing Technology Support (MATES II) Task Order 0005: Manufacturing Integration and Technology Evaluation to Enable Technology Transition. Subtask Phase 0 Study Task: Manufacturing Technology (ManTech) and Systems Engineering For Quick Reaction Systems

DTIC Science & Technology

2014-10-01

Porosity from gas entrapment & shrinkage 4 Continuous Fiber Ti Metal Matrix Composites (Aircraft panels and rotor components) [14...process models for casting, forging, and welding , and software capability to integrate various independent models with design, thermal, and structural...Applications, Ph.D. Thesis, Queen’s College, University of Oxford, (2007). 14. S.A. Singerman and J.J. Jackson, Titanium Metal Matrix Composites for

Development of tellurium oxide and lead-bismuth oxide glasses for mid-wave infra-red transmission optics

NASA Astrophysics Data System (ADS)

Zhou, Beiming; Rapp, Charles F.; Driver, John K.; Myers, Michael J.; Myers, John D.; Goldstein, Jonathan; Utano, Rich; Gupta, Shantanu

2013-03-01

Heavy metal oxide glasses exhibiting high transmission in the Mid-Wave Infra-Red (MWIR) spectrum are often difficult to manufacture in large sizes with optimized physical and optical properties. In this work, we researched and developed improved tellurium-zinc-barium and lead-bismuth-gallium heavy metal oxide glasses for use in the manufacture of fiber optics, optical components and laser gain materials. Two glass families were investigated, one based upon tellurium and another based on lead-bismuth. Glass compositions were optimized for stability and high transmission in the MWIR. Targeted glass specifications included low hydroxyl concentration, extended MWIR transmission window, and high resistance against devitrification upon heating. Work included the processing of high purity raw materials, melting under controlled dry Redox balanced atmosphere, finning, casting and annealing. Batch melts as large as 4 kilograms were sprue cast into aluminum and stainless steel molds or temperature controlled bronze tube with mechanical bait. Small (100g) test melts were typically processed in-situ in a 5%Au°/95%Pt° crucible. Our group manufactured and evaluated over 100 different experimental heavy metal glass compositions during a two year period. A wide range of glass melting, fining, casting techniques and experimental protocols were employed. MWIR glass applications include remote sensing, directional infrared counter measures, detection of explosives and chemical warfare agents, laser detection tracking and ranging, range gated imaging and spectroscopy. Enhanced long range mid-infrared sensor performance is optimized when operating in the atmospheric windows from ~ 2.0 to 2.4μm, ~ 3.5 to 4.3μm and ~ 4.5 to 5.0μm.

Nano-casted Metal Oxide Aerogels as Dual Purpose Structural Components for Space Exploration

NASA Technical Reports Server (NTRS)

Vassilaras, Plousia E.

2004-01-01

NASA missions and space exploration rely on strong, ultra lightweight materials. Such materials are needed for building up past and present space vehicles such as the Sojourner Rover (1997) or the two MERs (2003), but also for a number of components and/or systems including thermal insulators, Solar Sails, Rigid Aeroshells, and Ballutes. The purpose of my internship here at Glenn Research Center is to make dual purpose materials; materials that in addition to being lightweight have electronic, photophysical and magnetic properties and, therefore, act as electronic components and sensors as well as structural components. One type of ultra lightweight material of great interest is aerogels, which have densities ranging from 0.003 g/cc to 0.8 g/cc . However, aerogels are extremely fragile and, as a result, have limited practical applications. Recently, Glenn Research Center has developed a process of nano-casting polymers onto the inorganic network of silica-based aerogels increasing the strength 300 fold while only increasing the density 3 fold. By combining the process of nano-casting polymers with inorganic oxide networks other than silica, we are actively pursuing lightweight dual purpose materials. To date, thirty different inorganic oxide aerogels have been prepared using either standard sol-gel chemistry or a non-alkoxide method involving metal chloride precursors and an epoxide; epichlorohydrin, propylene oxide or trimethylene oxide, as proton scavengers. More importantly, preliminary investigations show that the residual surface hydroxyl groups on each of these inorganic oxide aerogels can be successfully crosslinked with urethane. In addition to characterizing physical and mechanical properties such as density, strength and flexibility, each of these metal oxide aerogels are being characterized for thermal and electronic conductivity and magnetic and optical properties.

An Analysis of Industrial Technology Curriculum and Its Significance to the Casting Industry.

ERIC Educational Resources Information Center

Hauser, Roger Emmett

The purpose of this study was to determine to what extent industrial technology programs are training technologists in light of the needs of the casting industry. To determine the type of curriculum needed to prepare individuals for entry into the casting industry, and to study industrial technology programs as they relate to metal casting,…

Seal welded cast iron nuclear waste container

DOEpatents

Filippi, Arthur M.; Sprecace, Richard P.

1987-01-01

This invention identifies methods and articles designed to circumvent metallurgical problems associated with hermetically closing an all cast iron nuclear waste package by welding. It involves welding nickel-carbon alloy inserts which are bonded to the mating plug and main body components of the package. The welding inserts might be bonded in place during casting of the package components. When the waste package closure weld is made, the most severe thermal effects of the process are restricted to the nickel-carbon insert material which is far better able to accommodate them than is cast iron. Use of nickel-carbon weld inserts should eliminate any need for pre-weld and post-weld heat treatments which are a problem to apply to nuclear waste packages. Although the waste package closure weld approach described results in a dissimilar metal combination, the relative surface area of nickel-to-iron, their electrochemical relationship, and the presence of graphite in both materials will act to prevent any galvanic corrosion problem.

8. VIEW OF FOUNDRY INDUCTION FURNACES, MODULE J. THE FOUNDRY ...

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

8. VIEW OF FOUNDRY INDUCTION FURNACES, MODULE J. THE FOUNDRY CASTING PROCESS WAS CONDUCTED IN A VACUUM. PLUTONIUM METAL WAS MELTED IN ONE OF FOUR ELECTRIC INDUCTION FURNACES TO FORM INGOTS. - Rocky Flats Plant, Plutonium Manufacturing Facility, North-central section of Plant, just south of Building 776/777, Golden, Jefferson County, CO

Coating Bores of Light Metal Engine Blocks with a Nanocomposite Material using the Plasma Transferred Wire Arc Thermal Spray Process

NASA Astrophysics Data System (ADS)

Bobzin, K.; Ernst, F.; Zwick, J.; Schlaefer, T.; Cook, D.; Nassenstein, K.; Schwenk, A.; Schreiber, F.; Wenz, T.; Flores, G.; Hahn, M.

2008-09-01

Engine blocks of modern passenger car engines are generally made of light metal alloys, mostly hypoeutectic AlSi-alloys. Due to their low hardness, these alloys do not meet the tribological requirements of the system cylinder running surface—piston rings—lubricating oil. In order to provide a suitable cylinder running surface, nowadays cylinder liners made of gray cast iron are pressed in or cast into the engine block. A newer approach is to apply thermal spray coatings onto the cylinder bore walls. Due to the geometric conditions, the coatings are applied with specifically designed internal diameter thermal spray systems. With these processes a broad variety of feedstock can be applied, whereas mostly low-alloyed carbon steel feedstock is being used for this application. In the context of this work, an iron-based wire feedstock has been developed, which leads to a nanocrystalline coating. The application of this material was carried out with the Plasma Transferred Wire Arc system. AlMgSi0.5 liners were used as substrates. The coating microstructure and the properties of the coatings were analyzed.

Thin sol-gel-derived silica coatings on dental pure titanium casting.

PubMed

Yoshida, K; Kamada, K; Sato, K; Hatada, R; Baba, K; Atsuta, M

1999-01-01

The sol-gel dipping process, in which liquid silicon alkoxide is transformed into a solid silicon-oxygen network, can produce a thin film coating of silica (SiO(2)). The features of this method are high homogeneity and purity of the thin SiO(2) film and a low sinter temperature, which are important in the preparation of coating films that can protect metallic ion release from the metal substrate and prevent attachment of dental plaque. We evaluated the surface properties of dental pure titanium casting coated with a thin SiO(2) or SiO(2)/F-hybrid film by the sol-gel dipping process. The metal specimens were pretreated by dipping in isopropylalcohol solution containing 10 wt% 3-aminopropyl trimethoxysilane and treated by dipping in the silica precursor solution for 5 min, withdrawal at a speed of 2 mm/min, air-drying for 20 min at room temperature, heating at 120 degrees C for 20 min, and then storing at room temperature. Both SiO(2) and SiO(2)/F films bonded strongly (above 55 MPa) to pure titanium substrate by a tensile test. SiO(2(-)) and SiO(2)/F-coated specimens immersed in 1 wt% of lactic acid solution for two weeks showed significantly less release of titanium ions (30. 5 ppb/cm(2) and 9.5 ppb/cm(2), respectively) from the substrate than noncoated specimens (235.2 ppb/cm(2)). Hydrophobilization of SiO(2(-)) and SiO(2)/F-coated surfaces resulted in significant increases of contact angle of water (81.6 degrees and 105.7 degrees, respectively) compared with noncoated metal specimens (62.1 degrees ). The formation of both thin SiO(2) and SiO(2)/F-hybrid films by the sol-gel dipping process on the surface of dental pure titanium casting may be useful clinically in enhancing the bond strength of dental resin cements to titanium, preventing titanium ions release from the substrate, and reducing the accumulation of dental plaque attaching to intraoral dental restorations. Copyright 1999 John Wiley & Sons, Inc.

Does the casting mode influence microstructure, fracture and properties of different metal ceramic alloys?

PubMed

Bauer, José Roberto de Oliveira; Grande, Rosa Helena Miranda; Rodrigues-Filho, Leonardo Eloy; Pinto, Marcelo Mendes; Loguercio, Alessandro Dourado

2012-01-01

The aim of the present study was to evaluate the tensile strength, elongation, microhardness, microstructure and fracture pattern of various metal ceramic alloys cast under different casting conditions. Two Ni-Cr alloys, Co-Cr and Pd-Ag were used. The casting conditions were as follows: electromagnetic induction under argon atmosphere, vacuum, using blowtorch without atmosphere control. For each condition, 16 specimens, each measuring 25 mm long and 2.5 mm in diameter, were obtained. Ultimate tensile strength (UTS) and elongation (EL) tests were performed using a Kratos machine. Vickers Microhardness (VM), fracture mode and microstructure were analyzed by SEM. UTS, EL and VM data were statistically analyzed using ANOVA. For UTS, alloy composition had a direct influence on casting condition of alloys (Wiron 99 and Remanium CD), with higher values shown when cast with Flame/Air (p < 0.05). The factors 'alloy" and 'casting condition" influenced the EL and VM results, generally presenting opposite results, i.e., alloy with high elongation value had lower hardness (Wiron 99), and casting condition with the lowest EL values had the highest VM values (blowtorch). Both factors had significant influence on the properties evaluated, and prosthetic laboratories should select the appropriate casting method for each alloy composition to obtain the desired property.

Influence of tray rigidity and impression technique on accuracy of polyvinyl siloxane impressions.

PubMed

Hoyos, Alex; Soderholm, Karl-Johan

2011-01-01

The aim of this study was to determine how tray rigidity and impression technique affect the accuracy of polyvinyl siloxane impressions. Disposable plastic trays and metallic Rim-Lock trays were used in combination with a heavy/light body technique or with two different putty-wash techniques. For each technique-tray combination, 10 impressions were made of a master cast with two steel abutments representing the mandibular right first premolar and second molar, between which a steel rod was placed at the ridge level. Each steel abutment had five marks, while the steel rod in between the two abutments had only one mark, which served as a reference point. With a universal measuring microscope, the x-, y-, and z-coordinates were recorded for each mark on the master cast and impressions. The distances between the different marks and the reference point on the impressions were calculated and compared with those of the master cast. All techniques used with the plastic trays had distances that were significantly different from the master cast (P < .05), while for the metal trays, it was only the heavy/light body technique that resulted in distances that were significantly different from the master cast (P < .05). Plastic trays produced less accurate impressions than metal trays. When metal trays were used, putty-based impressions were dimensionally better than heavy/light body impressions.

PROTECTIVELY COVERED ARTICLE AND METHOD OF MANUFACTURE

DOEpatents

Plott, R.F.

1958-10-28

A method of casting a protective jacket about a ura nium fuel element that will bond completely to the uranium without the use of stringers or supports that would ordinarily produce gaps in the cast metal coating and bond is presented. Preformed endcaps of alumlnum alloyed with 13% silicon are placed on the ends of the uranium fuel element. These caps will support the fuel element when placed in a mold. The mold is kept at a ing alloy but below that of uranium so the cast metal jacket will fuse with the endcaps forming a complete covering and bond to the fuel element, which would otherwise oxidize at the gaps or discontinuities lefi in the coating by previous casting methods.

Automation of Space Processing Applications Shuttle payloads

NASA Technical Reports Server (NTRS)

Crosmer, W. E.; Neau, O. T.; Poe, J.

1975-01-01

The Space Processing Applications Program is examining the effect of weightlessness on key industrial materials processes, such as crystal growth, fine-grain casting of metals, and production of unique and ultra-pure glasses. Because of safety and in order to obtain optimum performance, some of these processes lend themselves to automation. Automation can increase the number of potential Space Shuttle flight opportunities and increase the overall productivity of the program. Five automated facility design concepts and overall payload combinations incorporating these facilities are presented.

Development of the manufacture of billets based on high-strength aluminum alloys

NASA Astrophysics Data System (ADS)

Korostelev, V. F.; Denisov, M. S.; Bol'shakov, A. E.; Van Khieu, Chan

2017-09-01

When pressure is applied upon casting as a factor of external impact on melt, the problems related mainly to filling of molds are solved; however, some casting defects cannot be avoided. The experimental results demonstrate that complete compensation of shrinkage under pressure can be achieved by compressing of casting by 8-10% prior to beginning of solidification and by 2-3% during the transition of a metal from the liquid to the solid state. It is mentioned that the procedure based on compressing a liquid metal can be efficiently applied for manufacture of high-strength aluminum alloy castings. The selection of engineering parameters is substantiated. Examples of castings made of V95 alloy according to the developed procedure are given. In addition, the article discusses the problems related to designing of engineering and special-purpose equipment, software, and control automation.

[Effect of heat treatment on the structure of a Cu-Zn-Al-Ni system dental alloy].

PubMed

Guastaldi, A C; Adorno, A T; Beatrice, C R; Mondelli, J; Ishikiriama, A; Lacefield, W

1990-01-01

This article characterizes the structural phases present in the copper-based metallic alloy system "Cu-Zn-Al-Ni" developed for dental use, and relates those phases to other properties. The characterization was obtained after casting (using the lost wax process), and after heat treatment. In order to obtain better corrosion resistance by changing the microstructure, the castings were submitted to 30, 45 and 60 minutes of heat treatment at the following temperatures: 750 degrees C, 800 degrees C, and 850 degrees C. The various phases were analyzed using X-ray diffraction and scanning electron microscopy (SEM). The results after heat treatment showed a phase (probably Cu3Al), that could be responsible for the improvement in the alloy's resistance to corrosion as compared to the as-cast structure.

Finite-Element Analysis of Melt Flow in Horizontal Twin-Roll Casting of Magnesium Alloy AZ31

NASA Astrophysics Data System (ADS)

Park, Jong-Jin

Twin-roll casting has been useful in production of thin strips of metals. Especially, the process of horizontal twin-roll casting is often used for magnesium and aluminum alloys, which are lighter in weight and smaller in specific heat as well as latent heat in comparison to steel. In the present investigation, where magnesium alloy AZ31 was targeted, asymmetric behavior of the melt flow due to the gravity was examined in terms of contact length and pressure, and the nozzle for melt ejection was modified for its shape and location. Variations of the melt flow including vortexes were investigated in consideration of heterogeneous nucleation and uniform microstructure. The melt flow was further examined in the perspective of possible randomness of the grain orientation through thickness under differential speeds of rolls.

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

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

Weiss, David; Purgert, Robert; Rhudy, Richard

2000-04-21

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

Grindability of cast Ti-Hf alloys.

PubMed

Kikuchi, Masafumi; Takahashi, Masatoshi; Sato, Hideki; Okuno, Osamu; Nunn, Martha E; Okabe, Toru

2006-04-01

As part of our systematic studies characterizing the properties of titanium alloys, we investigated the grindability of a series of cast Ti-Hf alloys. Alloy buttons with hafnium concentrations up to 40 mass% were made using an argon-arc melting furnace. Each button was cast into a magnesia-based mold using a dental titanium casting machine; three specimens were made for each metal. Prior to testing, the hardened surface layer was removed. The specimens were ground at five different speeds for 1 min at 0.98 N using a carborundum wheel on an electric dental handpiece. Grindability was evaluated as the volume of metal removed per minute (grinding rate) and the volume ratio of metal removed compared to the wheel material lost (grinding ratio). The data were analyzed using ANOVA. A trend of increasing grindability was found with increasing amounts of hafnium, although there was no statistical difference in the grindability with increasing hafnium contents. We also found that hafnium may be used to harden or strengthen titanium without deteriorating the grindability.

Manufacturing Methods and Technology Project Summary Reports

DTIC Science & Technology

1985-06-01

Computer -Aided Design (CAD)/ Computer -Aided Manufacturing (CAM) Process for the Production of Cold Forged Gears Project 483 6121 - Robotic Welding and...Caliber Projectile Bodies Project 682 8370 - Automatic Inspection and 1-I1 Process Control of Weapons Parts Manufacturing METALS Project 181 7285 - Cast...designed for use on each project. Experience suggested that a general purpose computer interface might be designed that could be used on any project

Research on the use of space resources

NASA Technical Reports Server (NTRS)

Carroll, W. F. (Editor)

1983-01-01

The second year of a multiyear research program on the processing and use of extraterrestrial resources is covered. The research tasks included: (1) silicate processing, (2) magma electrolysis, (3) vapor phase reduction, and (4) metals separation. Concomitant studies included: (1) energy systems, (2) transportation systems, (3) utilization analysis, and (4) resource exploration missions. Emphasis in fiscal year 1982 was placed on the magma electrolysis and vapor phase reduction processes (both analytical and experimental) for separation of oxygen and metals from lunar regolith. The early experimental work on magma electrolysis resulted in gram quantities of iron (mixed metals) and the identification of significant anode, cathode, and container problems. In the vapor phase reduction tasks a detailed analysis of various process concepts led to the selection of two specific processes designated as ""Vapor Separation'' and ""Selective Ionization.'' Experimental work was deferred to fiscal year 1983. In the Silicate Processing task a thermophysical model of the casting process was developed and used to study the effect of variations in material properties on the cooling behavior of lunar basalt.

Filler metal alloy for welding cast nickel aluminide alloys

DOEpatents

Santella, Michael L.; Sikka, Vinod K.

1998-01-01

A filler metal alloy used as a filler for welding east nickel aluminide alloys contains from about 15 to about 17 wt. % chromium, from about 4 to about 5 wt. % aluminum, equal to or less than about 1.5 wt. % molybdenum, from about 1 to about 4.5 wt. % zirconium, equal to or less than about 0.01 wt. % yttrium, equal to or less than about 0.01 wt. % boron and the balance nickel. The filler metal alloy is made by melting and casting techniques such as are melting the components of the filler metal alloy and east in copper chill molds.

Large structural, thin-wall castings made of metals subject to hot tearing, and their fabrication

NASA Technical Reports Server (NTRS)

Smashey, Russell W. (Inventor)

2001-01-01

An article, such as a gas turbine engine mixer, is made by providing a mold structure defining a thin-walled, hollow article, and a base metal that is subject to hot tear cracking when cast in a generally equiaxed polycrystalline form, such as Rene' 108 and Mar-M247. The article is fabricated by introducing the molten base metal into the mold structure, and directionally solidifying the base metal in the mold structure to form a directionally oriented structure. The directionally oriented structure may be formed of a single grain or oriented multiple grains.

Evaluation of three variables affecting the casting of base metal alloys.

PubMed

Wight, T A; Grisius, R J; Gaugler, R W

1980-04-01

All the vented samples with sprue widths of 2 mm or more were defect free, whereas the corresponding unvented samples had extensive voids and porosity in all but one casting. All castings with a sprue width of 1 mm were defective regardless of whether or not vents were used. The thickness of the investment above the pattern had no effect on casting results.

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

ERIC Educational Resources Information Center

Hall, Mary Ann

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

Alloy with metallic glass and quasi-crystalline properties

DOEpatents

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

2004-02-17

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

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

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

David Schwam

2012-12-15

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

Influence of porcelain firing and cementation on the marginal adaptation of metal-ceramic restorations prepared by different methods.

PubMed

Kaleli, Necati; Saraç, Duygu

2017-05-01

Marginal adaptation plays an important role in the survival of metal-ceramic restorations. Porcelain firings and cementation may affect the adaptation of restorations. Moreover, conventional casting procedures and casting imperfections may cause deteriorations in the marginal adaptation of metal-ceramic restorations. The purpose of this in vitro study was to compare the marginal adaptation after fabrication of the framework, porcelain application, and cementation of metal-ceramic restorations prepared by using the conventional lost-wax technique, milling, direct metal laser sintering (DMLS), and LaserCUSING, a direct process powder-bed system. Alterations in the marginal adaptation of the metal frameworks during the fabrication stages and the precision of fabrication methods were evaluated. Forty-eight metal dies simulating prepared premolar and molar abutment teeth were fabricated to investigate marginal adaptation. They were divided into 4 groups (n=12) according to the fabrication method used (group C serving as the control group: lost-wax method; group M: milling method; group LS: DMLS method; group DP: direct process powder-bed method). Sixty marginal discrepancy measurements were recorded separately on each abutment tooth after fabrication of the framework, porcelain application, and cementation by using a stereomicroscope. Thereafter, each group was divided into 3 subgroups according to the measurements recorded in each fabrication stage: subgroup F (framework), subgroup P (porcelain application), and subgroup C (cementation). Data were statistically analyzed with univariate analysis of variance (followed by 1-way ANOVA and Tamhane T2 test (α=.05). The lowest marginal discrepancy values were observed in restorations prepared by using the direct process powder-bed method, and this was significantly different (P<.001) from the other methods. The highest marginal discrepancy values were recorded after the cementation procedure in all groups. The results showed that the direct process powder-bed method is quite successful in terms of marginal adaptation. The marginal discrepancy increased after porcelain application and cementation. Copyright © 2016 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

A comparative study of the accuracy between plastic and metal impression transfer copings for implant restorations.

PubMed

Fernandez, Monica A; Paez de Mendoza, Carmen Y; Platt, Jeffrey A; Levon, John A; Hovijitra, Suteera T; Nimmo, Arthur

2013-07-01

A precise transfer of the position and orientation of the antirotational mechanism of an implant to the working cast is particularly important to achieve optimal fit of the final restoration. This study evaluated and compared the accuracy of metal and plastic impression copings for use in a full-arch mandibular edentulous simulation with four implants. Metal and plastic impression transfer copings for two implant systems, Nobel Biocare™ Replace and Straumann SynOcta®, were assessed on a laboratory model to simulate clinical practice. The accuracy of producing stone casts using these plastic and metal impression transfer copings was measured against a standard prosthetic framework consisting of a cast gold bar. A total of 20 casts from the four combinations were obtained. The fit of the framework on the cast was tested by a noncontact surface profilometer, the Proscan 3D 2000 A, using the one-screw test. The effects of implant/system and impression/coping material on gap measurements were analyzed using repeated measures ANOVA. The findings of this in vitro study were as follows: plastic copings demonstrated significantly larger average gaps than metal for Straumann (p = 0.001). Plastic and metal copings were not significantly different for Nobel (p = 0.302). Nobel had significantly larger average gaps than Straumann for metal copings (p = 0.003). Nobel had marginally smaller average gaps than Straumann (p = 0.096) for plastic copings. The system-by-screw location interaction was significant as well (p < 0.001), indicating significant differences among the four screw locations, but the location differences were not the same for the two systems. A rank transformation of the data was necessary due to the nonnormal distribution of the gap measurements. No adjustments were made for multiple comparisons. The metal impression copings were more accurate than plastic copings when using the Straumann system, and there was no difference between metal and plastic copings for the Nobel Replace system. The system-by-screw location was not conclusive, showing no correlation within each system. © 2013 by the American College of Prosthodontists.

Development of an inverse heat conduction model and its application to determination of heat transfer coefficient during casting solidification

NASA Astrophysics Data System (ADS)

Zhang, Liqiang; Reilly, Carl; Li, Luoxing; Cockcroft, Steve; Yao, Lu

2014-07-01

The interfacial heat transfer coefficient (IHTC) is required for the accurate simulation of heat transfer in castings especially for near net-shape processes. The large number of factors influencing heat transfer renders quantification by theoretical means a challenge. Likewise experimental methods applied directly to temperature data collected from castings are also a challenge to interpret because of the transient nature of many casting processes. Inverse methods offer a solution and have been applied successfully to predict the IHTC in many cases. However, most inverse approaches thus far focus on use of in-mold temperature data, which may be a challenge to obtain in cases where the molds are water-cooled. Methods based on temperature data from the casting have the potential to be used however; the latent heat released during the solidification of the molten metal complicates the associated IHTC calculations. Furthermore, there are limits on the maximum distance the thermocouples can be placed from the interface under analysis. An inverse conduction based method have been developed, verified and applied successfully to temperature data collected from within an aluminum casting in proximity to the mold. A modified specific heat method was used to account for latent heat evolution in which the rate of change of fraction solid with temperature was held constant. An analysis conducted with the inverse model suggests that the thermocouples must be placed no more than 2 mm from the interface. The IHTC values calculated for an aluminum alloy casting were shown to vary from 1,200 to 6,200 Wm-2 K-1. Additionally, the characteristics of the time-varying IHTC have also been discussed.

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

NASA Astrophysics Data System (ADS)

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

2016-06-01

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

Cast Metals Coalition Technology Transfer and Program Management Final Report

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

Gwyn, Mike

2009-03-31

The Cast Metals Coalition (CMC) partnership program was funded to ensure that the results of the Department of Energy's (DOE) metalcasting research and development (R&D) projects are successfully deployed into industry. Specifically, the CMC program coordinated the transfer and deployment of energy saving technologies and process improvements developed under separately funded DOE programs and projects into industry. The transition of these technologies and process improvements is a critical step in the path to realizing actual energy savings. At full deployment, DOE funded metalcasting R&D results are projected to save 55% of the energy used by the industry in 1998. Thismore » closely aligns with DOE's current goal of driving a 25% reduction in industrial energy intensity by 2017. In addition to benefiting DOE, these energy savings provide metalcasters with a significant economic advantage. Deployment of already completed R&D project results and those still underway is estimated to return over 500% of the original DOE and industry investment. Energy savings estimates through December 2008 from the Energy-Saving Melting and Revert Reduction Technology (E-SMARRT) portfolio of projects alone are 12 x 1012 BTUs, with a projection of over 50 x 1012 BTUs ten years after program completion. These energy savings and process improvements have been made possible through the unique collaborative structure of the CMC partnership. The CMC team consists of DOE's Office of Industrial Technology, the three leading metalcasting technical societies in the U.S: the American Foundry Society; the North American Die Casting Association; and the Steel Founders Society of America; and the Advanced Technology Institute (ATI), a recognized leader in distributed technology management. CMC provides collaborative leadership to a complex industry composed of approximately 2,100 companies, 80% of which employ less than 100 people, and only 4% of which employ more than 250 people. Without collaboration, new technologies enabling energy efficiencies and environment-friendly improvements are slow to develop, and have trouble obtaining a broad application. The CMC team was able to effectively and efficiently transfer the results of DOE's metalcasting R&D projects to industry by utilizing and delivering the numerous communication vehicles identified in the proposal. The three metalcasting technical associations achieved significant technology transition results under this program. In addition to reaching over 23,000 people per year through Modern Casting and 28,000 through Engineered Casting Solutions, AFS had 84 national publications and reached over 1,200 people annually through Cast Metals Institute (CMI) education courses. NADCA's education department reached over 1,000 people each year through their courses, in addition to reaching over 6,000 people annually through Die Casting Engineer, and publishing 58 papers. The SFSA also published 99 research papers and reached over 1,000 people annually through their member newsletters. In addition to these communication vehicles, the CMC team conducted numerous technical committee meetings, project reviews, and onsite visits. All of these efforts to distribute the latest metalcasting technologies contributed to the successful deployment of DOE's R&D projects into industry. The DOE/CMC partnership demonstrated significant success in the identification and review of relevant and easy-to-implement metalcasting energy-saving processes and technologies so that the results are quickly implemented and become general practice. The results achieved in this program demonstrate that sustained technology transfer efforts are a critical step in the deployment of R&D projects to industry.« less

Online monitoring of corrosion behavior in molten metal using laser-induced breakdown spectroscopy

NASA Astrophysics Data System (ADS)

Zeng, Qiang; Pan, Congyuan; Li, Chaoyang; Fei, Teng; Ding, Xiaokang; Du, Xuewei; Wang, Qiuping

2018-04-01

The corrosion behavior of structure materials in direct contact with molten metals is widespread in metallurgical industry. The corrosion of casting equipment by molten metals is detrimental to the production process, and the corroded materials can also contaminate the metals being produced. Conventional methods for studying the corrosion behavior by molten metal are offline. This work explored the application of laser-induced breakdown spectroscopy (LIBS) for online monitoring of the corrosion behavior of molten metal. The compositional changes of molten aluminum in crucibles made of 304 stainless steel were obtained online at 1000 °C. Several offline techniques were combined to determine the corrosion mechanism, which was highly consistent with previous studies. Results proved that LIBS was an efficient method to study the corrosion mechanism of solid materials in molten metal.

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

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

Das, S.

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

Electromagnetic augmentation for casting of thin metal sheets

DOEpatents

Hull, J.R.

1987-10-28

Thin metal sheets are cast by magnetically levitating molten metal deposited in a model within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled by the water-cooled walls of the mold to form a solid metal sheet. A conducting shield is electrically coupled to the molten metal sheet to provide a return path for eddy currents induced in the metal sheet by the current in the AC conducting coils. In another embodiment, a DC conducting coil is coupled to the metal sheet for providing a direct current therein which interacts with the magnetic field to levitate the moving metal sheet. Levitation of the metal sheet in both molten and solid forms reduces its contact pressure with the mold walls while maintaining sufficient engagement therebetween to permit efficient conductive cooling by the mold through which a coolant fluid may be circulated. 8 figs.

A systematic review of dowel (post) and core materials and systems.

PubMed

Theodosopoulou, Joanna N; Chochlidakis, Konstantinos M

2009-08-01

The aim of this systematic review was to determine which dowel (post) and core system is the most successful when used in vivo to restore endodontically treated teeth. A MEDLINE, a Cochrane, and an EMBASE search (three specified searches) were conducted to identify randomized (RCT) and nonrandomized controlled clinical trials (CCT), cohort (CS), and case control studies (CCS) until January 2008, conducted on humans, and published in English, German, and French, relating to dowel and core systems for restoring endodontically treated teeth. Also, a hand search was conducted, along with contact with the authors when needed. The MEDLINE, Cochrane, and EMBASE searches identified 997, 141, and 25 published articles, respectively. Ten articles from the MEDLINE and seven articles from the Cochrane search (that were also identified in the MEDLINE search) met the inclusion and validity assessment criteria. Six out of the ten studies were RCTs, two were CCTs, and two CSs. The RCT studies suggest that carbon fiber in resin matrix dowels are significantly better than precious alloy cast dowels (number needed to treat, NNT = 8.30). Tapered gold alloy cast dowels are better than ParaPost gold alloy cast dowels (NNT = 13.15). ParaPost prefabricated dowels are slightly better than ParaPost cast dowels (NNT = 175.4). Glass fiber dowels are significantly better than metal screw dowels (NNT = 5.46), but worse than titanium (NNT =-21.73) (moderately). Carbon fiber dowels are worse than gold alloy cast dowels (significantly) (NNT =-5.81) and than amalgam dowels (NNT =-125) (slightly). The CCT studies suggest that metal dowels are better (NNT = 21.73) but also worse than cast dowels (NNT =-33.33) depending on the remaining amount of coronal hard tissue. Quartz fiber dowels show success rates similar to and worse than glass fiber-reinforced dowels (NNT =-37.03). The results from the CS studies suggest that carbon fiber in resin matrix dowels are better (moderately) than carbon fiber + quartz and quartz fiber dowels. Titanium dowels with a composite build-up are better (moderately) than gold alloy cast dowels. According to the studies of the highest levels of evidence, carbon fiber in resin matrix dowels are significantly better than precious alloy cast dowels (RCT). Glass fiber dowels are significantly better than metal screw dowels (RCT) and moderately better than quartz fiber dowels (CCT). Carbon fiber dowels are significantly worse than metal dowels (of precious alloy) (RCT). Prefabricated metal dowels are slightly better than cast dowels (RCT), but moderately worse when no collar of the dentin above the gingiva could be achieved (CCT).

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

Faster, Less Expensive Dies Using RSP Tooling

NASA Astrophysics Data System (ADS)

Knirsch, James R.

2007-08-01

RSP Tooling is an indirect spray form additive process that can produce production tooling for virtually any forming process and from virtually any metal. In the past 24 months a significant amount of research and development has been performed. This resulted in an increase in the basic metallurgical understanding of what transpires during the rapid solidification of the metal, significant improvements in the production machine up time, ceramic developments that have improved finish, process changes that have resulted in a shorter lead time for tool delivery, and the testing of many new alloys. RSP stands for Rapid Solidification Process and is the key to the superior metallurgical properties that result from the technology. Most metals that are sprayed in the process leave the machine with the same physical properties as the same metal normally achieves through heat treatment and in some cases the properties are superior. Many new applications are being pursued including INVAR tools for aerospace composite materials, and bimetallic tools made from tool steel and beryllium copper for die casting and plastic injection molding. Recent feasibility studies have been performed with tremendous success.

Experimental Exploration of Metal Cable as Reinforcement in 3D Printed Concrete

PubMed Central

Ahmed, Zeeshan Y.; Jutinov, Evgeniy R.; Salet, Theo A. M.

2017-01-01

The Material Deposition Method (MDM) is enjoying increasing attention as an additive method to create concrete mortar structures characterised by a high degree of form-freedom, a lack of geometrical repetition, and automated construction. Several small-scale structures have been realised around the world, or are under preparation. However, the nature of this construction method is unsuitable for conventional reinforcement methods to achieve ductile failure behaviour. Sometimes, this is solved by combining printing with conventional casting and reinforcing techniques. This study, however, explores an alternative strategy, namely to directly entrain a metal cable in the concrete filament during printing to serve as reinforcement. A device is introduced to apply the reinforcement. Several options for online reinforcement media are compared for printability. Considerations specific to the manufacturing process are discussed. Subsequently, pull-out tests on cast and printed specimens provide an initial characterisation of bond behaviour. Bending tests furthermore show the potential of this reinforcement method. The bond stress of cables in printed concrete was comparable to values reported for smooth rebar but lower than that of the same cables in cast concrete. The scatter in experimental results was high. When sufficient bond length is available, ductile failure behaviour for tension parallel to the filament direction can be achieved, even though cable slip occurs. Further improvements to the process should pave the way to achieve better post-crack resistance, as the concept in itself is feasible. PMID:29144426

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

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

Heestand, G.; Jaskolski, T.

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

Homogenizing Advanced Alloys: Thermodynamic and Kinetic Simulations Followed by Experimental Results

NASA Astrophysics Data System (ADS)

Jablonski, Paul D.; Hawk, Jeffrey A.

2017-01-01

Segregation of solute elements occurs in nearly all metal alloys during solidification. The resultant elemental partitioning can severely degrade as-cast material properties and lead to difficulties during post-processing (e.g., hot shorts and incipient melting). Many cast articles are subjected to a homogenization heat treatment in order to minimize segregation and improve their performance. Traditionally, homogenization heat treatments are based upon past practice or time-consuming trial and error experiments. Through the use of thermodynamic and kinetic modeling software, NETL has designed a systematic method to optimize homogenization heat treatments. Use of the method allows engineers and researchers to homogenize casting chemistries to levels appropriate for a given application. The method also allows for the adjustment of heat treatment schedules to fit limitations on in-house equipment (capability, reliability, etc.) while maintaining clear numeric targets for segregation reduction. In this approach, the Scheil module within Thermo-Calc is used to predict the as-cast segregation present within an alloy, and then diffusion controlled transformations is used to model homogenization kinetics as a function of time and temperature. Examples of computationally designed heat treatments and verification of their effects on segregation and properties of real castings are presented.

Electron Beam Freeform Fabrication for Cost Effective Near-Net Shape Manufacturing

NASA Technical Reports Server (NTRS)

Taminger, Karen M.; Hafley, Robert A.

2006-01-01

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cm3/hr (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Electron Beam Freeform Fabrication (EBF3) for Cost Effective Near-Net Shape Manufacturing

NASA Technical Reports Server (NTRS)

Taminger, Karen M.; Hafley, Robert A.

2006-01-01

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cubic centimeters per hour (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

40 CFR 464.01 - Applicability.

Code of Federal Regulations, 2010 CFR

2010-07-01

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

Energy and Process Optimization and Benchmarking of Army Industrial Processes

DTIC Science & Technology

2006-09-01

casting is a metal part formed by pouring molten iron, steel, aluminum, zinc , titanium, magnesium, copper, brass, bronze or cobalt, in nearly all...blanketing techniques. The loss of high-priced alloys is also mini- mized, while slag or dross rates are cut in half to help decrease disposal costs...fabricated of iron and steel; hot dip coating such items with aluminum, lead, or zinc ; retin- ning cans and utensils; (3) engraving, chasing and

40 CFR 471.44 - Pretreatment standards for existing sources (PSES).

Code of Federal Regulations, 2013 CFR

2013-07-01

... chill casting contact cooling water. Subpart D—PSES Pollutant or pollutant property Maximum for any one...) Shot casting contact cooling water. Subpart D—PSES Pollutant or pollutant property Maximum for any 1 day Maximum for monthly average mg/off-kg (pounds per million off-pounds) of precious metals shot cast...

40 CFR 471.44 - Pretreatment standards for existing sources (PSES).

Code of Federal Regulations, 2014 CFR

2014-07-01

... chill casting contact cooling water. Subpart D—PSES Pollutant or pollutant property Maximum for any one...) Shot casting contact cooling water. Subpart D—PSES Pollutant or pollutant property Maximum for any 1 day Maximum for monthly average mg/off-kg (pounds per million off-pounds) of precious metals shot cast...

40 CFR 471.44 - Pretreatment standards for existing sources (PSES).

Code of Federal Regulations, 2011 CFR

2011-07-01

... chill casting contact cooling water. Subpart D—PSES Pollutant or pollutant property Maximum for any one...) Shot casting contact cooling water. Subpart D—PSES Pollutant or pollutant property Maximum for any 1 day Maximum for monthly average mg/off-kg (pounds per million off-pounds) of precious metals shot cast...

40 CFR 471.44 - Pretreatment standards for existing sources (PSES).

Code of Federal Regulations, 2010 CFR

2010-07-01

... chill casting contact cooling water. Subpart D—PSES Pollutant or pollutant property Maximum for any one...) Shot casting contact cooling water. Subpart D—PSES Pollutant or pollutant property Maximum for any 1 day Maximum for monthly average mg/off-kg (pounds per million off-pounds) of precious metals shot cast...

40 CFR 471.44 - Pretreatment standards for existing sources (PSES).

Code of Federal Regulations, 2012 CFR

2012-07-01

... chill casting contact cooling water. Subpart D—PSES Pollutant or pollutant property Maximum for any one...) Shot casting contact cooling water. Subpart D—PSES Pollutant or pollutant property Maximum for any 1 day Maximum for monthly average mg/off-kg (pounds per million off-pounds) of precious metals shot cast...

Effect of Low-Melting Metals (Pb, Bi, Cd, In) on the Structure, Phase Composition, and Properties of Casting Al-5% Si-4% Cu Alloy

NASA Astrophysics Data System (ADS)

Yakovleva, A. O.; Belov, N. A.; Bazlova, T. A.; Shkalei, I. V.

2018-01-01

The effect of low-melting metals (Pb, Bi, Cd, In) on the structure, phase composition, and properties of the Al-5% Si-4% Cu alloy was studied using calculations. Polythermal sections have been reported, which show that the considered systems are characterized by the presence of liquid regions and monotectic reactions. The effect of low-melting metals on the microstructure and hardening of base alloy in the cast and heat-treated states has been studied.

FerriCast: a macrocyclic photocage for Fe3+.

PubMed

Kennedy, Daniel P; Incarvito, Christopher D; Burdette, Shawn C

2010-02-01

The non-siderophoric Fe(3+) photocage FerriCast (4,5-dimethoxy-2-nitrophenyl)-[4-(1-oxa-4,10-dithia-7-aza-cyclododec-7-yl)phenyl] methanol (2) has been prepared in high yield using an optimized two-step reaction sequence that utilizes a trimethylsilyl trifluoromethanesulfonate (TMSOTf) assisted electrophilic aromatic substitution as the key synthetic step. Spectrophotometric assessment of Fe(3+) binding to FerriCast revealed a binding stoichiometry and metal ion affinity dependent on the nature of the counterion. Exposure of FerriCast to 350 nm light initiates a photoreaction that converts FerriCast into FerriUnc (4,5-dimethoxy-2-nitrosophenyl)-[4-(1-oxa-4,10-dithia-7-aza-cyclododec-7-yl)phenyl]-methanone), which binds Fe(3+) less strongly owing to resonance delocalization of the anilino lone pair into the benzophenone pi-system. The release of Fe(3+) upon photolysis of FerriCast also was evaluated using a previously reported turn-on fluorescent sensor that utilizes the same macrocyclic ligand (4-(1-oxa-4,10-dithia-7-aza-cyclododec-7-yl)phenyl, AT(2)12C4). In contrast to the original reports on AT(2)12C4-based Fe(3+) sensors, FerriCast does not interact with ferric iron in aqueous solution. Introduction of oxygen containing solvents (MeOH, H(2)O, DMSO, MES, and phosphate buffers) to CH(3)CN solutions of metalated FerriCast lead to rapid decomplexation as measured by UV-visible spectroscopy. Further investigations contradicted the published conclusions on the aqueous coordination chemistry of AT(2)12C4, but also confirmed the unique and unexpected selectivity of the macrocycle for Fe(3+) in nonaqueous solvents. The crystallographic analysis of [Cu(AT(2)12C4)Cl](+) provides a rare example of a bifurcated hydrogen bond, and evidence for redox chemistry with the ligand. Spectrophotometric analysis of the model ligand with redox active metal ions provide evidence for AT(2)12C4(*+), a quasi-stable species the presence of which suggests caution should be taken when evaluating the interaction of aniline-containing systems with redox active metal ions.

Fabrication of U-10 wt.%Zr Metallic Fuel Rodlets for Irradiation Test in BOR-60 Fast Reactor

DOE PAGES

Kim, Ki-Hwan; Kim, Jong-Hwan; Oh, Seok-Jin; ...

2016-01-01

The fabrication technology for metallic fuel has been developed to produce the driver fuel in a PGSFR in Korea since 2007. In order to evaluate the irradiation integrity and validate the in-reactor of the starting metallic fuel with FMS cladding for the loading of the metallic fuel, U-10 wt.%Zr fuel rodlets were fabricated and evaluated for a verification of the starting driver fuel through an irradiation test in the BOR-60 fast reactor. The injection casting method was applied to U-10 wt.%Zr fuel slugs with a diameter of 5.5 mm. Consequently, fuel slugs per melting batch without casting defects were fabricated through the developmentmore » of advanced casting technology and evaluation tests. The optimal GTAW welding conditions were also established through a number of experiments. In addition, a qualification test was carried out to prove the weld quality of the end plug welding of the metallic fuel rodlets. The wire wrapping of metallic fuel rodlets was successfully accomplished for the irradiation test. Thus, PGSFR fuel rodlets have been soundly fabricated for the irradiation test in a BOR-60 fast reactor.« less

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

Asmussen, Robert M.; Lawter, Amanda R.; Stephenson, John R.

Washington River Protection Solutions (WRPS) is collecting relevant available data on waste forms for use as a supplemental immobilization technology, to provide the additional capacity needed to treat low-activity waste (LAW) in Hanford Site tanks and complete the tank waste cleanup mission in a timely and cost-effective manner. One candidate supplemental waste form, fabricated using a low-temperature process, is a cementitious grout called Cast Stone. Cast Stone has been under investigation for this application at Pacific Northwest National Laboratory (PNNL) since initial screening tests in FY13. This report is the culmination of work to lower the diffusivities of Tc andmore » I from Cast Stone using getters. Getters are compounds added to a system designed to selectively sequester a species of interest to provide increased stability to the species. The work contained within this report is related to waste form development and testing, and does not directly support the 2017 integrated disposal facility (IDF) performance assessment. However, this work contains valuable information which may be used in performance assessment maintenance past FY17, and in future waste form development. This report on performance characterization of Tc and I getters in Cast Stone fabricated with simulated LAW covers several areas of interest and major findings to WRPS: investigating performance of potassium metal sulfide (KMS-2-SS) and tin (II) apatite (Sn-A) as Tc getters when incorporated into Cast Stone; investigating performance of silver exchanged zeolite (Ag-Z) and argentite (Arg) as I getters when incorporated into Cast Stone; utilizing sequential addition of Tc and I getters to overcome any deleterious interactions between the getters in solution; determining, for the first time, Tc distribution within the cured Cast Stone and its evolution during leaching; and performing solid state characterization of getters and Cast Stone samples to support leach test findings and develop a mechanistic understanding of the processes that control Tc and I release into solution.« less

X-ray tomography investigation of intensive sheared Al–SiC metal matrix composites

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

De Giovanni, Mario; Warnett, Jason M.; Williams, Mark A.

2015-12-15

X-ray computed tomography (XCT) was used to characterise three dimensional internal structure of Al–SiC metal matrix composites. The alloy composite was prepared by casting method with the application of intensive shearing to uniformly disperse SiC particles in the matrix. Visualisation of SiC clusters as well as porosity distribution were evaluated and compared with non-shearing samples. Results showed that the average particle size as well as agglomerate size is smaller in sheared sample compared to conventional cast samples. Further, it was observed that the volume fraction of porosity was reduced by 50% compared to conventional casting, confirming that the intensive shearingmore » helps in deagglomeration of particle clusters and decrease in porosity of Al–SiC metal matrix composites. - Highlights: • XCT was used to visualise 3D internal structure of Al-SiC MMC. • Al-SiC MMC was prepared by casting with the application of intensive shearing. • SiC particles and porosity distribution were evaluated. • Results show shearing deagglomerates particle clusters and reduces porosity in MMC.« less

Development of Integrated Die Casting Process for Large Thin-Wall Magnesium Applications

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

Carter, Jon T.; Wang, Gerry; Luo, Alan

The purpose of this project was to develop a process and product which would utilize magnesium die casting and result in energy savings when compared to the baseline steel product. The specific product chosen was a side door inner panel for a mid-size car. The scope of the project included: re-design of major structural parts of the door, design and build of the tooling required to make the parts, making of parts, assembly of doors, and testing (both physical and simulation) of doors. Additional work was done on alloy development, vacuum die casting, and overcasting, all in order to improvemore » the performance of the doors and reduce cost. The project achieved the following objectives: 1. Demonstrated ability to design a large thin-wall magnesium die casting. 2. Demonstrated ability to manufacture a large thin-wall magnesium die casting in AM60 alloy. 3. Tested via simulations and/or physical tests the mechanical behavior and corrosion behavior of magnesium die castings and/or lightweight experimental automotive side doors which incorporate a large, thin-wall, powder coated, magnesium die casting. Under some load cases, the results revealed cracking of the casting, which can be addressed with re-design and better material models for CAE analysis. No corrosion of the magnesium panel was observed. 4. Using life cycle analysis models, compared the energy consumption and global warming potential of the lightweight door with those of a conventional steel door, both during manufacture and in service. Compared to a steel door, the lightweight door requires more energy to manufacture but less energy during operation (i.e., fuel consumption when driving vehicle). Similarly, compared to a steel door, the lightweight door has higher global warming potential (GWP) during manufacture, but lower GWP during operation. 5. Compared the conventional magnesium die casting process with the “super-vacuum” die casting process. Results achieved with cast tensile bars suggest some improvement in tensile properties with vacuum casting. Plant trials with large castings revealed cavity fill issues attributed to cooling and partial solidification of metal in the shot sleeve while waiting for vacuum to be established in the die cavity. 6. Developed age-hardenable Mg-based alloys as potential alternatives to the AM60 and AZ91 alloys typically used in automotive applications. Mg-7%Al-based alloys having Sn or Sn+Si additions exhibited significant age hardening, but more work is needed to demonstrate significant improvement in tensile properties. Corrosion behavior of these alloys is between those of AM60 and AZ91 alloys. 7. Evaluated the die casting of magnesium directly onto either steel or aluminum tubes as a potential process to make large lightweight subassemblies. Samples were free of gross defects, but additional work is needed to increase the interfacial shear strength. Overall, the project demonstrated that an automotive door-in-white design incorporating a die cast magnesium inner panel and a stamped aluminum outer panel can achieve approximately 50% mass reduction compared to the stamped steel baseline door-in-white. This leads to reduced energy consumption when driving the vehicle, which should more than offset the increased embedded energy of manufacture associated with the lighter metals. However, additional design work would be needed in order to meet the mechanical performance required of a door. Development of high-strength, high-ductility magnesium alloy castings would help make this technology more attractive for potential use in the side doors on automobiles. Also, increased use of recycled magnesium and aluminum would reduce the embedded energy and greenhouse gas emissions associated with the manufacture of this type of lightweight door. Commercialization planning of the type of lightweight door technology addressed in this project would be contingent upon the doors meeting all technical performance requirements of the car maker. The specific lightweight door developed in this project didn’t meet some of those requirements, but a preliminary business case study was conducted anyhow. This study considered the ratio of cost increase to mass decrease when the lightweight door is compared to a baseline steel door. The ratio was found to be in an acceptable range for some vehicle programs, especially if the number of such vehicles to be produced is equal to or slightly less than the estimated 250,000-shot life of the die set. This would allow for the investment in the dies to be spread across many parts and thereby help minimize the cost increase.« less

Casting Simulation of an Austrian Bronze Age Sword Hilt

NASA Astrophysics Data System (ADS)

Pola, Annalisa; Mödlinger, Marianne; Piccardo, Paolo; Montesano, Lorenzo

2015-07-01

Bronze Age swords with a metal hilt can be considered the peak of Bronze Age casting technologies. To reconstruct the casting techniques used more than 3000 years ago, a metal hilted sword of the Schalenknauf type from Lower Austria was studied with the aid of macroscopic analyses and simulation of mold filling and casting solidification. A three-dimensional model of the hilt was created based on optical scanner measurements performed on a hilt recently discovered during archaeological excavations. Three different configurations of the gating system were considered, two on the pommel disk and one on the knob, and the effect of its location on the formation of casting defects was investigated. Three-dimensional computed tomography was used to detect internal defects, such as gas and shrinkage porosity, which were then compared with those calculated by simulation. The best match between actual and predicted hilt quality demonstrated the location of the gating system, which turned out to be on the pommel disk.

Power supplies for dual-frequency induction melting of metals

NASA Astrophysics Data System (ADS)

Lusgin, V. I.; Koptyakov, A. S.; Petrov, A. U.; Zinovev, K. A.; Kamaev, D. A.

2018-02-01

The article discusses the benefits of multi frequency induction melting in the production of synthetic cast iron, structural (electric circuit) principles of dual frequency Power supplies of melting systems. The ways of electric power regulation of low frequency and high frequency components of the current in the inductor sections of furnace are demonstrated, namely power rescheduling at the metal melting stage, alloying stage and decarburizing of synthetic cast iron.

Property enchancement of polyimide films by way of the incorporation of lanthanide metal ions

NASA Technical Reports Server (NTRS)

Thompson, David W.

1993-01-01

Lanthanide metal ions were incorporated into the polyimide derived from 2,2-bis(3,4-dicarboxyphenyl) hexafluoropropane dianhydride (6FDA) and 1,3-bis(aminophenoxy) benzene (APB) in an attempt to produce molecular level metal-polymer composites. The lanthanide series of metal ions (including aluminum, scandium, and yttrium) provide discrete and stable metal ions in the 3+ oxidation state. Throughout the series there is a uniform variation in ionic size ranging from 50 pm for aluminum to a maximum of 103.4 pm for cerium and gradually decreasing again to 84.8 pm for lutetium. The high charge-to-size ratio for these ions as well as the ability to obtain large coordination numbers makes them excellent candidates for interacting with the polymer substructure. The distinct lack of solubility of simple lanthanide salts such as the acetates and halides has made it difficult to obtain metal ions distributed in the polymer framework as discrete ions or metal complexes rather than microcomposites of metal clusters. (Lanthanum nitrates are quite soluble, but the presence of the strongly oxidizing nitrate ion leads to serious degradation of the polymer upon thermal curing. This work was successful at extending the range of soluble metals salts by using chelating agents derived from the beta-diketones dipivaloylmethane, dibenzoylmethane, trifluoroacetylacetone, and hexafluoroacetylacetone. Metal acetates which are insoluble in dimethylacetamide dissolve readily in the presence of the diketones. Addition of the polyimide yields a homogeneous resin which is then cast into a clear film. Upon curing clear films were obtained with the dibenzoylmethane and trifluoroacetylacetone ligands. The dipavaloylmethane precipitates the metal during the film casting process, and hexafluoroacetylacetone gives cured films which are deformed and brittle. These clear films are being evaluated for the effect of the metal ions on the coefficient of thermal expansion, resistance to atomic oxygen, and on selective gas permeability. Much more commonly than above, polyimide films are prepared by casting the film as the poly(amic acid) precursor which is then converted to the imidized form during the thermal cure cycle. Very limited success was achieved in the past in adding lanthanide metal ions to the amide precursors because of gellation and lack of solubility. With the use of the diketone ligands cited above, the solubility and gellation problems were overcome. However, the films after curing were clear but unacceptably brittle. Attempts to overcome this cure embrittlement problem are in progress.

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

The effect of hydrogen peroxide concentration on metal ion release from dental casting alloys.

PubMed

Al-Salehi, S K; Hatton, P V; Johnson, A; Cox, A G; McLeod, C

2008-04-01

There are concerns that tooth bleaching agents may adversely affect dental materials. The aim of this study was to test the hypothesis that increasing concentrations of hydrogen peroxide (HP) are more effective than water at increasing metal ion release from two typical dental casting alloys during bleaching. Discs (n = 28 for each alloy) were prepared by casting and heat treated to simulate a typical porcelain-firing cycle. Discs (n = 7) of each alloy were immersed in either 0%, 3%, 10% or 30% (w/v) HP solutions for 24 h at 37 degrees C. Samples were taken for metal ion release determination using inductively coupled plasma-mass spectrometry and the data analysed using a two-way anova followed by a one-way anova. The surface roughness of each disc was measured using a Talysurf contact profilometer before and after bleaching and the data analysed using a paired t-test. With the exception of gold, the differences in metal ion concentration after treatment with 0% (control) and each of 3%, 10% and 30% HP (w/v) were statistically significant (P < 0.05). Metal ion release from the two alloys increased with increasing HP concentrations (over 3000% increase in Ni and 1400% increase in Pd ions were recorded when HP concentration increased from 0% to 30%). Surface roughness values of the samples before and after bleaching were not significantly different (P > 0.05) Exposure of the two dental casting alloys to HP solutions increased metal ion release of all the elements except gold.

Test and evaluation of Apollo 14 composite casting demonstration specimens and flight and control samples

NASA Technical Reports Server (NTRS)

Fabiniak, R. C.; Fabiniak, T. J.

1971-01-01

The results of experiments 1, 2, and 10 of the Apollo 14 composite casting demonstration are discussed. The purpose of the demonstration, with regard to samples 1 and 2, was to obtain preliminary data on the liquid phase sintering process in a weightless environment. With regard to sample 10, the purpose was to obtain preliminary information on how to achieve uniform dispersion of dense particles on a metal matrix by employing shaking modes or forces in the system when the metal matrix is molten. Results of the demonstrations were interpreted in a quantitative and qualitative manner. For experiment 1 it was found that the tungsten particles were redistributed more uniformly in the flight sample than in the control sample. Experiment 2 results indicate that complete melting may not have occured and thus a high degree of significance cannot be associated with the qualitative results relating to particle redistribution data. The particle-matrix system of experiment 10 was found to be nonwetting.

Theoretical Estimation of the Processes While Using Casting Methods of Obtaining MMC

NASA Astrophysics Data System (ADS)

Popov, V.

2017-08-01

It is a well-known problem that silicone carbide particles are poorly wetted by aluminum melt, which is a main limiting factor for wide use of metal matrix composites within linear technologies. This paper seeks to find a theoretical explanation of this problem. As result, paper recommends to use solid methods for preparation of MMC with nanoreinforcements.

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.

Modeling the spray casting process

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

El-Haggar, S.M.; Muoio, N.; Crowe, C.T.

1995-12-31

Spray forming is a process in which a liquid metal is atomized into very small droplets and deposited on a substrate. These small droplets cool very rapidly in a high velocity gas jet, giving rise to smaller grain structure and improved mechanical properties. This paper presents a numerical model, based on the trajectory approach, for the velocity and thermal properties of the droplets in the jet and predicts the deposition pattern and the state of the droplets upon contact with the substrate.

Evolution of Non-metallic Inclusions and Precipitates in Oriented Silicon Steel

NASA Astrophysics Data System (ADS)

Luo, Yan; Yang, Wen; Ren, Qiang; Hu, Zhiyuan; Li, Ming; Zhang, Lifeng

2018-06-01

The evolution of inclusions in oriented silicon steel during the manufacturing process was carried out by chemical composition analysis, non-aqueous electrolytic corrosion, and thermodynamic calculation. The morphology, composition, and size of inclusions were analyzed introducing field emission scanning electron microscope. The oxides were mainly formed during the secondary refining, and the nitrides, sulfides, and compounds were formed during the solidification and cooling of steel in the processes of continuous casting and hot rolling.

Structure-property characterization of rheocast and VADER processed IN-100 superalloy. Ph.D. Thesis. Final Report

NASA Technical Reports Server (NTRS)

Cheng, J. J. A.; Apelian, D.

1985-01-01

Two recent solidification processes have been applied in the production of IN-100 nickel-base superalloy: rheocasting and vacuum arc double electrode remelting (VADER). A detailed microstructural examination has been made of the products of these two processes; associated tensile strength and fatigue crack propagation (FCP) rate at an elevated temperature were evaluated. In rheocasting, processing variables that have been evaluated include stirring speed, isothermal stirring time and volume fraction solid during isothermal stirring. VADER processed IN-100 was purchased from Special Metals Corp., New Hartford, NY. As-cast ingots were subjected to hot isostatic pressing (HIP) and heat treatment. Both rheocasting and VADER processed materials yield fine and equiaxed spherical structures, with reduced macrosegregation in comparison to ingot materials. The rheocast structures are discussed on the basis of the Vogel-Doherty-Cantor model of dendrite arm fragmentation. The rheocast ingots evaluated were superior in yield strength to both VADER and commercially cast IN-100 alloy. Rheocast and VADER ingots may have higher crack propagation resistance than P/M processed material.

Adjustable hinge permits movement of knee in plaster cast

NASA Technical Reports Server (NTRS)

Maley, W. E.

1967-01-01

Metal knee hinge with an adjustable sleeve worn on the outside of a leg cast facilitates movement of the knee joint. This helps eliminate stiffness of the knee and eliminates bulkiness and adjustment difficulty.

40 CFR 464.41 - Specialized definitions.

Code of Federal Regulations, 2011 CFR

2011-07-01

... AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Zinc Casting Subcategory § 464.41... parameter under PSES (§ 464.45) and PSNS (§ 464.46) for the zinc subcategory and is comprised of a discrete...

40 CFR 464.37 - Effluent limitations guidelines representing the degree of effluent reduction attainable by the...

Code of Federal Regulations, 2010 CFR

2010-07-01

... AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Ferrous Casting Subcategory § 464.37 Effluent limitations guidelines representing the degree of effluent...

Additive Manufacturing of Fuel Injectors

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

Sadek Tadros, Dr. Alber Alphonse; Ritter, Dr. George W.; Drews, Charles Donald

Additive manufacturing (AM), also known as 3D-printing, has been shifting from a novelty prototyping paradigm to a legitimate manufacturing tool capable of creating components for highly complex engineered products. An emerging AM technology for producing metal parts is the laser powder bed fusion (L-PBF) process; however, industry manufacturing specifications and component design practices for L-PBF have not yet been established. Solar Turbines Incorporated (Solar), an industrial gas turbine manufacturer, has been evaluating AM technology for development and production applications with the desire to enable accelerated product development cycle times, overall turbine efficiency improvements, and supply chain flexibility relative to conventionalmore » manufacturing processes (casting, brazing, welding). Accordingly, Solar teamed with EWI on a joint two-and-a-half-year project with the goal of developing a production L-PBF AM process capable of consistently producing high-nickel alloy material suitable for high temperature gas turbine engine fuel injector components. The project plan tasks were designed to understand the interaction of the process variables and their combined impact on the resultant AM material quality. The composition of the high-nickel alloy powders selected for this program met the conventional cast Hastelloy X compositional limits and were commercially available in different particle size distributions (PSD) from two suppliers. Solar produced all the test articles and both EWI and Solar shared responsibility for analyzing them. The effects of powder metal input stock, laser parameters, heat treatments, and post-finishing methods were evaluated. This process knowledge was then used to generate tensile, fatigue, and creep material properties data curves suitable for component design activities. The key process controls for ensuring consistent material properties were documented in AM powder and process specifications. The basic components of the project were: • Powder metal input stock: Powder characterization, dimensional accuracy, metallurgical characterization, and mechanical properties evaluation. • Process parameters: Laser parameter effects, post-printing heat-treatment development, mechanical properties evaluation, and post-finishing technique. • Material design curves: Room and elevated temperature tensiles, low cycle fatigue, and creep rupture properties curves generated. • AM specifications: Key metal powder characteristics, laser parameters, and heat-treatment controls identified.« less

Electron Beam Freeform Fabrication: A Rapid Metal Deposition Process

NASA Technical Reports Server (NTRS)

Taminger, Karen M. B.; Hafley, Robert A.

2003-01-01

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley REsearch Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. The EBF process introduces metal wire feedstock into a molten pool that is created and sustained using a focused electron beam in a vacuum environment. Thus far, this technique has been demonstrated on aluminum and titanium alloys of interest for aerospace structural applications nickel and ferrous based alloys are also planned. Deposits resulting from 2219 aluminum demonstrations have exhibited a range of grain morphologies depending upon the deposition parameters. These materials ave exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF process is capable of bulk metal deposition at deposition rated in excess of 2500 cubic centimeters per hour (150 cubic inches per our) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Composite carbon foam electrode

DOEpatents

Mayer, Steven T.; Pekala, Richard W.; Kaschmitter, James L.

1997-01-01

Carbon aerogels used as a binder for granularized materials, including other forms of carbon and metal additives, are cast onto carbon or metal fiber substrates to form composite carbon thin film sheets. The thin film sheets are utilized in electrochemical energy storage applications, such as electrochemical double layer capacitors (aerocapacitors), lithium based battery insertion electrodes, fuel cell electrodes, and electrocapacitive deionization electrodes. The composite carbon foam may be formed by prior known processes, but with the solid particles being added during the liquid phase of the process, i.e. prior to gelation. The other forms of carbon may include carbon microspheres, carbon powder, carbon aerogel powder or particles, graphite carbons. Metal and/or carbon fibers may be added for increased conductivity. The choice of materials and fibers will depend on the electrolyte used and the relative trade off of system resistivty and power to system energy.

Accuracy of Small Base Metal Dental Castings,

DTIC Science & Technology

1980-07-10

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

Machinability of cast commercial titanium alloys.

PubMed

Watanabe, I; Kiyosue, S; Ohkubo, C; Aoki, T; Okabe, T

2002-01-01

This study investigated the machinability of cast orthopedic titanium (metastable beta) alloys for possible application to dentistry and compared the results with those of cast CP Ti, Ti-6Al-4V, and Ti-6Al-7Nb, which are currently used in dentistry. Machinability was determined as the amount of metal removed with the use of an electric handpiece and a SiC abrasive wheel turning at four different rotational wheel speeds. The ratios of the amount of metal removed and the wheel volume loss (machining ratio) were also evaluated. Based on these two criteria, the two alpha + beta alloys tested generally exhibited better results for most of the wheel speeds compared to all the other metals tested. The machinability of the three beta alloys employed was similar or worse, depending on the speed of the wheel, compared to CP Ti. Copyright 2002 Wiley Periodicals, Inc.

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

PubMed

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

2000-01-01

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

Freckle Defect Formation near the Casting Interfaces of Directionally Solidified Superalloys

PubMed Central

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

2016-01-01

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

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

PubMed

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

2016-11-16

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

Study of Shell Zone Formation in Lithographic and Anodizing Quality Aluminum Alloys: Experimental and Numerical Approach

NASA Astrophysics Data System (ADS)

Brochu, Christine; Larouche, André; Hark, Robert

Shell thickness is an important quality factor for lithographic and anodizing quality aluminum alloys. Increasing pressure is placed on casting plants to produce a thinner shell zone for these alloys. This study, based on plant trials and mathematical modelling highlights the most significant parameters influencing shell zone formation. Results obtained show the importance of metal temperature and distribution and mould metal level on shell zone formation. As an answer to specific plant problems, this study led to the development of improved metal distribution systems for DC casting of litho and anodizing quality alloys.

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

NASA Astrophysics Data System (ADS)

Balout, Bahaa

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

Castable plastic mold with electroplatable base

DOEpatents

Domeier, Linda A.; Morales, Alfredo M.; Gonzales, Marcela G.; Keifer, Patrick M.

2004-01-20

A sacrificial plastic mold having an electroplatable backing is provided as are methods of making such a mold via the infusion of a castable liquid formulation through a porous metal substrate (sheet, screen, mesh or foam) and into the features of a micro-scale master mold. Upon casting and demolding, the porous metal substrate is embedded within the cast formulation and projects a plastic structure with features determined by the mold tool. The plastic structure provides a sacrificial plastic mold mechanically bonded to the porous metal substrate, which provides a conducting support suitable for electroplating either contiguous or non-contiguous metal replicates. After electroplating and lapping, the sacrificial plastic can be dissolved, leaving the desired metal structure bonded to the porous metal substrate. Optionally, the electroplated structures may be debonded from the porous substrate by selective dissolution of the porous substrate or a coating thereon.

Modeling transport phenomena and uncertainty quantification in solidification processes

NASA Astrophysics Data System (ADS)

Fezi, Kyle S.

Direct chill (DC) casting is the primary processing route for wrought aluminum alloys. This semicontinuous process consists of primary cooling as the metal is pulled through a water cooled mold followed by secondary cooling with a water jet spray and free falling water. To gain insight into this complex solidification process, a fully transient model of DC casting was developed to predict the transport phenomena of aluminum alloys for various conditions. This model is capable of solving mixture mass, momentum, energy, and species conservation equations during multicomponent solidification. Various DC casting process parameters were examined for their effect on transport phenomena predictions in an alloy of commercial interest (aluminum alloy 7050). The practice of placing a wiper to divert cooling water from the ingot surface was studied and the results showed that placement closer to the mold causes remelting at the surface and increases susceptibility to bleed outs. Numerical models of metal alloy solidification, like the one previously mentioned, are used to gain insight into physical phenomena that cannot be observed experimentally. However, uncertainty in model inputs cause uncertainty in results and those insights. The analysis of model assumptions and probable input variability on the level of uncertainty in model predictions has not been calculated in solidification modeling as yet. As a step towards understanding the effect of uncertain inputs on solidification modeling, uncertainty quantification (UQ) and sensitivity analysis were first performed on a transient solidification model of a simple binary alloy (Al-4.5wt.%Cu) in a rectangular cavity with both columnar and equiaxed solid growth models. This analysis was followed by quantifying the uncertainty in predictions from the recently developed transient DC casting model. The PRISM Uncertainty Quantification (PUQ) framework quantified the uncertainty and sensitivity in macrosegregation, solidification time, and sump profile predictions. Uncertain model inputs of interest included the secondary dendrite arm spacing, equiaxed particle size, equiaxed packing fraction, heat transfer coefficient, and material properties. The most influential input parameters for predicting the macrosegregation level were the dendrite arm spacing, which also strongly depended on the choice of mushy zone permeability model, and the equiaxed packing fraction. Additionally, the degree of uncertainty required to produce accurate predictions depended on the output of interest from the model.

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

PubMed

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

1975-03-01

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

Use of freeze-casting in advanced burner reactor fuel design

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

Lang, A. L.; Yablinsky, C. A.; Allen, T. R.

2012-07-01

This paper will detail the modeling of a fast reactor with fuel pins created using a freeze-casting process. Freeze-casting is a method of creating an inert scaffold within a fuel pin. The scaffold is created using a directional solidification process and results in open porosity for emplacement of fuel, with pores ranging in size from 300 microns to 500 microns in diameter. These pores allow multiple fuel types and enrichments to be loaded into one fuel pin. Also, each pore could be filled with varying amounts of fuel to allow for the specific volume of fission gases created by thatmore » fuel type. Currently fast reactors, including advanced burner reactors (ABR's), are not economically feasible due to the high cost of operating the reactors and of reprocessing the fuel. However, if the fuel could be very precisely placed, such as within a freeze-cast scaffold, this could increase fuel performance and result in a valid design with a much lower cost per megawatt. In addition to competitive costs, freeze-cast fuel would also allow for selective breeding or burning of actinides within specific locations in fast reactors. For example, fast flux peak locations could be utilized on a minute scale to target specific actinides for transmutation. Freeze-cast fuel is extremely flexible and has great potential in a variety of applications. This paper performs initial modeling of freeze-cast fuel, with the generic fast reactor parameters for this model based on EBR-II. The core has an assumed power of 62.5 MWt. The neutronics code used was Monte Carlo N-Particle (MCNP5) transport code. Uniform pore sizes were used in increments of 100 microns. Two different freeze-cast scaffold materials were used: ceramic (MgO-ZrO{sub 2}) and steel (SS316L). Separate models were needed for each material because the freeze-cast ceramic and metal scaffolds have different structural characteristics and overall porosities. Basic criticality results were compiled for the various models. Preliminary results show that criticality is achievable with freeze-cast fuel pins despite the significant amount of inert fuel matrix. Freeze casting is a promising method to achieve very precise fuel placement within fuel pins. (authors)« less

Present status of titanium removable dentures--a review of the literature.

PubMed

Ohkubo, C; Hanatani, S; Hosoi, T

2008-09-01

Although porcelain and zirconium oxide might be used for fixed partial dental prostheses instead of conventional dental metals in the near future, removable partial denture (RPD) frameworks will probably continue to be cast with biocompatible metals. Commercially pure (CP) titanium has appropriate mechanical properties, it is lightweight (low density) compared with conventional dental alloys, and has outstanding biocompatibility that prevents metal allergic reactions. This literature review describes the laboratory conditions needed for fabricating titanium frameworks and the present status of titanium removable prostheses. The use of titanium for the production of cast RPD frameworks has gradually increased. There are no reports about metallic allergy apparently caused by CP titanium dentures. The laboratory drawbacks still remain, such as the lengthy burn-out, inferior castability and machinability, reaction layer formed on the cast surface, difficulty of polishing, and high initial costs. However, the clinical problems, such as discoloration of the titanium surfaces, unpleasant metal taste, decrease of clasp retention, tendency for plaque to adhere to the surface, detachment of the denture base resin, and severe wear of titanium teeth, have gradually been resolved. Titanium RPD frameworks have never been reported to fail catastrophically. Thus, titanium is recommended as protection against metal allergy, particularly for large-sized prostheses such as RPDs or complete dentures.

Surface quality and microstructure of low-vacuum sintered orthodontic bracket 17-4 PH stainless steel fabricated by MIM process

NASA Astrophysics Data System (ADS)

Suharno, Bambang; Suharno, Lingga Pradinda; Saputro, Hantoro Restucondro; Irawan, Bambang; Prasetyadi, Tjokro; Ferdian, Deni; Supriyadi, Sugeng

2018-02-01

Surface roughness and microstructure play important role on orthodontic bracket quality. Therefore, orthodontic brackets need to have smooth surface roughness to reduce the friction and bacterial adhesion. Microstructure of orthodontic brackets also determine the mechanical properties and corrosion resistance. There are two methods to produce orthodontic bracket, investment casting and metal injection molding. The purpose of this study is to observe the surface roughness and microstructure of orthodontic bracket which were made from two different fabrication methods. To produce orthodontic bracket with metal injection molding method, 17-4 PH stainless steel feedstock was injected to the orthodontic bracket mold using injection molding machine. After injection, the binder was eliminated with solvent and thermal debinding. Solvent debinding process was conducted with hexane at 50 °C on magnetic stirrer for 1.5 hours. Thermal debinding process was conducted at 510 °C with 0.5 °C/min heat rate and 120 min holding time. Hereafter, sintering process were performed with vacuum tube furnace at 1360 °C with heat rate 5 °C/min and 90 min holding time in low vacuum atmosphere. To produce orthodontic bracket with investment casting method, the wax was injected into the mold then the wax pattern was arranged into the tree form. The tree form was then dipped into ceramic slurry and allowed to harden, the ceramic slurry has a thickness in the region of 10 mm. The ceramic mold was then heated at a temperature of over than 1100°C to strengthen the ceramic mold and to remove the remaining wax. After that, the molten 17-4 PH stainless steel was poured into the ceramic mold at a temperature of over 1600°C. The natural cooling process was carried out at temperature of 25°C, after which the ceramic mold was broken away. Then, the orthodontic bracket was cut from the tree form. The results show that the orthodontic bracket which were made with investment casting fabrication method have low porosity, high density, and there is no indication of secondary phase on the microstructure. However, it has rough brackets surface. Whereas, the production of orthodontic brackets using metal injection molding method resulted in better surface roughness. But, it has relatively high porosity, presence of another phase on the microstructure, and low density.

Optimization of permeability for quality improvement by using factorial design

NASA Astrophysics Data System (ADS)

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

2017-05-01

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

Electrically Conductive Polyimide Films Containing Gold Surface

NASA Technical Reports Server (NTRS)

Caplan, Maggie L.; Stoakley, Diane M.; St. Clair, Anne K.

1994-01-01

Polyimide films exhibiting high thermo-oxidative stability and including electrically conductive surface layers containing gold made by casting process. Many variations of basic process conditions, ingredients, and sequence of operations possible, and not all resulting versions of process yield electrically conductive films. Gold-containing layer formed on film surface during cure. These metallic gold-containing polyimides used in film and coating applications requiring electrical conductivity, high reflectivity, exceptional thermal stability, and/or mechanical integrity. They also find commercial potential in areas ranging from thin films for satellite antennas to decorative coatings and packaging.

Corrosion behavior of as-received and previously cast type III gold alloy.

PubMed

Ayad, Mohamed F; Ayad, Ghada M

2010-04-01

The rationale for using gold alloys is based largely upon their alleged ability to resist corrosion, but little information is available to determine the corrosion behavior of recast alloys. This study characterized the elemental composition of as-received and recast type III gold alloy and examined the in vitro corrosion behavior in two media using a potentiodynamic polarization technique. Seventy-eight disk-shaped specimens were prepared from a type III gold alloy under three casting protocols according to the proportion of as-received and recast gold alloy (n = 26). (1) Group as received (100% as-received metal), (2) group 50% to 50% (50% wt. new metal, 50% wt. once recast metal), and (3) group recast (100% once recast metal). The surface structures of 20 specimens from each group were examined under scanning electron microscopy, and their elemental compositions were determined using X-ray energy-dispersive spectroscopy. Further, the potentiodynamic cyclic polarization between -1000 and +1000 mV (SCE) were performed for six specimens from each casting protocol in 0.09% NaCl solution (n = 3) and Fusayama artificial saliva (n = 3) at 37 degrees C. Zero-current potential and corrosion current density were determined. The data were analyzed with 1-way ANOVA and the Ryan-Einot-Gabriel-Welsch multiple-range test t (alpha= 0.05). Elemental composition was significantly different among the casting groups (p < 0.001). The mean weight percentage values were 72.4 to 75.7% Au, 4.5 to 7.0% Pd, 10.7 to 11.1% Ag, 7.8 to 8.4% Cu, and 1.0 to 1.4% Zn. The mean values for Zero-current potential and corrosion current density for all casting protocols were not significant (p > 0.05); however, the difference between the electrolytes was significant (p < 0.001). Fusayama artificial saliva seemed to offer the most corrosive environment. Type III gold alloy in any casting protocol retained passivity under electrochemical conditions similar to the oral environment. Moreover, high-gold type III alloys from reputable manufacturers and recasting protocol tested should produce acceptable corrosion-resistant castings.

Liquid metal magnetohydrodynamics

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

Lielpeteris, J.; Moreau, R.

1989-01-01

Liquid metal MHD is the subject of this book. It is of central importance in fields like metals processing, energy conversion, nuclear engineering (fast breeders or fusion reactors), geomagnetism and astrophysics. In some circumstances fluid flow phenomena are controlled by an existing magnetic field; the melts in induction furnaces or the liquid metal blanket around future tokamak fusion reactors being significant examples. In other cases the application of an external magnetic field (or of an electric current) may generate drastic modifications in the fluid motion and in the transfer rates; such effects may be used to develop new technologies (electromagneticmore » shaping) or to improve existing techniques (electromagnetic stirring in continuous casting). In the core of the Earth, fluid motion and magnetic fields are both present and their interaction governs important phenomena.« less

Low temperature vapor phase digestion of graphite

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

Pierce, Robert A.

2017-04-18

A method for digestion and gasification of graphite for removal from an underlying surface is described. The method can be utilized to remove graphite remnants of a formation process from the formed metal piece in a cleaning process. The method can be particularly beneficial in cleaning castings formed with graphite molding materials. The method can utilize vaporous nitric acid (HNO.sub.3) or vaporous HNO.sub.3 with air/oxygen to digest the graphite at conditions that can avoid damage to the underlying surface.

Metal Matrix Composite Materials for Aerospace Applications

NASA Technical Reports Server (NTRS)

Bhat, Biliyar N.; Jones, C. S. (Technical Monitor)

2001-01-01

Metal matrix composites (MMC) are attractive materials for aerospace applications because of their high specific strength, high specific stiffness, and lower thermal expansion coefficient. They are affordable since complex parts can be produced by low cost casting process. As a result there are many commercial and Department of Defense applications of MMCs today. This seminar will give an overview of MMCs and their state-of-the-art technology assessment. Topics to be covered are types of MMCs, fabrication methods, product forms, applications, and material selection issues for design and manufacture. Some examples of current and future aerospace applications will also be presented and discussed.

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

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

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 channelmore » 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.« less

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

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

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 channelmore » 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.« less

Molten metal injector system and method

DOEpatents

Meyer, Thomas N.; Kinosz, Michael J.; Bigler, Nicolas; Arnaud, Guy

2003-04-01

Disclosed is a molten metal injector system including a holder furnace, a casting mold supported above the holder furnace, and a molten metal injector supported from a bottom side of the mold. The holder furnace contains a supply of molten metal having a metal oxide film surface. The bottom side of the mold faces the holder furnace. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The injector projects into the holder furnace and is in fluid communication with the mold cavity. The injector includes a piston positioned within a piston cavity defined by a cylinder for pumping the molten metal upward from the holder furnace and injecting the molten metal into the mold cavity under pressure. The piston and cylinder are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder further includes a molten metal intake for receiving the molten metal into the piston cavity. The molten metal intake is located below the metal oxide film surface of the molten metal when the holder furnace contains the molten metal. A method of injecting molten metal into a mold cavity of a casting mold is also disclosed.

MOLDS FOR CASTING PLUTONIUM

DOEpatents

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

1962-02-27

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

Comparative Evaluation of Marginal Accuracy of a Cast Fixed Partial Denture Compared to Soldered Fixed Partial Denture Made of Two Different Base Metal Alloys and Casting Techniques: An In vitro Study.

PubMed

Jei, J Brintha; Mohan, Jayashree

2014-03-01

The periodontal health of abutment teeth and the durability of fixed partial denture depends on the marginal adaptation of the prosthesis. Any discrepancy in the marginal area leads to dissolution of luting agent and plaque accumulation. This study was done with the aim of evaluating the accuracy of marginal fit of four unit crown and bridge made up of Ni-Cr and Cr-Co alloys under induction and centrifugal casting. They were compared to cast fixed partial denture (FPD) and soldered FPD. For the purpose of this study a metal model was fabricated. A total of 40 samples (4-unit crown and bridge) were prepared in which 20 Cr-Co samples and 20 Ni-Cr samples were fabricated. Within these 20 samples of each group 10 samples were prepared by induction casting technique and other 10 samples with centrifugal casting technique. The cast FPD samples obtained were seated on the model and the samples were then measured with travelling microscope having precision of 0.001 cm. Sectioning of samples was done between the two pontics and measurements were made, then the soldering was made with torch soldering unit. The marginal discrepancy of soldered samples was measured and all findings were statistically analysed. The results revealed minimal marginal discrepancy with Cr-Co samples when compared to Ni-Cr samples done under induction casting technique. When compared to cast FPD samples, the soldered group showed reduced marginal discrepancy.

Microstructural Analysis of Severe Plastic Deformed Twin Roll Cast AZ31 for the Optimization of Superplastic Properties

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

Young, John P.; Askari, Hesam A.; Heiden, Michael J.

2013-07-08

In recent years magnesium alloys have attracted significant attention as potential candidates to replace many of the heavier metals used in some automotive applications. However, the limited formability of magnesium and its alloys at room temperature has driven interest in the superplastic forming magnesium as an alternative shaping method. Severe plastic deformation techniques have become a well studied method of refining the grain size and modifying the microstructural characteristics of many magnesium alloys to achieve greater superplastic properties. In this study twin roll cast (TRC) AZ31 magnesium alloy was subjected to equal channel angular pressing (ECAP) and friction stir weldingmore » (FSW). The influence of these severe plastic deformation processes on the grain size, texture and grain boundary character distribution was investigated to identify the optimum severe plastic deformation process for the superplastic forming of AZ31.« less

Comparison of optimization algorithms for the slow shot phase in HPDC

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

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

Code of Federal Regulations, 2011 CFR

2011-07-01

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

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

Code of Federal Regulations, 2014 CFR

2014-07-01

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

Thermal and convection analyses of the dendrite remelting rocket experiment; Experiment 74-21 in the space processing rocket program

NASA Technical Reports Server (NTRS)

Grodzka, P. G.; Pond, J. E.; Spradley, J. W.; Johnson, M. H.

1976-01-01

The Dendrite Remelting Rocket Experiment was performed aboard a Black Brant VC Sounding Rocket during a period which gravity levels of approximately 0.00001 g prevailed. The experiment consisted of cooling an aqueous ammonium chloride solution in a manner such that crystallization of ammonium chloride crystals proceeded throughout a three minute period of zero-g. The crystallization process during flight was recorded on 35 mm panatomic-x film. A number of ground crystallizations were similarly recorded for comparison purposes. The convective and thermal conditions in aqueous and metallic liquid systems were assessed under conditions of the flight experiment to help establish the relevance of the rocket experiment to metals casting phenomena. The results indicate that aqueous or metallic convective velocities in the Dendrite Remelting Rocket Experiment cell are of insignificant magnitudes at the 0.0001 to 0.00001 g levels of the experiment. The crystallization phenomena observed in the Rocket Experiment, therefore, may be indicative of how metals will solidify in low-g.

Apparatus And Method For Producing Single Crystal Metallic Objects

DOEpatents

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

2006-03-14

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

Formation Mechanism of Surface Crack in Low Pressure Casting of A360 Alloy

NASA Astrophysics Data System (ADS)

Liu, Shan-Guang; Cao, Fu-Yang; Ying, Tao; Zhao, Xin-Yi; Liu, Jing-Shun; Shen, Hong-Xian; Guo, Shu; Sun, Jian-Fei

2017-12-01

A surface crack defect is normally found in low pressure castings of Al alloy with a sudden contraction structure. To further understand the formation mechanism of the defect, the mold filling process is simulated by a two-phase flow model. The experimental results indicate that the main reason for the defect deformation is the mismatching between the height of liquid surface in the mold and pressure in the crucible. In the case of filling, a sudden contraction structure with an area ratio smaller than 0.5 is obtained, and the velocity of the liquid front increases dramatically with the influence of inertia. Meanwhile, the pressurizing speed in the crucible remains unchanged, resulting in the pressure not being able to support the height of the liquid level. Then the liquid metal flows back to the crucible and forms a relatively thin layer solidification shell on the mold wall. With the increasing pressure in the crucible, the liquid level rises again, engulfing the shell and leading to a surface crack. As the filling velocity is characterized by the damping oscillations, surface cracks will form at different heights. The results shed light on designing a suitable pressurizing speed for the low pressure casting process.

Capacitor with a composite carbon foam electrode

DOEpatents

Mayer, Steven T.; Pekala, Richard W.; Kaschmitter, James L.

1999-01-01

Carbon aerogels used as a binder for granularized materials, including other forms of carbon and metal additives, are cast onto carbon or metal fiber substrates to form composite carbon thin film sheets. The thin film sheets are utilized in electrochemical energy storage applications, such as electrochemical double layer capacitors (aerocapacitors), lithium based battery insertion electrodes, fuel cell electrodes, and electrocapacitive deionization electrodes. The composite carbon foam may be formed by prior known processes, but with the solid partides being added during the liquid phase of the process, i.e. prior to gelation. The other forms of carbon may include carbon microspheres, carbon powder, carbon aerogel powder or particles, graphite carbons. Metal and/or carbon fibers may be added for increased conductivity. The choice of materials and fibers will depend on the electrolyte used and the relative trade off of system resistivity and power to system energy.

Method for fabricating composite carbon foam

DOEpatents

Mayer, Steven T.; Pekala, Richard W.; Kaschmitter, James L.

2001-01-01

Carbon aerogels used as a binder for granularized materials, including other forms of carbon and metal additives, are cast onto carbon or metal fiber substrates to form composite carbon thin film sheets. The thin film sheets are utilized in electrochemical energy storage applications, such as electrochemical double layer capacitors (aerocapacitors), lithium based battery insertion electrodes, fuel cell electrodes, and electrocapacitive deionization electrodes. The composite carbon foam may be formed by prior known processes, but with the solid particles being added during the liquid phase of the process, i.e. prior to gelation. The other forms of carbon may include carbon microspheres, carbon powder, carbon aerogel powder or particles, graphite carbons. Metal and/or carbon fibers may be added for increased conductivity. The choice of materials and fibers will depend on the electrolyte used and the relative trade off of system resistivity and power to system energy.

Capacitor with a composite carbon foam electrode

DOEpatents

Mayer, S.T.; Pekala, R.W.; Kaschmitter, J.L.

1999-04-27

Carbon aerogels used as a binder for granularized materials, including other forms of carbon and metal additives, are cast onto carbon or metal fiber substrates to form composite carbon thin film sheets. The thin film sheets are utilized in electrochemical energy storage applications, such as electrochemical double layer capacitors (aerocapacitors), lithium based battery insertion electrodes, fuel cell electrodes, and electrocapacitive deionization electrodes. The composite carbon foam may be formed by prior known processes, but with the solid particles being added during the liquid phase of the process, i.e. prior to gelation. The other forms of carbon may include carbon microspheres, carbon powder, carbon aerogel powder or particles, graphite carbons. Metal and/or carbon fibers may be added for increased conductivity. The choice of materials and fibers will depend on the electrolyte used and the relative trade off of system resistivity and power to system energy. 1 fig.

Composite carbon foam electrode

DOEpatents

Mayer, S.T.; Pekala, R.W.; Kaschmitter, J.L.

1997-05-06

Carbon aerogels used as a binder for granulated materials, including other forms of carbon and metal additives, are cast onto carbon or metal fiber substrates to form composite carbon thin film sheets. The thin film sheets are utilized in electrochemical energy storage applications, such as electrochemical double layer capacitors (aerocapacitors), lithium based battery insertion electrodes, fuel cell electrodes, and electrocapacitive deionization electrodes. The composite carbon foam may be formed by prior known processes, but with the solid particles being added during the liquid phase of the process, i.e. prior to gelation. The other forms of carbon may include carbon microspheres, carbon powder, carbon aerogel powder or particles, graphite carbons. Metal and/or carbon fibers may be added for increased conductivity. The choice of materials and fibers will depend on the electrolyte used and the relative trade off of system resistivity and power to system energy. 1 fig.

[Measurement of chemical agents in metallurgy field: electric steel plant].

PubMed

Cottica, D; Grignani, E; Ghitti, R; Festa, D; Apostoli, P

2012-01-01

The steel industry maintains its important position in the context of the Italian production involving thousands of workers. The iron and steel processes are divided into primary steel industry, production of intermediate minerals, and secondary steel, scrap from the production of semi-finished industrial and consumer sector (metal inserted into components and metal used for dissipative uses, primarily coatings) and industrial waste. The paper presents the results of environmental monitoring carried out in some electric steel plant for the measurement of airborne chemicals that characterize the occupational exposure of workers employed in particular area like electric oven, to treatment outside the furnace, continuous casting area. For the sampling of the pollutants were used both personal and in fixed positions samplers. The pollutants measured are those typical of steel processes inhalable dust, metals, respirable dust, crystalline silica, but also Polycyclic Aromatic Hydrocarbons (PAH), polychlorinated dioxins (PCDDs) and polychlorinated dibenzofurans (PCDFs).

The three-dimensional morphology of growing dendrites

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

Gibbs, J. W.; Mohan, K. A.; Gulsoy, E. B.

The processes controlling the morphology of dendrites have been of great interest to a wide range of communities, since they are examples of an out-of-equilibrium pattern forming system, there is a clear connection with battery failure processes, and their morphology sets the properties of many metallic alloys. We determine the three-dimensional morphology of free growing metallic dendrites using a novel X-ray tomographic technique that improves the temporal resolution by more than an order of magnitude compared to conventional techniques. These measurements show that the growth morphology of metallic dendrites is surprisingly different from that seen in model systems, the morphologymore » is not self-similar with distance back from the tip, and that this morphology can have an unexpectedly strong influence on solute segregation in castings. As a result, these experiments also provide benchmark data that can be used to validate simulations of free dendritic growth.« less

The three-dimensional morphology of growing dendrites

DOE PAGES

Gibbs, J. W.; Mohan, K. A.; Gulsoy, E. B.; ...

2015-07-03

The processes controlling the morphology of dendrites have been of great interest to a wide range of communities, since they are examples of an out-of-equilibrium pattern forming system, there is a clear connection with battery failure processes, and their morphology sets the properties of many metallic alloys. We determine the three-dimensional morphology of free growing metallic dendrites using a novel X-ray tomographic technique that improves the temporal resolution by more than an order of magnitude compared to conventional techniques. These measurements show that the growth morphology of metallic dendrites is surprisingly different from that seen in model systems, the morphologymore » is not self-similar with distance back from the tip, and that this morphology can have an unexpectedly strong influence on solute segregation in castings. As a result, these experiments also provide benchmark data that can be used to validate simulations of free dendritic growth.« less

Inboard seal mounting

DOEpatents

Hayes, John R.

1983-01-01

A regenerator assembly for a gas turbine engine has a hot side seal assembly formed in part by a cast metal engine block having a seal recess formed therein that is configured to supportingly receive ceramic support blocks including an inboard face thereon having a regenerator seal face bonded thereto. A pressurized leaf seal is interposed between the ceramic support block and the cast metal engine block to bias the seal wear face into sealing engagement with a hot side surface of a rotary regenerator matrix.

Acquisition of a Modified Suction Casting Instrument for the Fabrication of Radiation Tolerant Bulk nNanostructured Metallic Materials

DTIC Science & Technology

2015-01-13

Cu/ Nb films”, Philos. Mag., 84, 1021-1028, (2004). [23] D. H. Ryan, J. M. D. Coey, “Magnetic properties of iron-rich Fe- Zr glasses”, Phys. Rev. B...2226, (1982). [26] K. Fukamichi, R. J. Gambino, T. R. McGuire, “ Electrical resistivity and Hall effect in FeZr amorphous sputtered films”, J. Appl...fabricate several bulk nanostructured metallic materials. In particular we fabricated bulk nanostructured Fe- Zr alloys via suction casting technique. The as

Effects of different production technologies on mechanical and metallurgical properties of precious metal denture alloys

NASA Astrophysics Data System (ADS)

Ferro, Paolo; Battaglia, Eleonora; Capuzzi, Stefano; Berto, Filippo

2017-12-01

Precious metal alloys can be supplied in traditional plate form or innovative drop form with high degree of purity. The aim of the present work is to evaluate the influence of precious metal alloy form on metallurgical and mechanical properties of the final dental products with particular reference to metal-ceramic bond strength and casting defects. A widely used alloy for denture was selected; its nominal composition was close to 55 wt% Pd - 34 wt% Ag - 6 wt% In - 3 wt% Sn. Specimens were produced starting from the alloy in both plate and drop forms. A specific test method was developed to obtain results that could be representative of the real conditions of use. In order to achieve further information about the adhesion behaviour and resistance, the fracture surfaces of the samples were observed using `Scanning Electron Microscopy (SEM)'. Moreover, material defects caused by the moulding process were studied. The form of the alloy before casting does not significantly influence the shear bond strength between the metal and the ceramic material (p-value=0,976); however, according to SEM images, products from drop form alloy show less solidification defects compared to products obtained with plate form alloy. This was attributed to the absence of polluting additives used in the production of drop form alloy. This study shows that the use of precious metal denture alloys supplied in drop form does not affect the metal-ceramic bond strength compared to alloys supplied in the traditional plate form. However, compared to the plate form, the drop form is found free of solidification defects, less expensive to produce and characterized by minor environmental impacts.

Analysis of four dental alloys following torch/centrifugal and induction/ vacuum-pressure casting procedures.

PubMed

Thompson, Geoffrey A; Luo, Qing; Hefti, Arthur

2013-12-01

Previous studies have shown casting methodology to influence the as-cast properties of dental casting alloys. It is important to consider clinically important mechanical properties so that the influence of casting can be clarified. The purpose of this study was to evaluate how torch/centrifugal and inductively cast and vacuum-pressure casting machines may affect the castability, microhardness, chemical composition, and microstructure of 2 high noble, 1 noble, and 1 base metal dental casting alloys. Two commonly used methods for casting were selected for comparison: torch/centrifugal casting and inductively heated/ vacuum-pressure casting. One hundred and twenty castability patterns were fabricated and divided into 8 groups. Four groups were torch/centrifugally cast in Olympia (O), Jelenko O (JO), Genesis II (G), and Liberty (L) alloys. Similarly, 4 groups were cast in O, JO, G, and L by an inductively induction/vacuum-pressure casting machine. Each specimen was evaluated for casting completeness to determine a castability value, while porosity was determined by standard x-ray techniques. Each group was metallographically prepared for further evaluation that included chemical composition, Vickers microhardness, and grain analysis of microstructure. Two-way ANOVA was used to determine significant differences among the main effects. Statistically significant effects were examined further with the Tukey HSD procedure for multiple comparisons. Data obtained from the castability experiments were non-normal and the variances were unequal. They were analyzed statistically with the Kruskal-Wallis rank sum test. Significant results were further investigated statistically with the Steel-Dwass method for multiple comparisons (α=.05). The alloy type had a significant effect on surface microhardness (P<.001). In contrast, the technique used for casting did not affect the microhardness of the test specimen (P=.465). Similarly, the interaction between the alloy and casting technique was not significant (P=.119). A high level of castability (98.5% on average) was achieved overall. The frequency of casting failures as a function of alloy type and casting method was determined. Failure was defined as a castability index score of <100%. Three of 28 possible comparisons between alloy and casting combinations were statistically significant. The results suggested that casting technique affects the castability index of alloys. Radiographic analysis detected large porosities in regions near the edge of the castability pattern and infrequently adjacent to noncast segments. All castings acquired traces of elements found in the casting crucibles. The grain size for each dental casting alloy was generally finer for specimens produced by the induction/vacuum-pressure method. The difference was substantial for JO and L. This study demonstrated a relation between casting techniques and some physical properties of metal ceramic casting alloys. Copyright © 2013 Editorial Council for the Journal of Prosthetic Dentistry. Published by Mosby, Inc. All rights reserved.

Comparison of joint designs for laser welding of cast metal plates and wrought wires.

PubMed

Takayama, Yasuko; Nomoto, Rie; Nakajima, Hiroyuki; Ohkubo, Chikahiro

2013-01-01

The purpose of the present study was to compare joint designs for the laser welding of cast metal plates and wrought wire, and to evaluate the welded area internally using X-ray micro-focus computerized tomography (micro-CT). Cast metal plates (Ti, Co-Cr) and wrought wires (Ti, Co-Cr) were welded using similar metals. The specimens were welded using four joint designs in which the wrought wires and the parent metals were welded directly (two designs) or the wrought wires were welded to the groove of the parent metal from one or both sides (n = 5). The porosity and gap in the welded area were evaluated by micro-CT, and the maximum tensile load of the welded specimens was measured with a universal testing machine. An element analysis was conducted using an electron probe X-ray microanalyzer. The statistical analysis of the results was performed using Bonferroni's multiple comparisons (α = 0.05). The results included that all the specimens fractured at the wrought wire when subjected to tensile testing, although there were specimens that exhibited gaps due to the joint design. The wrought wires were affected by laser irradiation and observed to melt together and onto the filler metal. Both Mo and Sn elements found in the wrought wire were detected in the filler metal of the Ti specimens, and Ni was detected in the filler metal of the Co-Cr specimens. The four joint designs simulating the designs used clinically were confirmed to have adequate joint strength provided by laser welding.

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

NASA Astrophysics Data System (ADS)

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

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

Aluminum Alloy and Article Cast Therefrom

NASA Technical Reports Server (NTRS)

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

2003-01-01

A cast article from an aluminum alloy, which has improved mechanical properties at elevated temperatures, has the following composition in weight percent: Silicon 14 - 25.0, Copper 5.5 - 8.0, Iron 0.05 - 1.2, Magnesium 0.5 - 1.5, Nickel 0.05 - 0.9, Manganese 0.05 - 1.0, Titanium 0.05 - 1.2, Zirconium 0.05 - 1.2, Vanadium 0.05 - 1.2, Zinc 0.05 - 0.9, Phosphorus 0.001 - 0.1, and the balance is Aluminum, wherein the silicon-to-magnesium ratio is 10 - 25, and the copper-to-magnesium ratio is 4 - 15. The aluminum alloy contains a simultaneous dispersion of three types of Al3X compound particles (X=Ti, V, Zr) having a LI2, crystal structure, and their lattice parameters are coherent to the aluminum matrix lattice. A process for producing this cast article is also disclosed, as well as a metal matrix composite, which includes the aluminum alloy serving as a matrix and containing up to about 60% by volume of a secondary filler material.

Effect of minor chemistry elements on GTA weld fusion zone characteristics of a commercial grade titanium

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

Marya, S.K.

1996-06-01

Gas Tungsten Arc Welding (GTAW) is the most common technique employed in the fabrication of rolled thin tubes. One of the major manufacturing problems concerns the stability of weld fusion zone on materials from different casts, notwithstanding stringent monitoring of the process parameters -- current, voltage and travel speed. These parameters determine the theoretical weld heat and are expected to control the instantaneous mass of melt. According to the data compiled by Sahoo et al., oxygen is known to reduce the surface tension of most of the metals. However, investigations on the role of minor changes in concentrations of elementsmore » like sulphur, oxygen, selenium, bismuth, aluminium, and titanium in steels have very often attributed the cast to cast variations to different temperature gradients of surface tension over the weldpool. To the author`s knowledge, no reported work so far has revealed changing weld profiles in autogeneous mechanized GTA welds on titanium due to minor composition changes.« less

Development of automated system based on neural network algorithm for detecting defects on molds installed on casting machines

NASA Astrophysics Data System (ADS)

Bazhin, V. Yu; Danilov, I. V.; Petrov, P. A.

2018-05-01

During the casting of light alloys and ligatures based on aluminum and magnesium, problems of the qualitative distribution of the metal and its crystallization in the mold arise. To monitor the defects of molds on the casting conveyor, a camera with a resolution of 780 x 580 pixels and a shooting rate of 75 frames per second was selected. Images of molds from casting machines were used as input data for neural network algorithm. On the preparation of a digital database and its analytical evaluation stage, the architecture of the convolutional neural network was chosen for the algorithm. The information flow from the local controller is transferred to the OPC server and then to the SCADA system of foundry. After the training, accuracy of neural network defect recognition was about 95.1% on a validation split. After the training, weight coefficients of the neural network were used on testing split and algorithm had identical accuracy with validation images. The proposed technical solutions make it possible to increase the efficiency of the automated process control system in the foundry by expanding the digital database.

Reverse freeze casting: a new method for fabricating highly porous titanium scaffolds with aligned large pores.

PubMed

Yook, Se-Won; Jung, Hyun-Do; Park, Chang-Hoon; Shin, Kwan-Ha; Koh, Young-Hag; Estrin, Yuri; Kim, Hyoun-Ee

2012-07-01

Highly porous titanium with aligned large pores up to 500 μm in size, which is suitable for scaffold applications, was successfully fabricated using the reverse freeze casting method. In this process we have newly developed, the Ti powders migrated spontaneously along the pre-aligned camphene boundaries at a temperature of 45.5°C and formed a titanium-camphene mixture with an aligned structure; this was followed by freeze drying and sintering. As the casting time increased from 24 to 48 h, the initial columnar structures turned into lamellar structures, with the porosity decreasing from 69 to 51%. This reduction in porosity caused the compressive yield strength to increase from 121 to 302 MPa, with an elastic modulus of the samples being in the range of 2-5 GPa. In addition, it was demonstrated that reverse freeze casting can also be successfully applied to various other raw powders, suggesting that the method developed in this work opens up new avenues for the production of a range of porous metallic and ceramic scaffolds with highly aligned pores. Copyright © 2012 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

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.

Surface texture and hardness of dental alloys processed by alternative technologies

NASA Astrophysics Data System (ADS)

Porojan, Liliana; Savencu, Cristina E.; Topală, Florin I.; Porojan, Sorin D.

2017-08-01

Technological developments have led to the implementation of novel digitalized manufacturing methods for the production of metallic structures in prosthetic dentistry. These technologies can be classified as based on subtractive manufacturing, assisted by computer-aided design/computer-aided manufacturing (CAD/CAM) systems, or on additive manufacturing (AM), such as the recently developed laser-based methods. The aim of the study was to assess the surface texture and hardness of metallic structures for dental restorations obtained by alternative technologies: conventional casting (CST), computerized milling (MIL), AM power bed fusion methods, respective selective laser melting (SLM) and selective laser sintering (SLS). For the experimental analyses metallic specimens made of Co-Cr dental alloys were prepared as indicated by the manufacturers. The specimen structure at the macro level was observed by an optical microscope and micro-hardness was measured in all substrates. Metallic frameworks obtained by AM are characterized by increased hardness, depending also on the surface processing. The formation of microstructural defects can be better controlled and avoided during SLM and MIL process. Application of power bed fusion techniques, like SLS and SLM, is currently a challenge in dental alloys processing.

Assessing ecotoxicity and uptake of metals and metalloids in relation to two different earthworm species (Eiseina hortensis and Lumbricus terrestris).

PubMed

Leveque, Thibaut; Capowiez, Yvan; Schreck, Eva; Mazzia, Christophe; Auffan, Mélanie; Foucault, Yann; Austruy, Annabelle; Dumat, Camille

2013-08-01

Due to diffuse atmospheric fallouts of process particles enriched by metals and metalloids, polluted soils concern large areas at the global scale. Useful tools to assess ecotoxicity induced by these polluted soils are therefore needed. Earthworms are currently used as biotest, however the influence of specie and earthworm behaviour, soil characteristics are poorly highlighted. Our aim was therefore to assess the toxicity of various polluted soils with process particles enriches by metals and metalloids (Pb, Cd, Cu, Zn, As and Sb) collected from a lead recycling facility on two earthworm species belonging to different ecological types and thus likely to have contrasted behavioural responses (Eiseina hortensis and Lumbricus terrestris). The combination of behavioural factors measurements (cast production and biomass) and physico-chemical parameters such as metal absorption, bioaccumulation by earthworms and their localization in invertebrate tissues provided a valuable indication of pollutant bioavailability and ecotoxicity. Soil characteristics influenced ecotoxicity and metal uptake by earthworms, as well as their soil bioturbation. Copyright © 2013 Elsevier Ltd. All rights reserved.

Light weight and high strength materials made of recycled steel and aluminum

NASA Astrophysics Data System (ADS)

Nounezi, Thomas

Recycling has proven not only to address today's economical, environmental and social issues, but also to be imperative for the sustainability of human technology. The current thesis has investigated the feasibility of a new philosophy for Recycling (Alloying-Recycling) using steel 1020 and aluminum 6061T6. The study was limited to the metallurgical aspects only and has highlighted the potential of recycled alloys made of recycled aluminum and steel to exhibit substantially increased wear resistance and strength-to-weight ratio as compared to initial primary materials. Three alloy-mixtures are considered: TN3 (5wt% 1020 +95wt% 6061T6); TN5 (0.7wt% 1020 + 99.3wt% 6061T6); and TN4 (10wt% 6061T6 + 90wt% 1020). A Tucker induction power supply system (3kW; 135-400 kHz) is used to melt the alloy mixtures for casting in graphite crucibles. Heat treatment of the cast samples is done using a radiation box furnace. Microscopy, Vickers hardness and pin-on-disc abrasive wear tests are performed. Casting destroyed the initial microstructures of the alloys leading to a hardness reduction in the as-cast and solution heat-treated aluminum rich samples to 60 Hv from 140 Hv. Ageing slightly increased the hardness of the cast samples and provided a wear resistance two times higher than that of the initial 6061T6 material. On the steel rich side, the hardness of the as-cast TN4 was 480 Hv, which is more than twice as high as the initial hardness of steel 1020 of 202 Hv; this hints to strong internal and residual stress, probably martensite formation during fast cooling following casting. Solution heat treatment lowered the hardness to the original value of steel 1020, but provided about ten (10) times higher wear resistance; this suggests higher ductility and toughness of normalised TN4 as compared to 1020. In addition, TN4 exhibits about 25% weight reduction as compared to 1020. The actual recycling process and the effect of non-metallic impurities shall be investigated in future works. Also, the casting and heat treatment processes need to be improved.

Mixed Matrix PVDF Membranes With in Situ Synthesized PAMAM Dendrimer-Like Particles: A New Class of Sorbents for Cu(II) Recovery from Aqueous Solutions by Ultrafiltration.

PubMed

Kotte, Madhusudhana Rao; Kuvarega, Alex T; Cho, Manki; Mamba, Bhekie B; Diallo, Mamadou S

2015-08-18

Advances in industrial ecology, desalination, and resource recovery have established that industrial wastewater, seawater, and brines are important and largely untapped sources of critical metals and elements. A Grand Challenge in metal recovery from industrial wastewater is to design and synthesize high capacity, recyclable and robust chelating ligands with tunable metal ion selectivity that can be efficiently processed into low-energy separation materials and modules. In our efforts to develop high capacity chelating membranes for metal recovery from impaired water, we report a one-pot method for the preparation of a new family of mixed matrix polyvinylidene fluoride (PVDF) membranes with in situ synthesized poly(amidoamine) [PAMAM] particles. The key feature of our new membrane preparation method is the in situ synthesis of PAMAM dendrimer-like particles in the dope solutions prior to membrane casting using low-generation dendrimers (G0 and G1-NH2) with terminal primary amine groups as precursors and epichlorohydrin (ECH) as cross-linker. By using a combined thermally induced phase separation (TIPS) and nonsolvent induced phase separation (NIPS) casting process, we successfully prepared a new family of asymmetric PVDF ultrafiltration membranes with (i) neutral and hydrophilic surface layers of average pore diameters of 22-45 nm, (ii) high loadings (∼48 wt %) of dendrimer-like PAMAM particles with average diameters of ∼1.3-2.4 μm, and (iii) matrices with sponge-like microstructures characteristics of membranes with strong mechanical integrity. Preliminary experiments show that these new mixed matrix PVDF membranes can serve as high capacity sorbents for Cu(II) recovery from aqueous solutions by ultrafiltration.

A cast metal core for a deformed implant body: case report.

PubMed

Soeno, Kohyoh; Jimbo, Ryo; Sawase, Takashi; Taira, Yohsuke

2006-12-01

The present report consists of a clinical evaluation of an osseointegrated implant using a cast metal core instead of abutment for a deformed implant body. The intramobile connector insert for the implant in the mandibular left first premolar region broke 7 years after the superstructure was attached to the implant system. The intramobile connector insert was replaced, and the prosthesis was reattached, but the new intramobile connector insert broke again 2 weeks later. A thorough examination confirmed deformation of the upper section of the implant body in the mandibular left first molar region. Breakage of the new intramobile connector insert in the mandibular left first premolar region was believed to be due to deformation of the implant body in the mandibular left first molar region. Therefore, a cast metal core was used to deal with the deformation of the implant body in this region. Although slight bone resorption was observed around the implant body after 5 years, no major problems were found in the implant body itself.

The benefits of metal-on-metal total hip replacements.

PubMed

Müller, M E

1995-02-01

The Müller's cast prosthesis with a concentric metal-on-metal articulation and 3 sliding bearings was used in Switzerland from 1965 to 1967. During the next 10 to 15 years, a number of hips in which the metal-to-metal systems were implanted were revised. Rather than osteoporosis and cranial migration occurring, the acetabular roofs were often sclerotic and the components showed no or only minor migration. At surgery, the capsule was almost normal and without signs of inflammation. Histologically, the capsule did not show the usual masses of giant cells associated with polyethylene particles. In the mid-1980s, different designs of metal-on-metal articulations were tested. From 1987 to 1990, this author developed, together with the biomaterial division of Sulzer Medical Technology, a pure titanium shell with a polyethylene-backed 28-mm forged cobalt-chromium liner insert. This combination has been successful, with no revisions required to date. In summary, with the present metal-on-metal articulations it is now possible to stop using the polyethylene. The successful long-term results of the cast cobalt-chromium metal-on-metal articulations of 1966 hold much promise for the future of the new-forged, more-precise, metallic socket.

Evaluation of Surface Roughness and Tensile Strength of Base Metal Alloys Used for Crown and Bridge on Recasting (Recycling).

PubMed

Agrawal, Amit; Hashmi, Syed W; Rao, Yogesh; Garg, Akanksha

2015-07-01

Dental casting alloys play a prominent role in the restoration of the partial dentition. Casting alloys have to survive long term in the mouth and also have the combination of structure, molecules, wear resistance and biologic compatibility. According to ADA system casting alloys were divided into three groups (wt%); high noble, Noble and predominantly base metal alloys. To evaluate the mechanical properties such as tensile strength and surface roughness of the new and recast base metal (nickel-chromium) alloys. Recasting of the base metal alloys derived from sprue and button, to make it reusable has been done. A total of 200 test specimens were fabricated using specially fabricated jig of metal and divided into two groups- 100 specimens of new alloy and 100 specimens of recast alloys, which were tested for tensile strength on universal testing machine and surface roughness on surface roughness tester. Tensile strength of new alloy showed no statistically significant difference (p-value>0.05) from recast alloy whereas new alloy had statistically significant surface roughness (Maximum and Average surface roughness) difference (p-value<0.01) as compared to recast alloy. Within the limitations of the study it is concluded that the tensile strength will not be affected by recasting of nickel-chromium alloy whereas surface roughness increases markedly.

Low-head feeding system for thin section castings

DOEpatents

Daniel, Sabah S.; Kleeb, Thomas R.; Lewis, Thomas W.; McDermott, John F.; Ozgu, Mustafa R.; Padfield, Ralph C.; Rego, Donovan N.; Vassilicos, Achilles

1990-01-01

A feed system is provided for conveying molten metal to a thin section caster having mold surfaces moving exclusively in the direction of casting. The feed system has a passage of circular cross section adjacent to one end thereof for receiving molten metal and a rectangular cross section at the delivery end thereof adjacent to the caster. The feed system is designed for supplying molten metal to the caster at low pressure for "closed-pool" type caster operation. The point of highest elevation in the metal flow passage of the feed system is on the upper surface of a transition portion where the cross section changes from circular to rectangular adjacent to the nozzle. The level or height of the high point above the centerline of the nozzle exit is selected so as to be less than the pressure of the metal measured in inches at the nozzle exit. This feature enables the maintenance of positive pressure in the metal within the feed system so that ingress of air into the metal is prevented.

Image Processing Techniques for Assessment of Dental Trays

DTIC Science & Technology

2001-10-25

170 patients having Angle Class I molar relationships with minor malocclusions and teeth including second molars fully erupted without loss of tooth...Abstract-A tray selected for the dental patient must adapt to the curvature of the teeth and allow the impression material to be in appropriate...brands of perforated metal trays with 170 lower arch cast models collected from patients having Angle Class 1 type occlusion with minor malocclusions

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

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

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

1995-09-01

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

Accuracy evaluation of metal copings fabricated by computer-aided milling and direct metal laser sintering systems

PubMed Central

Lee, Wan-Sun; Kim, Woong-Chul

2015-01-01

PURPOSE To assess the marginal and internal gaps of the copings fabricated by computer-aided milling and direct metal laser sintering (DMLS) systems in comparison to casting method. MATERIALS AND METHODS Ten metal copings were fabricated by casting, computer-aided milling, and DMLS. Seven mesiodistal and labiolingual positions were then measured, and each of these were divided into the categories; marginal gap (MG), cervical gap (CG), axial wall at internal gap (AG), and incisal edge at internal gap (IG). Evaluation was performed by a silicone replica technique. A digital microscope was used for measurement of silicone layer. Statistical analyses included one-way and repeated measure ANOVA to test the difference between the fabrication methods and categories of measured points (α=.05), respectively. RESULTS The mean gap differed significantly with fabrication methods (P<.001). Casting produced the narrowest gap in each of the four measured positions, whereas CG, AG, and IG proved narrower in computer-aided milling than in DMLS. Thus, with the exception of MG, all positions exhibited a significant difference between computer-aided milling and DMLS (P<.05). CONCLUSION Although the gap was found to vary with fabrication methods, the marginal and internal gaps of the copings fabricated by computer-aided milling and DMLS fell within the range of clinical acceptance (<120 µm). However, the statistically significant difference to conventional casting indicates that the gaps in computer-aided milling and DMLS fabricated restorations still need to be further reduced. PMID:25932310

Accuracy evaluation of metal copings fabricated by computer-aided milling and direct metal laser sintering systems.

PubMed

Park, Jong-Kyoung; Lee, Wan-Sun; Kim, Hae-Young; Kim, Woong-Chul; Kim, Ji-Hwan

2015-04-01

To assess the marginal and internal gaps of the copings fabricated by computer-aided milling and direct metal laser sintering (DMLS) systems in comparison to casting method. Ten metal copings were fabricated by casting, computer-aided milling, and DMLS. Seven mesiodistal and labiolingual positions were then measured, and each of these were divided into the categories; marginal gap (MG), cervical gap (CG), axial wall at internal gap (AG), and incisal edge at internal gap (IG). Evaluation was performed by a silicone replica technique. A digital microscope was used for measurement of silicone layer. Statistical analyses included one-way and repeated measure ANOVA to test the difference between the fabrication methods and categories of measured points (α=.05), respectively. The mean gap differed significantly with fabrication methods (P<.001). Casting produced the narrowest gap in each of the four measured positions, whereas CG, AG, and IG proved narrower in computer-aided milling than in DMLS. Thus, with the exception of MG, all positions exhibited a significant difference between computer-aided milling and DMLS (P<.05). Although the gap was found to vary with fabrication methods, the marginal and internal gaps of the copings fabricated by computer-aided milling and DMLS fell within the range of clinical acceptance (<120 µm). However, the statistically significant difference to conventional casting indicates that the gaps in computer-aided milling and DMLS fabricated restorations still need to be further reduced.

Materials processing in zero gravity. [space manufacturing

NASA Technical Reports Server (NTRS)

Wuenscher, H. F.

1973-01-01

Manufacturing processes which are expected to show drastic changes in a space environment due to the absence of earth gravity are classified according to (1) buoyancy and thermal convection sensitive processes and (2) processes where molecular forces like cohesion and adhesion remain as the relatively strongest and hence controlling factors. Some specific process demonstration experiments carried out during the Apollo 14 mission and in the Skylab program are described. These include chemical separation by electrophoresis, the M551 metals melting experiment, the M552 exothermic brazing experiment, the M553 sphere forming experiment, the M554 composite casting experiment, and the M555 gallium arsenide crystal growth experiment.

Advances in compact manufacturing for shape and performance controllability of large-scale components-a review

NASA Astrophysics Data System (ADS)

Qin, Fangcheng; Li, Yongtang; Qi, Huiping; Ju, Li

2017-01-01

Research on compact manufacturing technology for shape and performance controllability of metallic components can realize the simplification and high-reliability of manufacturing process on the premise of satisfying the requirement of macro/micro-structure. It is not only the key paths in improving performance, saving material and energy, and green manufacturing of components used in major equipments, but also the challenging subjects in frontiers of advanced plastic forming. To provide a novel horizon for the manufacturing in the critical components is significant. Focused on the high-performance large-scale components such as bearing rings, flanges, railway wheels, thick-walled pipes, etc, the conventional processes and their developing situations are summarized. The existing problems including multi-pass heating, wasting material and energy, high cost and high-emission are discussed, and the present study unable to meet the manufacturing in high-quality components is also pointed out. Thus, the new techniques related to casting-rolling compound precise forming of rings, compact manufacturing for duplex-metal composite rings, compact manufacturing for railway wheels, and casting-extruding continuous forming of thick-walled pipes are introduced in detail, respectively. The corresponding research contents, such as casting ring blank, hot ring rolling, near solid-state pressure forming, hot extruding, are elaborated. Some findings in through-thickness microstructure evolution and mechanical properties are also presented. The components produced by the new techniques are mainly characterized by fine and homogeneous grains. Moreover, the possible directions for further development of those techniques are suggested. Finally, the key scientific problems are first proposed. All of these results and conclusions have reference value and guiding significance for the integrated control of shape and performance in advanced compact manufacturing.

[The design of Co-Cr-Mo alloy combining the framework with porcelain fused to metal restorations and determination of the mechanical properties].

PubMed

Chao, Yong-lie; Lui, Chang-hong; Li, Ning; Yang, Xiao-yu

2005-02-01

To investigate a kind of Co-Cr-Mo alloys used for both porcelain fused to metal (PFM) restorations and casting framework of removable partial dentures. The Co-Cr-Mo alloy underwent the design for elementary compositions of the alloys and the production from the raw materials by means of a vacuum melt furnace. The strength, hardness, plasticity and casting ability of the alloy were examined with metal tensile test. Vickers hardness test and grid casting were examined respectively. The microstructure of the Co-Cr-Mo alloy was also inspected by scanning electron microscope and X-ray diffraction analysis. The elementary composition of DA9-4 alloy mainly consisted of Co 54%-67%, Cr 21%-26%, Mo 5%-8%, W 5%-8%, Si 1%-3%, Mn 0.1%-0.25% and trace elements. The yield strength of the alloy was 584 MPa, while the tensile strength was 736 MPa. The coefficient of expansion was 15.0%, the Vickers hardness reached 322, and the casting ratio exibited 100%. The DA9-4 Co-Cr-Mo alloy used for PFM and framework shown in this paper can meet the clinical demands and have reached the objects of the experiment plan.

METAL PRODUCTION AND CASTING

DOEpatents

Magel, T.T.

1958-03-01

This patent covers a method and apparatus for collecting the molten metal produced by high temperature metal salt reduction. It consists essentially of subjecting the reaction vessel to centrifugal force in order to force the liberatcd molten metal into a coherent molten mass, and allowing it to solidify there. The apparatus is particularly suitable for use with small quantities of rare metals.

High pressure die casting of Fe-based metallic glass.

PubMed

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

2016-10-11

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

High pressure die casting of Fe-based metallic glass

NASA Astrophysics Data System (ADS)

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

2016-10-01

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

High pressure die casting of Fe-based metallic glass

PubMed Central

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

2016-01-01

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

Mechanical characterization of SiC particulate & E-glass fiber reinforced Al 3003 hybrid metal matrix composites

NASA Astrophysics Data System (ADS)

Narayana, K. S. Lakshmi; Shivanand, H. K.

2018-04-01

Metal matrix composites constitute a class of low cost high quality materials which offer high performance for various industrial applications. The orientation of this research is towards the study of mechanical properties of as cast silicon carbide (SiC) particulates and Short E-Glass fibers reinforced Aluminum matrix composites (AMCs). The Hybrid metal matrix composite is developed by reinforcing SiC particulates of 100 microns and short E-Glass fibers of 2-3 mm length with Al 3003 in different compositions. The vortex method of stir casting was employed, in which the reinforcements were introduced into the vortex created by the molten metal by means of mechanical stirrer. The mechanical properties of the prepared metal matrix composites were analyzed. From the studies it was noticed that an improvement in mechanical properties of the reinforced alloys compared to unreinforced alloys.

The effect of water-soluble polymers on the microstructure and properties of freeze-cast alumina ceramics

NASA Astrophysics Data System (ADS)

Pekor, Christopher Michael

Porous ceramics can be divided into three separate classes based on their pore size: microporous ceramics with pores less than 2 nm, mesoporous ceramics with pores in the range of 2--50 nm and macroporous ceramics with pores that are greater than 50 nm. In particular, macroporous ceramics are used in a variety of applications such as refractories, molten metal filtration, diesel particulate filters, heterogeneous catalyst supports and biomedical scaffolds. Freeze casting is a novel method used to create macroporous ceramics. In this method growing ice crystals act as a template for the pores and are solidified, often directionally, through a ceramic dispersion and removed from the green body through a freeze drying procedure. This method has attracted some attention over the past few years due to its relative simplicity, flexibility and environmental friendliness. On top of this freeze casting is capable of producing materials with high pore volume fractions, which is an advantage over processing by packing and necking of particles, where the pore volume fraction is typically less than 50%. Many of the basic processing variables that affect the freeze cast microstructure, such as the temperature gradient, interfacial velocity and solid loading of the dispersion have been well established in the literature. On the other hand, areas such as the effect of additives on the microstructure and mechanical properties have not been covered in great detail. In this study the concept of constitutional supercooling from basic solidification theory is used to explain the effects of two water-soluble polymers, polyethylene glycol and polyvinyl alcohol, on the microstructure of freeze cast alumina ceramics. In addition, changes in the observed microstructure will be related to experimentally determined values of permeability and compressive strength.

Tribological studies of a Zr-based bulk metallic glass with different states

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

Jiang, Feng; Qu, Jun; Fan, Guojiang

The tribological characteristics of a bulk-metallic glass (BMG) Zr52.5Cu17.9Ni14.6Al10.0Ti5.0 (Vit 105) with different states have been studied. Friction and wear tests were conducted using a ball-on-flat reciprocating sliding apparatus against AISI E52100 bearing steel under dry condition. The observed wear resistance in an ascending order is deformed, crept, relaxed, and as-cast. Results suggested that the wear process of BMG alloys involved abrasion, adhesion, and oxidation. The differences in hardness, free volume, and embrittlement at different states significantly affected the friction and wear behaviors of the BMG alloys.

Characteristics comparison of weld metal zones welded to cast and forged steels for piston crown material

NASA Astrophysics Data System (ADS)

Moon, Kyung-Man; Kim, Yun-Hae; Lee, Myeong-Hoon; Baek, Tae-Sil

2015-03-01

An optimum repair welding for the piston crown which is one of the engine parts exposed to the combustion chamber is considered to be very important to prolong the engine lifetime from an economical point of view. In this study, two types of filler metals such as 1.25Cr-0.5Mo, 0.5Mo were welded with SMAW method and the other two types of filler metals such as Inconel 625 and 718 were welded with GTAW method, respectively, and the used base metals were the cast and forged steels of the piston crown material. The weld metal zones welded with Inconel 625 and 718 filler metals exhibited higher corrosion resistance compared to 1.25Cr-0.5Mo and 0.5Mo filler metals. In particular, the weld metal zone welded with Inconel 718 and 0.5Mo, filler metals indicated the best and worst corrosion resistance, respectively. Consequently, it is suggested that the corrosion resistance of the weld metal zone surely depends on the chemical components of each filler metal and welding method irrespective of the types of piston crown material.

Numerical simulation of turbulent flow and heat transfer in the wedge-shaped liquid metal pool of a twin-roll caster

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

Seyedein, S.H.; Hasan, H.

1997-03-01

Controlled flow and heat transfer are important for the quality of a strip in a twin-roll continuous casting process. A numerical study was carried out to investigate the two-dimensional turbulent flow and heat transfer in the liquid stainless-steel-filled wedge-shaped cavity formed by the two counterrotating rolls in a twin-roll continuous casting system. The turbulent characteristics of the flow were modeled using a low-Reynolds-number {kappa}-{epsilon} turbulence model due to Launder and Sharma. The arbitrary nature of the computational domain was accounted for through the use of a nonorthogonal boundary-fitted coordinate system on a staggered grid. A control-volume-based finite difference scheme wasmore » used to solve the transformed transport equations. This study is primarily focused on elucidating the inlet superheat dissipation in the melt pool with the rolls being maintained at a constant liquidus temperature of the steel. A parametric study was carried out to ascertain the effect of the inlet superheat, the casting speed, and the roll gap at the nip of the rotating rolls on the flow and heat transfer characteristics. The velocity fields show two counterrotating recirculation zones in the upstream region. The local Nusselt number on the roll surface shows significant variations. The contours of temperature and turbulent viscosity show the complex nature of the turbulent transport phenomena to be expected in a twin-roll casting process.« less

New method for shielding electron beams used for head and neck cancer treatment.

PubMed

Farahani, M; Eichmiller, F C; McLaughlin, W L

1993-01-01

Shields and stents of metals with high atomic number, which are custom cast in molds from the melt, are the materials most widely used to protect surrounding tissues during treatment of skin or oral lesions with therapeutic electron beams. An improved fabrication method is to mix a polysiloxane-metal composite, which is readily cast at room temperature by combining a metal-powder/polysiloxane resin mixture with a hardening catalyst. The purpose of the present study is to compare the shielding effectiveness of two different metal-polysiloxane composites with that of conventional cast Lipowitz metal (50.1% Bi, 26.6% Pb, 13.3% Sn, 10% Cd). Also, a 2(3) factorial experiment was run to investigate the effects and interactions of metal particle size (20-microns vs 100-microns diameter), the atomic weight of the metal (304 stainless steel vs 70% Ag, 30% Cu alloy), and the presence or absence of a layer of unfilled polymer added to the forward-scatter side of the shield. The composites of different thicknesses were made by blending 90% (w/w) metal powder separately with 10% polysiloxane base and catalyst. A thin GafChromic dosimeter film was placed between the shielding material and a polystyrene base to measure the radiation shielding effect of composite disc samples irradiated with a 6-MeV electron beam normal to the flat surface of the disc. The results show that composite shields with the metal of higher atomic weight and density (Ag-Cu) combined with an additional unfilled layer are more effective than the stainless-steel composite with a similar additional unfilled layer, in terms of diminishing the dose at the surface of the polystyrene backing material.(ABSTRACT TRUNCATED AT 250 WORDS)

Novel technologies for the lost foam casting process

NASA Astrophysics Data System (ADS)

Jiang, Wenming; Fan, Zitian

2018-03-01

Lost foam casting (LFC) is a green precision casting process categorized as a near net forming technology. Yet, despite its popularity, it still suffers from some technological problems, such as poor filling ability of the castings, coarse and non-dense microstructure, low mechanical properties for the Al and Mg LFC processes, and defective carburization for the low carbon steel LFC process. These drawbacks restrict the development and widespread application of the LFC process. To solve these problems, the present study developed several novel LFC technologies, namely, LFC technologies under vacuum and low pressure, vibration solidification, and pressure solidification conditions; expendable shell casting technology; and preparation technology of bimetallic castings based on the LFC process. The results showed that the LFC under vacuum and low pressure evidently improved the filling ability and solved the oxidization problem of the alloys, which is suitable for producing complex and thinwall castings. The vibration and pressure solidifications increased the compactness of the castings and refined the microstructure, significantly improving the mechanical properties of the castings. The expendable shell casting technology could solve the pore, carburization, and inclusion defects of the traditional LFC method, obtaining castings with acceptable surface quality. Moreover, the Al/Mg and Al/Al bimetallic castings with acceptable metallurgical bonding were successfully fabricated using the LFC process. These proposed novel LFC technologies can solve the current technological issues and promote the technological progress of the LFC process.

Controlled Directional Solidification of Aluminum - 7 wt Percent Silicon Alloys: Comparison Between Samples Processed on Earth and in the Microgravity Environment Aboard the International Space Station

NASA Technical Reports Server (NTRS)

Grugel, Richard N.; Tewari, Surendra N.; Erdman, Robert G.; Poirier, David R.

2012-01-01

An overview of the international "MIcrostructure Formation in CASTing of Technical Alloys" (MICAST) program is given. Directional solidification processing of metals and alloys is described, and why experiments conducted in the microgravity environment aboard the International Space Station (ISS) are expected to promote our understanding of this commercially relevant practice. Microstructural differences observed when comparing the aluminum - 7 wt% silicon alloys directionally solidified on Earth to those aboard the ISS are presented and discussed.

Sidewall containment of liquid metal with horizontal alternating magnetic fields

DOEpatents

Pareg, Walter F.

1990-01-01

An apparatus for confining molten metal with a horizontal alternating magnetic field. In particular, this invention employs a magnet that can produce a horizontal alternating magnetic field to confine a molten metal at the edges of parallel horizontal rollers as a solid metal sheet is cast by counter-rotation of the rollers.

Sidewall containment of liquid metal with horizontal alternating magnetic fields

DOEpatents

Praeg, Walter F.

1995-01-01

An apparatus for confining molten metal with a horizontal alternating magnetic field. In particular, this invention employs a magnet that can produce a horizontal alternating magnetic field to confine a molten metal at the edges of parallel horizontal rollers as a solid metal sheet is cast by counter-rotation of the rollers.

77 FR 32942 - Application(s) for Duty-Free Entry of Scientific Instruments

Federal Register 2010, 2011, 2012, 2013, 2014

2012-06-04

.... Intended Use: The instrument will be used to fabricate bulk nanostructured metals and metallic glasses, in particular Mg based alloys, CuNb, NiAl, Nb based alloys and metal matrix composites with oxide nanoparticles... oxide nanoparticles during the melting of metals. Suction casting is required to achieve nanocrystalline...

Some methods of increasing the density of metal in order to increase him corrosion resistance

NASA Astrophysics Data System (ADS)

Chumanov, I. V.; Anikeev, A. N.; Sergeev, D. V.; Maltseva, A. N.

2017-11-01

Methods to increase the density of metal in order to increase its corrosion resistance in an aggressive environment are examined in the article. Two steel grades, differing in the content of alloying elements, increasing the resistance to corrosion are selected for the manufacture of experimental metallic materials. Two technologies are chosen as methods for increasing the density, and as a result, corrosion resistance, of the experimental materials obtained: the first is electroslag remelting with rotation of the consumable electrode, the second is centrifugal casting with modification. The microstructure of the metal becomes more homogeneous, the degree of metal refining from non-metallic inclusions increases, the rate of crystallization during metal smelting by the ESR method increases with rotation of the consumable electrode. When ingots are produced by the method of centrifugal casting, they are modified with dispersed WC and TiC particles, which increases the crystallization rate, increases the metal density, corrosion and mechanical properties. The evaluation of their corrosion resistance with the help of the autoclaved test complex “Cortest” is made after obtaining ingots by various technologies.

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

PubMed

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

2011-06-01

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

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.

Three-Dimensional Analysis of Voids in AM60B Magnesium Tensile Bars Using Computed Tomography Imagery

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

Waters, A M

2001-05-01

In an effort to increase automobile fuel efficiency as well as decrease the output of harmful greenhouse gases, the automotive industry has recently shown increased interest in cast light metals such as magnesium alloys in an effort to increase weight savings. Currently several magnesium alloys such as AZ91 and AM60B are being used in structural applications for automobiles. However, these magnesium alloys are not as well characterized as other commonly used structural metals such as aluminum. This dissertation presents a methodology to nondestructively quantify damage accumulation due to void behavior in three dimensions in die-cast magnesium AM60B tensile bars asmore » a function of mechanical load. Computed tomography data was acquired after tensile bars were loaded up to and including failure, and analyzed to characterize void behavior as it relates to damage accumulation. Signal and image processing techniques were used along with a cluster labeling routine to nondestructively quantify damage parameters in three dimensions. Void analyses were performed including void volume distribution characterization, nearest neighbor distance calculations, shape parameters, and volumetric renderings of voids in the alloy. The processed CT data was used to generate input files for use in finite element simulations, both two- and three-dimensional. The void analyses revealed that the overwhelming source of failure in each tensile bar was a ring of porosity within each bar, possibly due to a solidification front inherent to the casting process. The measured damage parameters related to void nucleation, growth, and coalescence were shown to contribute significantly to total damage accumulation. Void volume distributions were characterized using a Weibull function, and the spatial distributions of voids were shown to be clustered. Two-dimensional finite element analyses of the tensile bars were used to fine-tune material damage models and a three-dimensional mesh of an extracted portion of one tensile bar including voids was generated from CT data and used as input to a finite element analysis.« less

Feasibility study on development of metal matrix composite by microwave stir casting

NASA Astrophysics Data System (ADS)

Lingappa, S. M.; Srinath, M. S.; Amarendra, H. J.

2018-04-01

Need for better service oriented materials has boosted the demand for metal matrix composite materials, which can be developed to have necessary properties. One of the most widely utilized metal matrix composite is Al-SiC, which is having a matrix made of aluminium metal and SiC as reinforcement. Lightweight and conductivity of aluminium, when combined with hardness and wear resistance of SiC provides an excellent platform for various applications in the field of electronics, automotives, and aerospace and so on. However, uniform distribution of reinforcement particles is an issue and has to be addressed. The present study is an attempt made to develop Al-SiC metal matrix composite by melting base metal using microwave hybrid heating technique, followed by addition of reinforcement and stirring the mixture for obtaining homogenous mixture. X-Ray Diffraction analysis shows the presence of aluminium and SiC in the cast material. Further, microstructural study shows the distribution of SiC particles in the grain boundaries.

Space Processing Applications Rocket project, SPAR 1

NASA Technical Reports Server (NTRS)

Reeves, F. (Compiler); Chassay, R. (Compiler)

1976-01-01

The experiment objectives, design/operational concepts, and final results of each of nine scientific experiments conducted during the first Space Processing Applications Rocket (SPAR) flight are summarized. The nine individual SPAR experiments, covering a wide and varied range of scientific materials processing objectives, were entitled: solidification of Pb-Sb eutectic, feasibility of producing closed-cell metal foams, characterization of rocket vibration environment by measurement of mixing of two liquids, uniform dispersions of crystallization processing, direct observation of solidification as a function of gravity levels, casting thoria dispersion-strengthened interfaces, contained polycrystalline solidification, and preparation of a special alloy for manufacturing of magnetic hard superconductor under zero-g environment.

One-piece, composite crucible with integral withdrawal/discharge section

DOEpatents

Besser, Matthew; Terpstra, Robert L.; Sordelet, Daniel J.; Anderson, Iver E.; Hartman, Alan D.; Argetsinger, Edward R.; Hansen, Jeffrey S.; Paige, Jack I.; Turner, Paul C.

2002-07-30

A one-piece, composite open-bottom casting mold with integral withdrawal section is fabricated by thermal spraying of materials compatible with and used for the continuous casting of shaped products of reactive metals and alloys such as, for example, titanium and its alloys or for the gas atomization thereof.

Evaluation and comparison of castability between an indigenous and imported Ni-Cr alloy.

PubMed

Ramesh, Ganesh; Padmanabhan, T V; Ariga, Padma; Subramanian, R

2011-01-01

Since 1907 casting restorations have been in use in dentistry. Numerous companies have been manufacturing and marketing base metal alloys. Gold was a major component of casting alloys. But alloys with less than 65% gold tarnished easily and the increase in cost of gold post-1970s lead to the revival of base metal alloys such as nickel-chromium and cobalt-chromium alloys which were in use since 1930s. This study was conducted to evaluate and compare the castability between an indigenous alloy and an imported alloy, as imported base metal alloys are considered to be expensive for fabrication of crowns and bridges. This study was conducted to evaluate and compare the castability (for the accurate fabrication of crowns and bridges) between an indigenous base metal alloy-Non-ferrous Materials Technology Development Centre (NFTDC), Hyderabad (Alloy A) -and an imported base metal alloys (Alloy B). Castability measurement was obtained by counting the number of completely formed line segments surrounding the 81 squares in the pattern and later calculating the percentage values. The percentage obtained was taken as the castability value for a particular base metal alloy. The percentage of castability was determined by counting only the number of completely cast segments in a perfect casting (81 × 2 = 162), and then multiplying the resulting fraction by 100 to give the percentage completeness. The Student t-test was used. When the castability of alloys A and B was compared, the calculated value was less than the tabular value (1.171 < 2.048) leading to the conclusion that castability between alloys A and B is insignificant. Therefore we conclude that both the alloys have the same castability. Using the above-mentioned materials and following the method to test castability, we were able to derive favorable results. As the results were satisfactory, we can conclude that the castability of the indigenous alloy is on par with the imported alloy.

The role of heat transfer in strip casting

NASA Astrophysics Data System (ADS)

Misra, Paretosh

The last few years have witnessed rapid developments in the area of strip casting of steel. It involves smaller capital and operating cost, lower greenhouse gas emissions, and an opportunity to create newer products due to a faster solidification rate that leads to a different solidification structure. Thus, ample reasons for interest in the technology exist. At the same time, it needs to be determined if the properties of a strip cast product can match those of a conventional product and if it is possible to produce steel strip at high production rates. The first objective of this work was to characterize the quality, structure, and properties of strip cast material of different chemistries and cast at different machines, to identify the critical operating conditions that would result in the best properties. Determination of the possible range of properties was also aimed, given that the structure of the material is different from the traditional material. The second objective was to investigate ways to increase the rate of heat transfer in strip casting, as that will also enhance the productivity of a strip caster. It was also envisaged to see what effect a high rate of heat transfer will have on the properties of the strip cast material. Results from the strip cast material characterization that was carried out to achieve the first objective indicated that an effective control of heat transfer is very important to get the best properties. Samples that showed best properties had a uniform solidification structure consisting of columnar grains running from the edge of a strip to the centerline, indicating a good control of heat transfer, and their dendrite spacings pointed towards a relatively faster rate of cooling between the rolls. These findings indicated that heat transfer is a core issue in strip casting. The mechanism of increase in the rate of heat transfer in strip casting due to the presence of liquid oxide films at the metal-mold interface was examined. It was discovered that these films originate from the metal itself. A high degree of interdendritic supersaturation can lead to the formation of low melting point oxide phases by the deoxidizing agents in the steel. As the temperature lowers further the film may get ejected out of the metal due to the non-wetting of the metal by the oxide phase. If enough oxide film can be generated then this can result in an almost two-fold increase in the rate of heat transfer during initial solidification---the first 20 milliseconds. The results indicate that if a proper control of these films is ensured then it provides an attractive alternative to increasing the roll diameter as a mechanism of increasing the rate of production of a strip caster. This mechanism will work even with smaller diameter rolls, in fact, perhaps better in that case due to a smaller interface area over which uniformity of heat transfer has to be ensured, thus leveraging its full advantages. If successfully implemented at a plant, this technique can help the strip casting machines to increase their productivity and emerge as a competitive technology to produce steel strip.

The Prediction of Long-Term Thermal Aging in Cast Austenitic Stainless Steel

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

Byun, Thak Sang; Yang, Ying; Lach, Timothy G.

Cast austenitic stainless steel (CASS) materials are extensively used for many massive primary coolant system components of light water reactors (LWRs) including coolant piping, valve bodies, pump casings, and piping elbows. Many of these components are operated in complex and persistently damaging environments of elevated temperature, high pressure, corrosive environment, and sometimes radiation for long periods of time. Since a large number of CASS components are installed in every nuclear power plant and replacing such massive components is prohibitively expensive, any significant degradation in mechanical properties that affects structural integrity, cracking resistance in particular, of CASS components will raise amore » serious concern on the performance of entire power plant. The CASS materials for nuclear components are highly corrosion-resistant Fe-Cr-Ni alloys with 300 series stainless steel compositions and mostly austenite (γ)–ferrite (δ) duplex structures, which result from the casting processes consisting of alloy melting and pouring or injecting liquid metal into a static or spinning mold. Although the commonly used static and centrifugal casting processes enable the fabrication of massive components with proper resistance to environmental attacks, the alloying and microstructural conditions are not highly controllable in actual fabrication, especially in the casting processes of massive components. In the corrosion-resistant Fe-Cr-Ni alloy system, the minor phase (i.e., the δ-ferrite phase) is inevitably formed during the casting process, and is in a non-equilibrium state subject to detrimental changes during exposure to elevated temperature and/or radiation. In general, relatively few critical degradation modes are expected within the current design lifetime of 40 years, given that the CASS components have been processed properly. It has been well known, however, that both the thermal aging and the neutron irradiation can cause degradation of static and impact toughness in the cast stainless steels, and if combined with any flaws formed during the fabrication process or in service, the thermal degradation in CASS components can be a serious concern for the integrity of the power plant. On the integrity of the CASS components during the extended lifetime of 60 years or longer, no conclusive prediction has been possible, primarily because no direct experience with these materials currently exists, and the aging behavior of CASS alloys still remains largely uncertain. The ongoing research for CASS aging, as part of the LWRS Program/Materials Aging and Degradation Pathway, is an integrated research using holistic experimental and modeling means to provide both the scientific understanding on the aging and failure phenomena and the practical models to predict the degree of property degradation.« less

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

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

Kuyucak, Selcuk; Li, Delin

2013-12-31

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

Biocompatibility of Advanced Manufactured Titanium Implants-A Review.

PubMed

Sidambe, Alfred T

2014-12-19

Titanium (Ti) and its alloys may be processed via advanced powder manufacturing routes such as additive layer manufacturing (or 3D printing) or metal injection moulding. This field is receiving increased attention from various manufacturing sectors including the medical devices sector. It is possible that advanced manufacturing techniques could replace the machining or casting of metal alloys in the manufacture of devices because of associated advantages that include design flexibility, reduced processing costs, reduced waste, and the opportunity to more easily manufacture complex or custom-shaped implants. The emerging advanced manufacturing approaches of metal injection moulding and additive layer manufacturing are receiving particular attention from the implant fabrication industry because they could overcome some of the difficulties associated with traditional implant fabrication techniques such as titanium casting. Using advanced manufacturing, it is also possible to produce more complex porous structures with improved mechanical performance, potentially matching the modulus of elasticity of local bone. While the economic and engineering potential of advanced manufacturing for the manufacture of musculo-skeletal implants is therefore clear, the impact on the biocompatibility of the materials has been less investigated. In this review, the capabilities of advanced powder manufacturing routes in producing components that are suitable for biomedical implant applications are assessed with emphasis placed on surface finishes and porous structures. Given that biocompatibility and host bone response are critical determinants of clinical performance, published studies of in vitro and in vivo research have been considered carefully. The review concludes with a future outlook on advanced Ti production for biomedical implants using powder metallurgy.

Biocompatibility of Advanced Manufactured Titanium Implants—A Review

PubMed Central

Sidambe, Alfred T.

2014-01-01

Titanium (Ti) and its alloys may be processed via advanced powder manufacturing routes such as additive layer manufacturing (or 3D printing) or metal injection moulding. This field is receiving increased attention from various manufacturing sectors including the medical devices sector. It is possible that advanced manufacturing techniques could replace the machining or casting of metal alloys in the manufacture of devices because of associated advantages that include design flexibility, reduced processing costs, reduced waste, and the opportunity to more easily manufacture complex or custom-shaped implants. The emerging advanced manufacturing approaches of metal injection moulding and additive layer manufacturing are receiving particular attention from the implant fabrication industry because they could overcome some of the difficulties associated with traditional implant fabrication techniques such as titanium casting. Using advanced manufacturing, it is also possible to produce more complex porous structures with improved mechanical performance, potentially matching the modulus of elasticity of local bone. While the economic and engineering potential of advanced manufacturing for the manufacture of musculo-skeletal implants is therefore clear, the impact on the biocompatibility of the materials has been less investigated. In this review, the capabilities of advanced powder manufacturing routes in producing components that are suitable for biomedical implant applications are assessed with emphasis placed on surface finishes and porous structures. Given that biocompatibility and host bone response are critical determinants of clinical performance, published studies of in vitro and in vivo research have been considered carefully. The review concludes with a future outlook on advanced Ti production for biomedical implants using powder metallurgy. PMID:28788296

Porosity inside a metal casting

NASA Technical Reports Server (NTRS)

2003-01-01

Pores and voids often form in metal castings on Earth (above) making them useless. A transparent material that behaves at a large scale in microgravity the way that metals behave at the microscopic scale on Earth, will help show how voids form and learn how to prevent them. Scientists are using the microgravity environment on the International Space Station to study how these bubbles form, move and interact. The Pore Formation and Mobility Investigation (PFMI) in the Microgravity Science Glovebox aboard the International Space Station uses a transparent material called succinonitrile that behaves like a metal to study this problem. Video images sent to the ground allow scientists to watch the behavior of the bubbles as they control the melting and freezing of the material. The bubbles do not float to the top of the material in microgravity, so they can study their interactions.

Recycle of radioactive scrap metal from the Oak Ridge Gaseous Diffusion Plant (K-25 Site)

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

Meehan, R.W.

1997-02-01

The scale of the metal available for reuse at the plant includes 22 million pounds of Ni, 17 million pounds of Al, 47 million pounds of copper, and 835 million pounds of steels. In addition there is a wide range of industrial equipment and other items of value. The author describes small bench scale and pilot plant scale efforts made at treating metal for decontamination and fabrication into cast stock or specialized containers for reuse within the DOE complex or release. These projects show that much of the material can be cleaned or chemically decontaminated to a level where itmore » can be free released to various markets. Of the remaining metals, much of it can be cast into products which can be absorbed within the DOE complex.« less

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.

Chemical segregation in metallic glass nanowires.

PubMed

Zhang, Qi; Li, Qi-Kai; Li, Mo

2014-11-21

Nanowires made of metallic glass have been actively pursued recently due to the superb and unique properties over those of the crystalline materials. The amorphous nanowires are synthesized either at high temperature or via mechanical disruption using focused ion beam. These processes have potential to cause significant changes in structure and chemical concentration, as well as formation of defect or imperfection, but little is known to date about the possibilities and mechanisms. Here, we report chemical segregation to surfaces and its mechanisms in metallic glass nanowires made of binary Cu and Zr elements from molecular dynamics simulation. Strong concentration deviation are found in the nanowires under the conditions similar to these in experiment via focused ion beam processing, hot imprinting, and casting by rapid cooling from liquid state. Our analysis indicates that non-uniform internal stress distribution is a major cause for the chemical segregation, especially at low temperatures. Extension is discussed for this observation to multicomponent metallic glass nanowires as well as the potential applications and side effects of the composition modulation. The finding also points to the possibility of the mechanical-chemical process that may occur in different settings such as fracture, cavitation, and foams where strong internal stress is present in small length scales.

Investigation of americium-241 metal alloys for target applications. [Alloys with cerium

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

Conner, W.V.

1980-01-01

Several americium-241 metal alloys have been investigated for possible use in the Lawrence Livermore National Laboratory Radiochemical Diagnostic Tracer Program. Alloys investigated have included uranium-americium, aluminum-americium, and cerium-americium. Uranium-americium alloys with the desired properties proved to be difficult to prepare, and work with this alloy was discontinued. Aluminum-americium alloys were much easier to prepare, but the alloy consisted of an aluminum-americium intermetallic compound (AmAl/sub 4/) in an aluminum matrix. This alloy could be cast and formed into shapes, but the low density of aluminum, and other problems; made the alloy unsuitable for the intended application. Americium metal was found tomore » have a high solid solubility in cerium and alloys prepared from these two elements exhibited all of the properties desired for the tracer program application. Cerium-americium alloys containing up to 34 wt % americium have been prepared using both comelting and coreduction techniques. The latter technique involves coreduction of Ce F/sub 4/ and AmF/sub 4/ with calcium metal in a sealed reduction vessel. Casting techniques have been developed for preparing up to eight 0.87 inch (2.2 cm) diameter disks in a single casting, and cerium-americium metal alloy disks containing from 10 to 25 wt % americium-241 have been prepared using these techniques.« less

Evaluation of Surface Roughness and Tensile Strength of Base Metal Alloys Used for Crown and Bridge on Recasting (Recycling)

PubMed Central

Hashmi, Syed W.; Rao, Yogesh; Garg, Akanksha

2015-01-01

Background Dental casting alloys play a prominent role in the restoration of the partial dentition. Casting alloys have to survive long term in the mouth and also have the combination of structure, molecules, wear resistance and biologic compatibility. According to ADA system casting alloys were divided into three groups (wt%); high noble, Noble and predominantly base metal alloys. Aim To evaluate the mechanical properties such as tensile strength and surface roughness of the new and recast base metal (nickel-chromium) alloys. Materials and Methods Recasting of the base metal alloys derived from sprue and button, to make it reusable has been done. A total of 200 test specimens were fabricated using specially fabricated jig of metal and divided into two groups- 100 specimens of new alloy and 100 specimens of recast alloys, which were tested for tensile strength on universal testing machine and surface roughness on surface roughness tester. Results Tensile strength of new alloy showed no statistically significant difference (p-value>0.05) from recast alloy whereas new alloy had statistically significant surface roughness (Maximum and Average surface roughness) difference (p-value<0.01) as compared to recast alloy. Conclusion Within the limitations of the study it is concluded that the tensile strength will not be affected by recasting of nickel-chromium alloy whereas surface roughness increases markedly. PMID:26393194

Internal fit of three-unit fixed dental prostheses produced by computer-aided design/computer-aided manufacturing and the lost-wax metal casting technique assessed using the triple-scan protocol.

PubMed

Dahl, Bjørn E; Dahl, Jon E; Rønold, Hans J

2018-02-01

Suboptimal adaptation of fixed dental prostheses (FDPs) can lead to technical and biological complications. It is unclear if the computer-aided design/computer-aided manufacturing (CAD/CAM) technique improves adaptation of FDPs compared with FDPs made using the lost-wax and metal casting technique. Three-unit FDPs were manufactured by CAD/CAM based on digital impression of a typodont model. The FDPs were made from one of five materials: pre-sintered zirconium dioxide; hot isostatic pressed zirconium dioxide; lithium disilicate glass-ceramic; milled cobalt-chromium; and laser-sintered cobalt-chromium. The FDPs made using the lost-wax and metal casting technique were used as reference. The fit of the FDPs was analysed using the triple-scan method. The fit was evaluated for both single abutments and three-unit FDPs. The average cement space varied between 50 μm and 300 μm. Insignificant differences in internal fit were observed between the CAD/CAM-manufactured FDPs, and none of the FPDs had cement spaces that were statistically significantly different from those of the reference FDP. For all FDPs, the cement space at a marginal band 0.5-1.0 mm from the preparation margin was less than 100 μm. The milled cobalt-chromium FDP had the closest fit. The cement space of FDPs produced using the CAD/CAM technique was similar to that of FDPs produced using the conventional lost-wax and metal casting technique. © 2017 Eur J Oral Sci.

Energy gap opening by crossing drop cast single-layer graphene nanoribbons.

PubMed

Yamada, Toyo Kazu; Fukuda, Hideto; Fujiwara, Taizo; Liu, Polin; Nakamura, Kohji; Kasai, Seiya; Vazquez de Parga, Amadeo L; Tanaka, Hirofumi

2018-08-03

Band gap opening of a single-layer graphene nanoribbon (sGNR) sitting on another sGNR, fabricated by drop casting GNR solution on Au(111) substrate in air, was studied by means of scanning tunneling microscopy and spectroscopy in an ultra-high vacuum at 78 K and 300 K. GNRs with a width of ∼45 nm were prepared by unzipping double-walled carbon nanotubes (diameter ∼15 nm) using the ultrasonic method. In contrast to atomically-flat GNRs fabricated via the bottom-up process, the drop cast sGNRs were buckled on Au(111), i.e., some local points of the sGNR are in contact with the substrate (d ∼ 0.5 nm), but other parts float (d ∼ 1-3 nm), where d denotes the measured distance between the sGNR and the substrate. In spite of the fact that the nanoribbons were buckled, dI/dV maps confirmed that each buckled sGNR had a metallic character (∼3.5 G o ) with considerable uniform local density of states, comparable to a flat sGNR. However, when two sGNRs crossed each other, the crossed areas showed a band gap between -50 and +200 meV around the Fermi energy, i.e., the only upper sGNR electronic property changed from metallic to p-type semiconducting, which was not due to the bending, but the electronic interactions between the up and down sGNRs.

Twin-belt continuous caster with containment and cooling of the exiting cast product for enabling high-speed casting of molten-center product

DOEpatents

Dykes, Charles D.; Daniel, Sabah S.; Wood, J. F. Barry

1990-02-20

In continuously casting molten metal into cast product by a twin-belt machine, it is desirable to achieve dramatic increases in speed (linear feet per minute) at which cast product exits the machine, particularly in installations where steel cast product is intended to feed a downstream regular rolling mill (as distinct from a planetary mill) operating in tandem with the twin-belt caster. Such high-speed casting produces product with a relatively thin shell and molten interior, and the shell tends to bulge outwardly due to metallostatic head pressure of the molten center. A number of cooperative features enable high-speed, twin-belt casting: (1) Each casting belt is slidably supported adjacent to the caster exit pulley for bulge control and enhanced cooling of cast product. (2) Lateral skew steering of each belt provides an effective increase in moving mold length plus a continuity of heat transfer not obtained with prior art belt steering apparatus. (3) The exiting slab is contained and supported downstream from the casting machine to prevent bulging of the shell of the cast product, and (4) spray cooling is incorporated in the exit containment apparatus for secondary cooling of cast product.

Strip casting with fluxing agent applied to casting roll

DOEpatents

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

1997-07-29

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

Research regarding the vacuuming of liquid steel on steel degassing

NASA Astrophysics Data System (ADS)

Magaon, M.; Radu, M.; Şerban, S.; Zgripcea, L.

2018-01-01

When the liquid steel comes in contact with the atmosphere of the elaboration aggregates, a process of gas diffusion into the metal bath takes place on the one hand, and on the other hand a process that allows them to pass from the metal bath into the atmosphere. The meaning of these processes is determined by a number of factors as follows: the quality of raw and auxiliary materials (moisture content, oils, etc.), the boiling intensity, the evacuation duration, the properties of used slags, the values of the casting ladle processing parameters (bubbling, vacuuming, etc.). The research was carried out at an electrical steelwork, equipped with an electric arc furnace type EBT (Electric Bottom Tapping) capacity 100t, LF (Ladle-Furnace) and VD (Vacuum Degassing) facilities, establishing some correlations between the vacuuming parameters from the V.D.facility and the amounts of hydrogen and nitrogen removed from the metal bath, as well as their removal efficiency, were taken into consideration. The obtained data was processed in MATLAB calculation program, the established correlations form was presented both in analytical and graphical form. The validity of these correlations was verified in practice, being particularly useful in research.

Sidewall containment of liquid metal with horizontal alternating magnetic fields

DOEpatents

Praeg, W.F.

1995-01-31

An apparatus is disclosed for confining molten metal with a horizontal alternating magnetic field. In particular, this invention employs a magnet that can produce a horizontal alternating magnetic field to confine a molten metal at the edges of parallel horizontal rollers as a solid metal sheet is cast by counter-rotation of the rollers. 19 figs.

[Effect of the change in sulphate and dissolved oxygen mass concentration on metal release in old cast iron distribution pipes].

PubMed

Wu, Yong-li; Shi, Bao-you; Sun, Hui-fang; Zhang, Zhi-huan; Gu, Jun-nong; Wang, Dong-sheng

2013-09-01

To understand the processes of corrosion by-product release and the consequent "red water" problems caused by the variation of water chemical composition in drinking water distribution system, the effect of sulphate and dissolved oxygen (DO) concentration on total iron release in corroded old iron pipe sections historically transporting groundwater was investigated in laboratory using small-scale pipe section reactors. The release behaviors of some low-level metals, such as Mn, As, Cr, Cu, Zn and Ni, in the process of iron release were also monitored. The results showed that the total iron and Mn release increased significantly with the increase of sulphate concentration, and apparent red water occurred when sulphate concentration was above 400 mg x L(-1). With the increase of sulfate concentration, the effluent concentrations of As, Cr, Cu, Zn and Ni also increased obviously, however, the effluent concentrations of these metals were lower than the influent concentrations under most circumstances, which indicated that adsorption of these metals by pipe corrosion scales occurred. Increasing DO within a certain range could significantly inhibit the iron release.

Fast and cheap fabrication of molding tools for polymer replication

NASA Astrophysics Data System (ADS)

Richter, Christiane; Kirschner, Nadine; Worgull, Matthias; Rapp, Bastian E.

2017-02-01

Polymer replication is a prerequisite for low-cost microstructure components for consumer and end user market. The production of cost-effective microstructure in polymers requires metal molding tools which are often fabricated by direct structuring methods like milling or laser machining both of which are time-consuming and cost-intensive. We present an alternative fabrication method based on replication processes which allows the cheap ( 50 €) and fast ( 12 h) replication of complex microstructures into metal. The process comprises three steps: 1. Generation of the microstructure in a photoresist via lithography. 2. Casting of the structure into a high-temperature silicone which serves as original mold for creation of the metal molding tool. 3. Melting of an eutectic alloy of Sn, Ag and Cu under light pressure directly inside of the silicone within an oven. After cooling to room temperature the metal molding tool can be used for polymer replication into conventional thermoplastic polymers. As a first example we structured polymethylmethacrylate (PMMA) foils with a thickness of 1 mm via hot embossing and feature sizes of 100 μm could be replicated with high fidelity.

Tensile Properties and Microstructure of Inconel 718 Fabricated with Electron Beam Freeform Fabrication (EBF(sup 3))

NASA Technical Reports Server (NTRS)

Bird, R. Keith; Hibberd, Joshua

2009-01-01

Electron beam freeform fabrication (EBF3) direct metal deposition processing was used to fabricate two Inconel 718 single-bead-width wall builds and one multiple-bead-width block build. Specimens were machined to evaluate microstructure and room temperature tensile properties. The tensile strength and yield strength of the as-deposited material from the wall and block builds were greater than those for conventional Inconel 718 castings but were less than those for conventional cold-rolled sheet. Ductility levels for the EBF3 material were similar to those for conventionally-processed sheet and castings. An unexpected result was that the modulus of the EBF3-deposited Inconel 718 was significantly lower than that of the conventional material. This low modulus may be associated with a preferred crystallographic orientation resultant from the deposition and rapid solidification process. A heat treatment with a high solution treatment temperature resulted in a recrystallized microstructure and an increased modulus. However, the modulus was not increased to the level that is expected for Inconel 718.

Effect of surface reaction layer on grindability of cast titanium alloys.

PubMed

Ohkubo, Chikahiro; Hosoi, Toshio; Ford, J Phillip; Watanabe, Ikuya

2006-03-01

The purpose of this study was to investigate the effect of the cast surface reaction layer on the grindability of titanium alloys, including free-machining titanium alloy (DT2F), and to compare the results with the grindability of two dental casting alloys (gold and Co-Cr). All titanium specimens (pure Ti, Ti-6Al-4V and DT2F) were cast using a centrifugal casting machine in magnesia-based investment molds. Two specimen sizes were used to cast the titanium metals so that the larger castings would be the same size as the smaller gold and Co-Cr alloy specimens after removal of the surface reaction layer (alpha-case). Grindability was measured as volume loss ground from a specimen for 1 min using a handpiece engine with a SiC abrasive wheel at 0.1 kgf and four circumferential wheel speeds. For the titanium and gold alloys, grindability increased as the rotational speed increased. There was no statistical difference (p>0.05) in grindability for all titanium specimens either with or without the alpha-case. Of the titanium metals tested, Ti-6 Al-4V had the greatest grindability at higher speeds, followed by DT2F and CP Ti. The grindability of the gold alloy was similar to that of Ti-6 Al-4V, whereas the Co-Cr alloy had the lowest grindability. The results of this study indicated that the alpha-case did not significantly affect the grindability of the titanium alloys. The free-machining titanium alloy had improved grindability compared to CP Ti.

Development of a new casting method to fabricate U–Zr alloy containing minor actinides

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

Jong Hwan Kim; Hoon Song; Hyung Tae Kim

2014-01-01

Metal fuel slugs of U–Zr alloys for a sodium-cooled fast reactor (SFR) have conventionally been fabricated using an injection casting method. However, casting alloys containing volatile radioactive constituents, such as Am, are problematic in a conventional injection casting method. As an alternative fabrication method, low pressure gravity casting has been developed. Casting soundness, microstructural characteristics, alloying composition, density, and fuel losses were evaluated for the following as-cast fuel slugs: U–10 wt% Zr, U–10 wt% Zr–5 wt% RE, and U–10 wt% Zr–5 wt% RE–5 wt% Mn. The U and Zr contents were uniform throughout the matrix, and impurities such as oxyen,more » carbon, and nitrogen satisfied the specification of total impurities less than 2,000 ppm. The appearance of the fuel slugs was generally sound, and the internal integrity was shown to be satisfactory based on gamma-ray radiography. In a volatile surrogate casting test, the U–Zr–RE–Mn fuel slug showed that nearly all of the manganese was retained when casting was done under an inert atmosphere.« less

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.

Pulsed Eddy Current Sensing for Critical Pipe Condition Assessment.

PubMed

Ulapane, Nalika; Alempijevic, Alen; Vidal Calleja, Teresa; Valls Miro, Jaime

2017-09-26

Pulsed Eddy Current (PEC) sensing is used for Non-Destructive Evaluation (NDE) of the structural integrity of metallic structures in the aircraft, railway, oil and gas sectors. Urban water utilities also have extensive large ferromagnetic structures in the form of critical pressure pipe systems made of grey cast iron, ductile cast iron and mild steel. The associated material properties render NDE of these pipes by means of electromagnetic sensing a necessity. In recent years PEC sensing has established itself as a state-of-the-art NDE technique in the critical water pipe sector. This paper presents advancements to PEC inspection in view of the specific information demanded from water utilities along with the challenges encountered in this sector. Operating principles of the sensor architecture suitable for application on critical pipes are presented with the associated sensor design and calibration strategy. A Gaussian process-based approach is applied to model a functional relationship between a PEC signal feature and critical pipe wall thickness. A case study demonstrates the sensor's behaviour on a grey cast iron pipe and discusses the implications of the observed results and challenges relating to this application.

Systematic approach to optimal design of induction heating installations for aluminum extrusion process

NASA Astrophysics Data System (ADS)

Zimin, L. S.; Sorokin, A. G.; Egiazaryan, A. S.; Filimonova, O. V.

2018-03-01

An induction heating system has a number of inherent benefits compared to traditional heating systems due to a non-contact heating process. It is widely used in vehicle manufacture, cast-rolling, forging, preheating before rolling, heat treatment, galvanizing and so on. Compared to other heating technologies, induction heating has the advantages of high efficiency, fast heating rate and easy control. The paper presents a new systematic approach to the design and operation of induction heating installations (IHI) in aluminum alloys production. The heating temperature in industrial complexes “induction heating - deformation” is not fixed in advance, but is determined in accordance with the maximization or minimization of the total economic performance during the process of metal heating and deformation. It is indicated that the energy efficient technological complex “IHI – Metal Forming (MF)” can be designed only with regard to its power supply system (PSS). So the task of designing systems of induction heating is to provide, together with the power supply system and forming equipment, the minimum energy costs for the metal retreating.

[Environmental toxicity of waste foundry sand].

PubMed

Zhang, Hai-Feng; Wang, Yu-Jue; Wang, Jin-Lin; Huang, Tian-You; Xiong, Ying

2013-03-01

The metal leaching characteristics and volatile organic compounds (VOCs) of five different types of waste foundry sands were analyzed with the toxicity characteristic leaching procedure (TCLP) and head space-gas chromatography (HS-GC). Microtox and soil dehydrogenase activity (DHA) tests were then used to evaluate the bio-effects of these waste sands. The results showed that due to the different metals poured and casting materials used to make the sand molds, there was significant difference among the five waste foundry sands in the compositions and concentrations of metal and organic pollutants. The concentrations of Fe in the leachates of iron and steel casting waste foundry sand exceeded the maximal allowable concentrations specified in the National Standard of Drinking Water Quality, whereas the As concentration in the leachate of aluminum casting waste foundry sand exceeded the standard. The five waste foundry sands had quite different compositions and levels of VOCs, which resulted in different levels of inhibition effects on the luminescent bacteria (30% and 95%). Additionally, the soil DHA tests suggested that metal pollutants in waste foundry sands may inhibit the soil microbial activity, whereas organics in the sands may slightly promote the microbial activity. The results of this study indicated that the waste foundry sands may pose considerable threat to the environment when improperly disposed.

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

PubMed Central

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

2018-01-01

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

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

PubMed

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

2018-02-25

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

Modeling of Dendritic Evolution of Continuously Cast Steel Billet with Cellular Automaton

NASA Astrophysics Data System (ADS)

Wang, Weiling; Ji, Cheng; Luo, Sen; Zhu, Miaoyong

2018-02-01

In order to predict the dendritic evolution during the continuous steel casting process, a simple mechanism to connect the heat transfer at the macroscopic scale and the dendritic growth at the microscopic scale was proposed in the present work. As the core of the across-scale simulation, a two-dimensional cell automaton (CA) model with a decentered square algorithm was developed and parallelized. Apart from nucleation undercooling and probability, a temperature gradient was introduced to deal with the columnar-to-equiaxed transition (CET) by considering its variation during continuous casting. Based on the thermal history, the dendritic evolution in a 4 mm × 40 mm region near the centerline of a SWRH82B steel billet was predicted. The influences of the secondary cooling intensity, superheat, and casting speed on the dendritic structure of the billet were investigated in detail. The results show that the predicted equiaxed dendritic solidification of Fe-5.3Si alloy and columnar dendritic solidification of Fe-0.45C alloy are consistent with in situ experimental results [Yasuda et al. Int J Cast Metals Res 22:15-21 (2009); Yasuda et al. ISIJ Int 51:402-408 (2011)]. Moreover, the predicted dendritic arm spacing and CET location agree well with the actual results in the billet. The primary dendrite arm spacing of columnar dendrites decreases with increasing secondary cooling intensity, or decreasing superheat and casting speed. Meanwhile, the CET is promoted as the secondary cooling intensity and superheat decrease. However, the CET is not influenced by the casting speed, owing to the adjusting of the flow rate of secondary spray water. Compared with the superheat and casting speed, the secondary cooling intensity can influence the cooling rate and temperature gradient in deeper locations, and accordingly exerts a more significant influence on the equiaxed dendritic structure.

Metallographic examination of the structure of the metal of cold arms of the nineteenth-early twentieth centuries made at the Zlatoust arms factory

NASA Astrophysics Data System (ADS)

Schastlivtsev, V. M.; Rodionov, D. P.; Gerasimov, V. Yu.; Khlebnikova, Yu. V.

2010-11-01

Data are given concerning the structure and the chemical composition of carbon steel used for making cold arms, which was produced at the Zlatoust arms factory in the nineteenth and early twentieth centuries. The results of the analysis of the structure of metal demonstrates the general trend of the development of metallurgy both at the Ural plants and in the world: from the creation of the crucible methods of production of cast steel to the mass production of cast steel by the Bessemer and Martin methods.

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

PubMed

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

2018-05-09

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

Method for cleaning bomb-reduced uranium derbies

DOEpatents

Banker, John G.; Wigginton, Hubert L.; Beck, David E.; Holcombe, Cressie E.

1981-01-01

The concentration of carbon in uranium metal ingots induction cast from derbies prepared by the bomb-reduction of uranium tetrafluoride in the presence of magnesium is effectively reduced to less than 100 ppm by removing residual magnesium fluoride from the surface of the derbies prior to casting. This magnesium fluoride is removed from the derbies by immersing them in an alkali metal salt bath which reacts with and decomposes the magnesium fluoride. A water quenching operation followed by a warm nitric acid bath and a water rinse removes the residual salt and reaction products from the derbies.