Casting materials

DOEpatents

Chaudhry, Anil R [Xenia, OH; Dzugan, Robert [Cincinnati, OH; Harrington, Richard M [Cincinnati, OH; Neece, Faurice D [Lyndurst, OH; Singh, Nipendra P [Pepper Pike, OH

2011-06-14

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

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.

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.

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.

Elimination of Hot Tears in Steel Castings by Means of Solidification Pattern Optimization

NASA Astrophysics Data System (ADS)

Kotas, Petr; Tutum, Cem Celal; Thorborg, Jesper; Hattel, Jesper Henri

2012-06-01

A methodology of how to exploit the Niyama criterion for the elimination of various defects such as centerline porosity, macrosegregation, and hot tearing in steel castings is presented. The tendency of forming centerline porosity is governed by the temperature distribution close to the end of the solidification interval, specifically by thermal gradients and cooling rates. The physics behind macrosegregation and hot tears indicate that these two defects also are dependent heavily on thermal gradients and pressure drop in the mushy zone. The objective of this work is to show that by optimizing the solidification pattern, i.e., establishing directional and progressive solidification with the help of the Niyama criterion, macrosegregation and hot tearing issues can be both minimized or eliminated entirely. An original casting layout was simulated using a transient three-dimensional (3-D) thermal fluid model incorporated in a commercial simulation software package to determine potential flaws and inadequacies. Based on the initial casting process assessment, multiobjective optimization of the solidification pattern of the considered steel part followed. That is, the multiobjective optimization problem of choosing the proper riser and chill designs has been investigated using genetic algorithms while simultaneously considering their impact on centerline porosity, the macrosegregation pattern, and primarily on hot tear formation.

Fabrication of hierarchically structured superhydrophobic PDMS surfaces by Cu and CuO casting

NASA Astrophysics Data System (ADS)

Migliaccio, Christopher P.; Lazarus, Nathan

2015-10-01

Poly(dimethylsiloxane) (PDMS) films decorated with hierarchically structured pillars are cast from large area copper and copper oxide negative molds. The molds are fabricated using a single patterning step and electroplating. The process of casting structured PDMS films is simpler and cheaper than alternatives based on deep reactive ion etching or laser roughening of bulk silicone. Texture imparted to the pillars from the mold walls renders the PDMS films superhydrophobic, with the contact angle/hysteresis of the most non-wetting surfaces measuring 164°/9° and 158°/10° for surfaces with and without application of a low surface energy coating. The usefulness of patterned PDMS films as a "self-cleaning" solar cell module covering is demonstrated and other applications are discussed.

3D patterned stem cell differentiation using thermo-responsive methylcellulose hydrogel molds.

PubMed

Lee, Wonjae; Park, Jon

2016-07-06

Tissue-specific patterned stem cell differentiation serves as the basis for the development, remodeling, and regeneration of the multicellular structure of the native tissues. We herein proposed a cytocompatible 3D casting process to recapitulate this patterned stem cell differentiation for reconstructing multicellular tissues in vitro. We first reconstituted the 2D culture conditions for stem cell fate control within 3D hydrogel by incorporating the sets of the diffusible signal molecules delivered through drug-releasing microparticles. Then, utilizing thermo-responsivity of methylcellulose (MC), we developed a cytocompatible casting process to mold these hydrogels into specific 3D configurations, generating the targeted spatial gradients of diffusible signal molecules. The liquid phase of the MC solution was viscous enough to adopt the shapes of 3D impression patterns, while the gelated MC served as a reliable mold for patterning the hydrogel prepolymers. When these patterned hydrogels were integrated together, the stem cells in each hydrogel distinctly differentiated toward individually defined fates, resulting in the formation of the multicellular tissue structure bearing the very structural integrity and characteristics as seen in vascularized bones and osteochondral tissues.

3D patterned stem cell differentiation using thermo-responsive methylcellulose hydrogel molds

NASA Astrophysics Data System (ADS)

Lee, Wonjae; Park, Jon

2016-07-01

Tissue-specific patterned stem cell differentiation serves as the basis for the development, remodeling, and regeneration of the multicellular structure of the native tissues. We herein proposed a cytocompatible 3D casting process to recapitulate this patterned stem cell differentiation for reconstructing multicellular tissues in vitro. We first reconstituted the 2D culture conditions for stem cell fate control within 3D hydrogel by incorporating the sets of the diffusible signal molecules delivered through drug-releasing microparticles. Then, utilizing thermo-responsivity of methylcellulose (MC), we developed a cytocompatible casting process to mold these hydrogels into specific 3D configurations, generating the targeted spatial gradients of diffusible signal molecules. The liquid phase of the MC solution was viscous enough to adopt the shapes of 3D impression patterns, while the gelated MC served as a reliable mold for patterning the hydrogel prepolymers. When these patterned hydrogels were integrated together, the stem cells in each hydrogel distinctly differentiated toward individually defined fates, resulting in the formation of the multicellular tissue structure bearing the very structural integrity and characteristics as seen in vascularized bones and osteochondral tissues.

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.

3D patterned stem cell differentiation using thermo-responsive methylcellulose hydrogel molds

PubMed Central

Lee, Wonjae; Park, Jon

2016-01-01

Tissue-specific patterned stem cell differentiation serves as the basis for the development, remodeling, and regeneration of the multicellular structure of the native tissues. We herein proposed a cytocompatible 3D casting process to recapitulate this patterned stem cell differentiation for reconstructing multicellular tissues in vitro. We first reconstituted the 2D culture conditions for stem cell fate control within 3D hydrogel by incorporating the sets of the diffusible signal molecules delivered through drug-releasing microparticles. Then, utilizing thermo-responsivity of methylcellulose (MC), we developed a cytocompatible casting process to mold these hydrogels into specific 3D configurations, generating the targeted spatial gradients of diffusible signal molecules. The liquid phase of the MC solution was viscous enough to adopt the shapes of 3D impression patterns, while the gelated MC served as a reliable mold for patterning the hydrogel prepolymers. When these patterned hydrogels were integrated together, the stem cells in each hydrogel distinctly differentiated toward individually defined fates, resulting in the formation of the multicellular tissue structure bearing the very structural integrity and characteristics as seen in vascularized bones and osteochondral tissues. PMID:27381562

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

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

Sabau, Adrian S; Porter, Wallace D

2008-01-01

In this study, the alloy shrinkage factors were obtained for the investment casting of 17-4PH stainless steel parts. For the investment casting process, unfilled wax and fused silica with a zircon prime coat were used for patterns and shell molds, respectively. Dimensions of the die tooling, wax pattern, and casting were measured using a Coordinate Measurement Machine. For all the properties, the experimental data available in the literature did not cover the entire temperature range necessary for process simulation. A comparison between the predicted material property data measured property data is made. It was found that most material properties weremore » accurately predicted over the most of the temperature range of the process. Several assumptions were made in order to obtain a complete set of mechanical property data at high temperatures. Thermal expansion measurements for the 17-4PH alloy were conducted at heating and cooling. As a function of temperature, the thermal expansion for both the alloy and shell mold materials showed different evolution at heating and cooling. Thus, one generic simulation were performed with thermal expansion obtained at heating and another one with thermal expansion obtained at cooling. The alloy dimensions were obtained from numerical simulation results of solidification, heat transfer, and deformation phenomena. As compared with experimental results, the numerical simulation results for the shrinkage factors were slightly over-predicted.« less

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

NASA Astrophysics Data System (ADS)

Sabau, Adrian S.; Porter, Wallace D.

2008-04-01

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

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)

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.

Precision Casting via Advanced Simulation and Manufacturing

NASA Technical Reports Server (NTRS)

1997-01-01

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

Limitation of Shrinkage Porosity in Aluminum Rotor Die Casting

NASA Astrophysics Data System (ADS)

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

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

Epoxy-resin patterns speed shell-molding of aluminum parts

NASA Technical Reports Server (NTRS)

1965-01-01

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

Transfer molding processes for nanoscale patterning of poly-L-lactic acid (PLLA) films

NASA Astrophysics Data System (ADS)

Dhakal, Rabin; Peer, Akshit; Biswas, Rana; Kim, Jaeyoun

2016-03-01

Nanoscale patterned structures composed of biomaterials exhibit great potential for the fabrication of functional biostructures. In this paper, we report cost-effective, rapid, and highly reproducible soft lithographic transfer-molding techniques for creating periodic micro- and nano-scale textures on poly (L-lactic acid) (PLLA) surface. These artificial textures can increase the overall surface area and change the release dynamics of the therapeutic agents coated on it. Specifically, we use the double replication technique in which the master pattern is first transferred to the PDMS mold and the pattern on PDMS is then transferred to the PLLA films through drop-casting as well as nano-imprinting. The ensuing comparison studies reveal that the drop-cast PLLA allows pattern transfer at higher levels of fidelity, enabling the realization of nano-hole and nano-cone arrays with pitch down to ~700 nm. The nano-patterned PLLA film was then coated with rapamycin to make it drug-eluting.

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

Modeling on Fluid Flow and Inclusion Motion in Centrifugal Continuous Casting Strands

NASA Astrophysics Data System (ADS)

Wang, Qiangqiang; Zhang, Lifeng; Sridhar, Seetharaman

2016-08-01

During the centrifugal continuous casting process, unreasonable casting parameters can cause violent level fluctuation, serious gas entrainment, and formation of frozen shell pieces at the meniscus. Thus, in the current study, a three-dimensional multiphase turbulent model was established to study the transport phenomena during centrifugal continuous casting process. The effects of nozzle position, casting and rotational speed on the flow pattern, centrifugal force acting on the molten steel, level fluctuation, gas entrainment, shear stress on mold wall, and motion of inclusions during centrifugal continuous casting process were investigated. Volume of Fluid model was used to simulate the molten steel-air two-phase. The level fluctuation and the gas entrainment during casting were calculated by user-developed subroutines. The trajectory of inclusions in the rotating system was calculated using the Lagrangian approach. The results show that during centrifugal continuous casting, a large amount of gas was entrained into the molten steel, and broken into bubbles of various sizes. The greater the distance to the mold wall, the smaller the centrifugal force. Rotation speed had the most important influence on the centrifugal force distribution at the side region. Angular moving angle of the nozzle with 8° and keeping the rotation speed with 60 revolutions per minute can somehow stabilize the level fluctuation. The increase of angular angle of nozzle from 8 to 18 deg and rotation speed from 40 to 80 revolutions per minute favored to decrease the total volume of entrained bubbles, while the increase of distance of nozzle moving left and casting speed had reverse effects. The trajectories of inclusions in the mold were irregular, and then rotated along the strand length. After penetrating a certain distance, the inclusions gradually moved to the center of billet and gathered there. More work, such as the heat transfer, the solidification, and the inclusions entrapment during centrifugal continuous casting, will be performed.

Quiet breathing in hindlimb casted mice.

PubMed

Receno, Candace N; Roffo, Katelynn E; Mickey, Marisa C; DeRuisseau, Keith C; DeRuisseau, Lara R

2018-06-07

The hindlimb casting model was developed to study skeletal muscle reloading following a period of unloading. It is unknown if ventilation parameters of mice are affected by the casting model. We tested the hypothesis that hindlimb casted mice have similar ventilatory patterns compared to mice with the casts removed. Male CD-1 mice underwent 14 days of hindlimb immobilization via plaster casting. Breathing parameters were obtained utilizing unrestrained barometric plethysmography (UBP). Breathing traces were analyzed with Ponemah software for breathing frequency, tidal volume (TV), and minute ventilation (MV). Frequency, TV and MV did not show any differences in quiet breathing patterns during or post-casting in mice. Thus, the hindlimb casting model does not complicate breathing during and after casting and should not interfere with the unloading and reloading of skeletal muscle. Copyright © 2018 Elsevier B.V. All rights reserved.

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.

Effect of inlet geometry on macrosegregation during the direct chill casting of 7050 alloy billets: experiments and computer modelling

NASA Astrophysics Data System (ADS)

Zhang, L.; Eskin, D. G.; Miroux, A.; Subroto, T.; Katgerman, L.

2012-07-01

Controlling macrosegregation is one of the major challenges in direct-chill (DC) casting of aluminium alloys. In this paper, the effect of the inlet geometry (which influences the melt distribution) on macrosegregation during the DC casting of 7050 alloy billets was studied experimentally and by using 2D computer modelling. The ALSIM model was used to determine the temperature and flow patterns during DC casting. The results from the computer simulations show that the sump profiles and flow patterns in the billet are strongly influenced by the melt flow distribution determined by the inlet geometry. These observations were correlated to the actual macrosegregation patterns found in the as-cast billets produced by having two different inlet geometries. The macrosegregation analysis presented here may assist in determining the critical parameters to consider for improving the casting of 7XXX aluminium alloys.

Corrosion cast study of the canine hepatic veins.

PubMed

Uršič, M; Vrecl, M; Fazarinc, G

2014-11-01

This study presents a detailed description of the distribution, diameters and drainage patterns of hepatic veins on the basis of the corrosion cast analysis in 18 dogs. We classified the hepatic veins in three main groups: the right hepatic veins of the caudate process and right lateral liver lobe, the middle hepatic veins of the right medial and quadrate lobes and the left hepatic veins of both left liver lobes and the papillary process. The corrosion cast study showed that the number of the veins in the Nomina Anatomica Veterinaria and most anatomical textbooks is underestimated. The number of various-sized hepatic veins of the right liver division ranged from 3 to 5 and included 1 to 4 veins from the caudate process and 2 to 4 veins from the right lateral liver lobe. Generally, in all corrosion casts, one middle-sized vein from the right part of the right medial lobe, which emptied separately in the caudal vena cava, was established. The other vein was a large-sized vein from the remainder of the central division, which frequently joined the common left hepatic vein from the left liver lobes. The common left hepatic vein was the largest of all the aforementioned hepatic veins.

Modified Surface Having Low Adhesion Properties to Mitigate Insect Residue Adhesion

NASA Technical Reports Server (NTRS)

Wohl, Christopher J., Jr. (Inventor); Smith, Joseph G., Jr. (Inventor); Siochi, Emilie J. (Inventor); Penner, Ronald K. (Inventor)

2016-01-01

A process to modify a surface to provide reduced adhesion surface properties to mitigate insect residue adhesion. The surface may include the surface of an article including an aircraft, an automobile, a marine vessel, all-terrain vehicle, wind turbine, helmet, etc. The process includes topographically and chemically modifying the surface by applying a coating comprising a particulate matter, or by applying a coating and also topographically modifying the surface by various methods, including but not limited to, lithographic patterning, laser ablation and chemical etching, physical vapor phase deposition, chemical vapor phase deposition, crystal growth, electrochemical deposition, spin casting, and film casting.

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.

TiC-Fe-Based Composite Coating Prepared by Self-Propagating High-Temperature Synthesis

NASA Astrophysics Data System (ADS)

He, Shen; Fan, Xi'an; Chang, Qingming; Xiao, Lixiang

2017-06-01

TiC-Fe-based composite coatings were prepared in situ by self-propagating high-temperature synthesis combined with vacuum expendable pattern casting process. The band-like TiC phase embedded in a continuous Fe binder. There were no obvious defects and impurities at the interface between coatings and matrices. Fe presented consecutively in the coating zones and substrate zones without interruption and the microhardness in the cross-sectional area of the coating-matrix reduces continuously from the coating to the matrix area, indicating a good metallurgical bonding between the coatings and matrices. The effect of casting temperature on the microstructure and hardness of TiC-Fe-based composite coating was investigated in detail. The TiC particles formed at low casting temperature were nearly spherical in shape, and the size of TiC particles increased with increasing casting temperature due to more agglomeration. The hardness of the coatings increased first and then decreased with increasing casting temperature, and reached the highest value of 68 HRC when the casting temperature was 1773 K (1500 °C), which was twice more than that of the matrix.

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.

Casting made simple using modified sprue design: an in vitro study.

PubMed

Baskaran, B Eswaran; Geetha Prabhu, K R; Prabhu, R; Krishna, G Phani; Eswaran, M A; Gajapathi, B

2014-01-01

Success in dental casting restorations for fixed partial dentures (FPDs) depends on the castability. Castability is described as the ability of an alloy to faithfully reproduce sharp detail and fine margins of a wax pattern. The goal of a prosthodontist is to provide the patient with restorations that fit precisely. Regardless of the alloy used for casting, the casting technique should yield a casted alloy, which should possess sufficient mass, surface hardness and minimal porosity after casting. Twenty patterns for casting were made from three-dimensional printed resin pattern simulating a 3 unit FPD and casted using modified sprue technique. Later test samples were cemented sequentially on stainless steel model using pressure indicating paste and evaluated for vertical marginal gap in eight predetermined reference areas. Marginal gap were measured in microns using Video Measuring System (VMS2010F-CIP Corporation, Korea). A portion of the axial wall of the cast abutments depicting premolar and molar were sectioned and embedded in acrylic resin and tested for micro hardness using Reichert Polyvar 2 Met Microhardness tester (Reichert, Austria) and porosity using Quantimet Image Analyzer (Quantimet Corporation London, England). The results obtained for marginal gap, micro hardness, and porosity of all test samples were tabulated, descriptive statistics were calculated and the values were found to be within the clinically acceptable range. The new sprue technique can be an alternative and convenient method for casting which would minimize metal wasting and less time consuming. However, further studies with same technique on various parameters are to be conducted for its broad acceptance.

Process for Making Ceramic Mold

NASA Technical Reports Server (NTRS)

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

2001-01-01

An improved process for slip casting molds that can be more economically automated and that also exhibits greater dimensional stability is disclosed. The process involves subjecting an investment pattern, preferably made from wax, to successive cycles of wet-dipping in a slurry of colloidal, silica-based binder and dry powder-coating, or stuccoing with plaster of Paris or calcium sulfate mixtures to produce a multi-layer shell over the pattern. The invention as claimed entails applying a primary and a secondary coating to the investment pattern. At least two wet-dipping on in a primary slurry and dry-stuccoing cycles provide the primary coating, and an additional two wet-dippings and dry-stuccoing cycles provide the secondary, or back-up, coating. The primary and secondary coatings produce a multi-layered shell pattern. The multi-layered shell pattern is placed in a furnace first to cure and harden, and then to vaporize the investment pattern, leaving a detailed, high precision shell mold.

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.

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.

Three-Dimensional Analysis of Internal Adaptations of Crowns Cast from Resin Patterns Fabricated Using Computer-Aided Design/Computer-Assisted Manufacturing Technologies.

PubMed

Liu, Yushu; Ye, Hongqiang; Wang, Yong; Zhao, Yijao; Sun, Yuchun; Zhou, Yongsheng

2018-05-17

To evaluate the internal adaptations of cast crowns made from resin patterns produced using three different computer-aided design/computer-assisted manufacturing technologies. A full-crown abutment made of zirconia was digitized using an intraoral scanner, and the design of the crown was finished on the digital model. Resin patterns were fabricated using a fused deposition modeling (FDM) 3D printer (LT group), a digital light projection (DLP) 3D printer (EV group), or a five-axis milling machine (ZT group). All patterns were cast in cobalt-chromium alloy crowns. Crowns made from traditional handmade wax patterns (HM group) were used as controls. Each group contained 10 samples. The internal gaps of the patterns were analyzed using a 3D replica method and optical digitization. The results were compared using Kruskal-Wallis analysis of variance (ANOVA), a one-sample t test, and signed rank test (α = .05). For the LT group, the marginal and axial gaps were significantly larger than in the other three groups (P < .05), but the occlusal adaptation did not reveal a significant difference (P > .05). In the ZT group, the axial gap was slightly smaller than in the HM group (P < .0083). All the means of gaps in all areas in the four groups were less than 150 μm. Casting crowns using casting patterns made from all three CAD/CAM systems could not produce the prescribed parameters, but the crowns showed clinically acceptable internal adaptations.

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

Nick Cannell; Adrian S. Sabau

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

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

Microstructure of Friction Stir Welded AlSi9Mg Cast with 5083 and 2017A Wrought Aluminum Alloys

NASA Astrophysics Data System (ADS)

Hamilton, C.; Kopyściański, M.; Dymek, S.; Węglowska, A.; Pietras, A.

2018-03-01

Wrought aluminum alloys 5083 and 2017A were each joined with cast aluminum alloy AlSi9Mg through friction stir welding in butt weld configurations. For each material system, the wrought and cast alloy positions, i.e., the advancing side or the retreating side, were exchanged between welding trials. The produced weldments were free from cracks and discontinuities. For each alloy configuration, a well-defined nugget comprised of alternating bands of the welded alloys characterized the microstructure. The degree of mixing, however, strongly depended on which wrought alloy was present and on its position during processing. In all cases, the cast AlSi9Mg alloy dominated the weld center regardless of its position during welding. Electron backscattered diffraction analysis showed that the grain size in both alloys (bands) constituting the nugget was similar and that the majority of grain boundaries exhibited a high angle character (20°-60°). Regardless of the alloy, however, all grains were elongated along the direction of the material plastic flow during welding. A numerical simulation of the joining process visualized the material flow patterns and temperature distribution and helped to rationalize the microstructural observations. The hardness profiles across the weld reflected the microstructure formed during welding and correlated well with the temperature changes predicted by the numerical model. Tensile specimens consistently fractured in the cast alloy near the weld nugget.

Effect of Heat Treatment on the Hardness and Wear of Grinding Balls

NASA Astrophysics Data System (ADS)

Aissat, Sahraoui; Sadeddine, Abdelhamid; Bradai, Mohand Amokrane; Younes, Rassim; Bilek, Ali; Benabbas, Abderrahim

2017-09-01

The effect quenching and tempering by different regimes on Rockwell hardness and wear processes of grinding balls 50 and 70 mm in diameter made of two melts of chromium-molybdenum cast iron is studied. The heating temperature for quenching is 850, 950, and 1050°C; the tempering temperature is 250, 400, and 600°C. Iron is analyzed in an electron microscope. Diffraction patterns are obtained. A model of cast iron wear is suggested and compared to the Davis model and to experimental results. An optimum heat treatment regime is proposed.

Applications of rapid prototyping technology in maxillofacial prosthetics.

PubMed

Sykes, Leanne M; Parrott, Andrew M; Owen, C Peter; Snaddon, Donald R

2004-01-01

The purpose of this study was to compare the accuracy, required time, and potential advantages of rapid prototyping technology with traditional methods in the manufacture of wax patterns for two facial prostheses. Two clinical situations were investigated: the production of an auricular prosthesis and the duplication of an existing maxillary prosthesis, using a conventional and a rapid prototyping method for each. Conventional wax patterns were created from impressions taken of a patient's remaining ear and an oral prosthesis. For the rapid prototyping method, a cast of the ear and the original maxillary prosthesis were scanned, and rapid prototyping was used to construct the wax patterns. For the auricular prosthesis, both patterns were refined clinically and then flasked and processed in silicone using routine procedures. Twenty-six independent observers evaluated these patterns by comparing them to the cast of the patient's remaining ear. For the duplication procedure, both wax patterns were scanned and compared to scans of the original prosthesis by generating color error maps to highlight volumetric changes. There was a significant difference in opinions for the two auricular prostheses with regard to shape and esthetic appeal, where the hand-carved prosthesis was found to be of poorer quality. The color error maps showed higher errors with the conventional duplication process compared with the rapid prototyping method. The main advantage of rapid prototyping is the ability to produce physical models using digital methods instead of traditional impression techniques. The disadvantage of equipment costs could be overcome by establishing a centralized service.

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.

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.

Modular Hydropower Engineering and Pilot Scale Manufacturing

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

Chesser, Phillip C.

Emrgy has developed, prototyped and tested a modular hydropower system for renewable energy generation. ORNL worked with Emrgy to demonstrate the use of additive manufacturing in the production of the hydrofoils and spokes for the hydrokinetic system. Specifically, during Phase 1 of this effort, ORNL printed and finished machined patterns for both the hydrofoils and spokes that were subsequently used in a sand casting manufacturing process. Emrgy utilized the sand castings for a pilot installation in Denver, CO, where the parts represented an 80% cost savings from the previous prototype build that was manufactured using subtractive manufacturing. In addition, themore » castings were completed with ORNL’s newly developed AlCeMg alloy that will be tested for performance improvements including higher corrosion resistance in a water application than the 6160 alloy used previously« less

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

COPE AND DRAG PATTERNS, EACH IS USED AT SEPARATE TIMES ...

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

COPE AND DRAG PATTERNS, EACH IS USED AT SEPARATE TIMES TO CREATE INDIVIDUAL MOLD. HALVES FOR AN EXHAUST MANIFOLD CASTING SIT IN FRONT OF MATCHPLATE PATTERNS WITH BOTH COPE AND DRAG SIDES AFFIXED TO A SINGLE PLATE, USED TO CREATE BOTH MOLD HALVES AT THE SAME TIME, IN THE BACKGROUND. - Southern Ductile Casting Company, Mold Making, 2217 Carolina Avenue, Bessemer, Jefferson County, AL

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

PubMed

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

2006-07-01

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

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.

Microstructures and Mechanical Properties of Co-Cr Dental Alloys Fabricated by Three CAD/CAM-Based Processing Techniques

PubMed Central

Kim, Hae Ri; Jang, Seong-Ho; Kim, Young Kyung; Son, Jun Sik; Min, Bong Ki; Kim, Kyo-Han; Kwon, Tae-Yub

2016-01-01

The microstructures and mechanical properties of cobalt-chromium (Co-Cr) alloys produced by three CAD/CAM-based processing techniques were investigated in comparison with those produced by the traditional casting technique. Four groups of disc- (microstructures) or dumbbell- (mechanical properties) specimens made of Co-Cr alloys were prepared using casting (CS), milling (ML), selective laser melting (SLM), and milling/post-sintering (ML/PS). For each technique, the corresponding commercial alloy material was used. The microstructures of the specimens were evaluated via X-ray diffractometry, optical and scanning electron microscopy with energy-dispersive X-ray spectroscopy, and electron backscattered diffraction pattern analysis. The mechanical properties were evaluated using a tensile test according to ISO 22674 (n = 6). The microstructure of the alloys was strongly influenced by the manufacturing processes. Overall, the SLM group showed superior mechanical properties, the ML/PS group being nearly comparable. The mechanical properties of the ML group were inferior to those of the CS group. The microstructures and mechanical properties of Co-Cr alloys were greatly dependent on the manufacturing technique as well as the chemical composition. The SLM and ML/PS techniques may be considered promising alternatives to the Co-Cr alloy casting process. PMID:28773718

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.

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.

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

Kinematic Gait Changes Following Serial Casting and Bracing to Treat Toe Walking in a Child With Autism.

PubMed

Barkocy, Marybeth; Dexter, James; Petranovich, Colleen

2017-07-01

To evaluate the effectiveness of serial casting in a child with autism spectrum disorder (ASD) exhibiting a toe-walking gait pattern with equinus contractures. Although many children with ASD toe walk, little research on physical therapy interventions exists for this population. Serial casting has been validated for use in idiopathic toe walking to increase passive dorsiflexion and improve gait, but not for toe walking in children with ASD. Serial casting followed by ankle-foot orthosis use was implemented to treat a child with ASD who had an obligatory equinus gait pattern. Gait analysis supported improvements in kinematic, spatial, and temporal parameters of gait, and the child maintained a consistent heel-toe gait at 2-year follow-up. STATEMENT OF CONCLUSION AND RECOMMENDATIONS FOR CLINICAL PRACTICE:: Serial casting followed by ankle-foot orthosis use is a viable treatment option for toe walking in children with ASD.

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

NASA Technical Reports Server (NTRS)

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

1993-01-01

A primary concern in modern fluid dynamics research is the experimental verification of computational aerothermodynamic codes. This research requires high precision and detail in the test model employed. Ceramic materials are used for these models because of their low heat conductivity and their survivability at high temperatures. To fabricate such models, slip casting techniques were developed to provide net-form, precision casting capability for high-purity ceramic materials in aqueous solutions. In previous slip casting techniques, block, or flask molds made of plaster-of-paris were used to draw liquid from the slip material. Upon setting, parts were removed from the flask mold and cured in a kiln at high temperatures. Casting detail was usually limited with this technique -- detailed parts were frequently damaged upon separation from the flask mold, as the molded parts are extremely delicate in the uncured state, and the flask mold is inflexible. Ceramic surfaces were also marred by 'parting lines' caused by mold separation. This adversely affected the aerodynamic surface quality of the model as well. (Parting lines are invariably necessary on or near the leading edges of wings, nosetips, and fins for mold separation. These areas are also critical for flow boundary layer control.) Parting agents used in the casting process also affected surface quality. These agents eventually soaked into the mold, the model, or flaked off when releasing the case model. Different materials were tried, such as oils, paraffin, and even an algae. The algae released best, but some of it remained on the model and imparted an uneven texture and discoloration on the model surface when cured. According to the present invention, a wax pattern for a shell mold is provided, and an aqueous mixture of a calcium sulfate-bonded investment material is applied as a coating to the wax pattern. The coated wax pattern is then dried, followed by curing to vaporize the wax pattern and leave a shell mold of the calcium sulfate-bonded investment material. The shell mold is cooled to room temperature, and a ceramic slip is poured therein. After a ceramic shell of desired thickness has set up in the shell mold, excess ceramic slip is poured out. While still wet, the shell mold is peeled from the ceramic shell to expose any delicate or detailed parts, after which the ceramic shell is cured to provide a complete, detailed, precision ceramic article without parting lines.

The fabrication of PLGA microvessel scaffolds with nano-patterned inner walls.

PubMed

Wang, Gou-Jen; Lin, Yan-Cheng; Hsu, Shan-Hui

2010-10-01

Poly (lactic-co-glycolic acid) (PLGA) is one of the most commonly used biodegradable, biocompatible materials. Nanostructured PLGA has immense potential for application in tissue engineering. In this article we discuss a novel approach for the fabrication of PLGA microvessel scaffolds with nanostructured inner walls. In this novel nano-patterning approach, the thermal reflow technique is first adapted to fabricate a semi-cylindrical photoresist master mold. A thin film of titanium and a thin film of aluminum are sputtered in sequence on the semi-cylindrical microvessel network. Aluminum foil anodization is then executed to transform the aluminum thin film into a porous anodic aluminum oxide (AAO) film. During the casting process a PLGA solution is cast on the AAO film to build up semi-cylindrical PLGA microstructures with nanostructured inner walls after which inductive coupled plasma (ICP) is implemented to assist bonding of the two PLGA structures. The result is the building of a network of microchannels with nano-patterned inner walls. Bovine endothelial cells (BECs) are carefully cultured in the scaffold via semi-dynamic seeding for 7 days. Observations show that the BECs grew more separately in a nano-patterned microvessel scaffold than they did in a smooth surface scaffold.

[The surface roughness analysis of the titanium casting founding by a new titanium casting investment material].

PubMed

Liang, Qin-ye; Wu, Xia-yi; Lin, Xue-feng

2012-04-01

To investigate the surface roughness property of the titanium castings cast in a new investment for titanium casting. Six wax patterns (20 mm × 20 mm × 0.5 mm) were invested using two investments: three in a new titanium investment material and three in the control material (Rematitan Plus). Six titanium specimens were obtained by conventional casting. After casting, surface roughness of the specimens were evaluated with a surface profilometer. The surface roughness of the specimens cast in new titanium investment material was (1.72 ± 0.08) µm, which was much smaller than that from Rematitan Plus [(1.91 ± 0.15) µm, P < 0.05]. The surfaces of titanium cast using these two investment materials are both smooth enough to fulfill the demand of the titanium precision-casting for prosthodontic clinical use.

Process for Forming a High Temperature Single Crystal Canted Spring

NASA Technical Reports Server (NTRS)

DeMange, Jeffrey J (Inventor); Ritzert, Frank J (Inventor); Nathal, Michael V (Inventor); Dunlap, Patrick H (Inventor); Steinetz, Bruce M (Inventor)

2017-01-01

A process for forming a high temperature single crystal canted spring is provided. In one embodiment, the process includes fabricating configurations of a rapid prototype spring to fabricate a sacrificial mold pattern to create a ceramic mold and casting a canted coiled spring to form at least one canted coil spring configuration based on the ceramic mold. The high temperature single crystal canted spring is formed from a nickel-based alloy containing rhenium using the at least one coil spring configuration.

Directional migration in the Hindu castes: inferences from mitochondrial, autosomal and Y-chromosomal data.

PubMed

Wooding, Stephen; Ostler, Christopher; Prasad, B V Ravi; Watkins, W Scott; Sung, Sandy; Bamshad, Mike; Jorde, Lynn B

2004-08-01

Genetic, ethnographic, and historical evidence suggests that the Hindu castes have been highly endogamous for several thousand years and that, when movement between castes does occur, it typically consists of females joining castes of higher social status. However, little is known about migration rates in these populations or the extent to which migration occurs between caste groups of low, middle, and high social status. To investigate these aspects of migration, we analyzed the largest collection of genetic markers collected to date in Hindu caste populations. These data included 45 newly typed autosomal short tandem repeat polymorphisms (STRPs), 411 bp of mitochondrial DNA sequence, and 43 Y-chromosomal single-nucleotide polymorphisms that were assayed in more than 200 individuals of known caste status sampled in Andrah Pradesh, in South India. Application of recently developed likelihood-based analyses to this dataset enabled us to obtain genetically derived estimates of intercaste migration rates. STRPs indicated migration rates of 1-2% per generation between high-, middle-, and low-status caste groups. We also found support for the hypothesis that rates of gene flow differ between maternally and paternally inherited genes. Migration rates were substantially higher in maternally than in paternally inherited markers. In addition, while prevailing patterns of migration involved movement between castes of similar rank, paternally inherited markers in the low-status castes were most likely to move into high-status castes. Our findings support earlier evidence that the caste system has been a significant, long-term source of population structuring in South Indian Hindu populations, and that patterns of migration differ between males and females. Copyright 2004 Springer-Verlag

Genetic structure of Rajaka caste and affinities with other caste populations of Andhra Pradesh, India.

PubMed

Parvatheesam, C; Babu, B V; Babu, M C

1997-01-01

The present study gives an account of the genetic structure in terms of distribution of a few genetic markers, viz., A1A2B0, Rh(D), G6PD deficiency and haemoglobin among the Rajaka caste population of Andhra Pradesh, India. The genetic relationships of the Rajaka caste with other Andhra caste populations were investigated in terms of genetic distance, i.e., Sq B (mn) of Balakrishnan and Sanghvi. Relatively lesser distance was established between the Rajaka and two Panchama castes. Also, the pattern of genetic distance corroborates the hierarchical order of the Hindu varna system.

Fabrication Process of Silicone-based Dielectric Elastomer Actuators

PubMed Central

Rosset, Samuel; Araromi, Oluwaseun A.; Schlatter, Samuel; Shea, Herbert R.

2016-01-01

This contribution demonstrates the fabrication process of dielectric elastomer transducers (DETs). DETs are stretchable capacitors consisting of an elastomeric dielectric membrane sandwiched between two compliant electrodes. The large actuation strains of these transducers when used as actuators (over 300% area strain) and their soft and compliant nature has been exploited for a wide range of applications, including electrically tunable optics, haptic feedback devices, wave-energy harvesting, deformable cell-culture devices, compliant grippers, and propulsion of a bio-inspired fish-like airship. In most cases, DETs are made with a commercial proprietary acrylic elastomer and with hand-applied electrodes of carbon powder or carbon grease. This combination leads to non-reproducible and slow actuators exhibiting viscoelastic creep and a short lifetime. We present here a complete process flow for the reproducible fabrication of DETs based on thin elastomeric silicone films, including casting of thin silicone membranes, membrane release and prestretching, patterning of robust compliant electrodes, assembly and testing. The membranes are cast on flexible polyethylene terephthalate (PET) substrates coated with a water-soluble sacrificial layer for ease of release. The electrodes consist of carbon black particles dispersed into a silicone matrix and patterned using a stamping technique, which leads to precisely-defined compliant electrodes that present a high adhesion to the dielectric membrane on which they are applied. PMID:26863283

Netcast™ Shape Casting Technology: A Technological Breakthrough that Enhances the Cost Effectiveness of Aluminum Forgings

NASA Astrophysics Data System (ADS)

Anderson, Mark; Bruski, Richard; Groszkiewicz, Daniel; Wagstaff, Bob

A new Direct Chill (DC) casting process is introduced to semi-continuous casting where near net shaped ingots are solidified. This process is currently being used at Alcan Engineered Cast Products (ECP) facility in Jonquiere, Canada, sectioned, then forged at Alcoa Automotive, Kentucky Casting Center (KCC). Finished forgings are machined and assembled into the Ford D/EW98 platform as suspension components. A brief description of the process and the implications on the forging process are presented.

Improving Metal Casting Process

NASA Technical Reports Server (NTRS)

1998-01-01

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

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

PubMed

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

1999-09-01

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

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.

Precision of Fit of Titanium and Cast Implant Frameworks Using a New Matching Formula

PubMed Central

Sierraalta, Marianella; Vivas, Jose L.; Razzoog, Michael E.; Wang, Rui-Feng

2012-01-01

Statement of the Problem. Fit of prosthodontic frameworks is linked to the lifetime survival of dental implants and maintenance of surrounding bone. Purpose. The purpose of this study was to evaluate and compare the precision of fit of milled one-piece Titanium fixed complete denture frameworks to that of conventional cast frameworks. Material and Methods. Fifteen casts fabricated from a single edentulous CAD/CAM surgical guide were separated in two groups and resin patterns simulating the framework for a fixed complete denture developed. Five casts were sent to dental laboratories to invest, cast in a Palladium-Gold alloy and fit the framework. Ten casts had the resin pattern scanned for fabrication of milled bars in Titanium. Using measuring software, positions of implant replicas in the definitive model were recorded. The three dimensional spatial orientation of each implant replica was matched to the implant replica. Results. Results demonstrated the mean vertical gap of the Cast framework was 0.021 (+0.004) mm and 0.012 (0.002) mm determined by fixed and unfixed best-fit matching coordinate system. For Titanium frameworks they were 0.0037 (+0.0028) mm and 0.0024 (+0.0005) mm, respectively. Conclusions. Milled one-piece Titanium fixed complete denture frameworks provided a more accurate precision of fit then traditional cast frameworks. PMID:22550486

A high resolution water soluble fullerene molecular resist for electron beam lithography.

PubMed

Chen, X; Palmer, R E; Robinson, A P G

2008-07-09

Traditionally, many lithography resists have used hazardous, environmentally damaging or flammable chemicals as casting solvent and developer. There is now a strong drive towards processes that are safer and more environmentally friendly. We report nanometre-scale patterning of a fullerene molecular resist film with electron beam lithography, using water as casting solvent and developer. Negative tone behaviour is demonstrated after exposure and development. The sensitivity of this resist to 20 keV electrons is 1.5 × 10(-2) C cm(-2). Arrays of lines with a width of 30-35 nm and pitches of 200 and 400 nm, and arrays of dots with a diameter of 40 nm and a pitch of 200 nm have been patterned at 30 keV. The etch durability of this resist was found to be ∼2 times that of a standard novolac based resist. Initial results of the chemical amplification of this material for enhanced sensitivity are also presented.

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

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

Thangirala, Mani

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

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.

Mossbauer and XRD characterization of the phase transformations in a Fe-Mn-Al-C-Mo-Si-Cu as cast alloy during tribology test

NASA Astrophysics Data System (ADS)

Ramos, J.; Piamba, J. F.; Sánchez, H.; Alcazar, G. A. Pérez

2015-06-01

In present study Fe-29.0Mn-6Al-0.9C-1.8Mo-1.6Si-0.4Cu (%w) alloy was obtained after melted in an induction furnace, and then molded as an ingot. From the as cast ingot it were cut samples for the different characterization measurements. The microstructure of the as-cast sample is of dendritic type and its XRD pattern was refined with the lines of the austenite, with a big volumetric fraction, and the lines of the martensite, with small volumetric fraction. The Mössbauer spectrum of the sample was fitted with a broad singlet which corresponds to disordered austenite. After the tribology test, its XRD pattern was refined with the lines of two austenite phases, one similar to the previous one and other with bigger lattice parameter. The total volumetric fraction of the austenite is smaller than that obtained for sample without wear. It was added the lines of the martensite phase with bigger volumetric fraction than that of the previous sample. The Mössbauer spectrum of the weared sample was fitted with two paramagnetic sites which correspond to the two Fe austenite phases and a hyperfine magnetic field distribution which is associated to the disordered original martensite and the new one which appears in the surface as a consequence of the wear process. These results show that during wear process the original austenite phase is transformed in martensite and in a new austenite phase. The increases of the martensitic phase improves mechanical properties and wear behavior.

Blended polymer materials extractable with supercritical carbon dioxide

NASA Astrophysics Data System (ADS)

Cai, Mei

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

Accuracy of cast posts fabricated by the direct and the indirect techniques.

PubMed

Rayyan, Mohammad R; Aldossari, Roa'a A; Alsadun, Sarah F; Hijazy, Fatimah R

2016-09-01

Patterns for custom cast posts and cores can be fabricated either by the direct or the indirect technique. Which technique is more accurate is unknown. The purpose of this in vitro study was to investigate the effect of pattern fabrication technique on the accuracy of post fit. Ten intact extracted premolar teeth with a single canal and similar dimensions received root canal treatment. The teeth were sectioned 2 mm above the cementoenamel junction. A total of 20 cast post and core patterns, 2 for each tooth, were fabricated, 10 with the direct technique and 10 with the indirect technique. Patterns were cast to produce 20 cast post and cores. Each tooth was scanned using a microcomputed tomography (μCT) system with a resolution of 14.5 μm, once with the post of the direct technique and once with the post of the indirect technique. Ct analyzer software was used to calculate the overall space between the post and canal walls and the space areas in 3 different standardized sections. The Student paired t test was used to determine any significant difference in the scores of the groups. The overall space between the canal walls and posts made with the direct technique ranged between 7.86 and 17.39 mm(3), with a mean value of 12.25 mm(3), whereas with the indirect technique, the space ranged between 6.68 and 18.02 mm(3), with a mean of 11.92 mm(3). No significant differences were found between the results of either technique (P>.05). Within the limitations of this study, neither the indirect nor direct pattern fabrication technique influenced the accuracy of post fitting. Copyright © 2016 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

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.

Riser Feeding Evaluation Method for Metal Castings Using Numerical Analysis

NASA Astrophysics Data System (ADS)

Ahmad, Nadiah

One of the design aspects that continues to create a challenge for casting designers is the optimum design of casting feeders (risers). As liquid metal solidifies, the metal shrinks and forms cavities inside the casting. In order to avoid shrinkage cavities, risers are added to the casting shape to supply additional molten metal when shrinkage occurs during solidification. The shrinkage cavities in the casting are compensated by controlling the cooling rate to promote directional solidification. This control can be achieved by designing the casting such that the cooling begins at the sections that are farthest away from the risers and ends at the risers. Therefore, the risers will solidify last and feed the casting with the molten metal. As a result, the shrinkage cavities formed during solidification are in the risers which are later removed from the casting. Since casting designers have to usually go through iterative processes of validating the casting designs which are very costly due to expensive simulation processes or manual trials and errors on actual casting processes, this study investigates more efficient methods that will help casting designers utilize their casting experiences systematically to develop good initial casting designs. The objective is to reduce the casting design method iterations; therefore, reducing the cost involved in that design processes. The aim of this research aims at finding a method that can help casting designers design effective risers used in sand casting process of aluminum-silicon alloys by utilizing the analysis of solidification simulation. The analysis focuses on studying the significance of pressure distribution of the liquid metal at the early stage of casting solidification, when heat transfer and convective fluid flow are taken into account in the solidification simulation. The mathematical model of casting solidification was solved using the finite volume method (FVM). This study focuses to improve our understanding of the feeding behavior in aluminum-silicon alloys and the effective feeding by considering the pressure gradient distribution of the molten metal at casting dendrite coherency point. For this study, we will identify the relationship between feeding efficiency, shrinkage behavior and how the change in riser size affects the pressure gradient in the casting. This understanding will be used to help in the design of effective risers.

Energy Consumption of Die Casting Operations

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

Jerald Brevick; clark Mount-Campbell; Carroll Mobley

2004-03-15

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

Selective attention determines emotional responses to novel visual stimuli.

PubMed

Raymond, Jane E; Fenske, Mark J; Tavassoli, Nader T

2003-11-01

Distinct complex brain systems support selective attention and emotion, but connections between them suggest that human behavior should reflect reciprocal interactions of these systems. Although there is ample evidence that emotional stimuli modulate attentional processes, it is not known whether attention influences emotional behavior. Here we show that evaluation of the emotional tone (cheery/dreary) of complex but meaningless visual patterns can be modulated by the prior attentional state (attending vs. ignoring) used to process each pattern in a visual selection task. Previously ignored patterns were evaluated more negatively than either previously attended or novel patterns. Furthermore, this emotional devaluation of distracting stimuli was robust across different emotional contexts and response scales. Finding that negative affective responses are specifically generated for ignored stimuli points to a new functional role for attention and elaborates the link between attention and emotion. This finding also casts doubt on the conventional marketing wisdom that any exposure is good exposure.

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.

Dimensional control of die castings

NASA Astrophysics Data System (ADS)

Karve, Aniruddha Ajit

The demand for net shape die castings, which require little or no machining, is steadily increasing. Stringent customer requirements are forcing die casters to deliver high quality castings in increasingly short lead times. Dimensional conformance to customer specifications is an inherent part of die casting quality. The dimensional attributes of a die casting are essentially dependent upon many factors--the quality of the die and the degree of control over the process variables being the two major sources of dimensional error in die castings. This study focused on investigating the nature and the causes of dimensional error in die castings. The two major components of dimensional error i.e., dimensional variability and die allowance were studied. The major effort of this study was to qualitatively and quantitatively study the effects of casting geometry and process variables on die casting dimensional variability and die allowance. This was accomplished by detailed dimensional data collection at production die casting sites. Robust feature characterization schemes were developed to describe complex casting geometry in quantitative terms. Empirical modeling was utilized to quantify the effects of the casting variables on dimensional variability and die allowance for die casting features. A number of casting geometry and process variables were found to affect dimensional variability in die castings. The dimensional variability was evaluated by comparisons with current published dimensional tolerance standards. The casting geometry was found to play a significant role in influencing the die allowance of the features measured. The predictive models developed for dimensional variability and die allowance were evaluated to test their effectiveness. Finally, the relative impact of all the components of dimensional error in die castings was put into perspective, and general guidelines for effective dimensional control in the die casting plant were laid out. The results of this study will contribute to enhancement of dimensional quality and lead time compression in the die casting industry, thus making it competitive with other net shape manufacturing processes.

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

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

Fasoyinu, Yemi

2014-03-31

Current vehicles use mostly ferrous components for structural applications. It is possible to reduce the weight of the vehicle by substituting these parts with those made from light metals such as aluminum and magnesium. Many alloys and manufacturing processes can be used to produce these light metal components and casting is known to be most economical. One of the high integrity casting processes is permanent mold casting which is the focus of this research report. Many aluminum alloy castings used in automotive applications are produced by the sand casting process. Also, aluminum-silicon (Al-Si) alloys are the most widely used alloymore » systems for automotive applications. It is possible that by using high strength aluminum alloys based on an aluminum-copper (Al-Cu) system and permanent mold casting, the performance of these components can be enhanced significantly. This will also help to further reduce the weight. However, many technological obstacles need to be overcome before using these alloys in automotive applications in an economical way. There is very limited information in the open literature on gravity and low-pressure permanent mold casting of high strength aluminum alloys. This report summarizes the results and issues encountered during the casting trials of high strength aluminum alloy 206.0 (Al-Cu alloy) and moderate strength alloy 535.0 (Al-Mg alloy). Five engineering components were cast by gravity tilt-pour or low pressure permanent mold casting processes at CanmetMATERIALS (CMAT) and two production foundries. The results of the casting trials show that high integrity engineering components can be produced successfully from both alloys if specific processing parameters are used. It was shown that a combination of melt processing and mold temperature is necessary for the elimination of hot tears in both alloys.« less

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

NASA Technical Reports Server (NTRS)

Frankhouser, W. L.

1980-01-01

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

Numerical simulation and optimization of casting process for complex pump

NASA Astrophysics Data System (ADS)

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

2017-09-01

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

Helium beam shadowing for high spatial resolution patterning of antibodies on microstructured diagnostic surfaces

PubMed Central

Cacao, Eliedonna; Sherlock, Tim; Nasrullah, Azeem; Kemper, Steven; Knoop, Jennifer; Kourentzi, Katerina; Ruchhoeft, Paul; Stein, Gila E; Atmar, Robert L; Willson, Richard C

2013-01-01

Abstract We have developed a technique for the high-resolution, self-aligning, and high-throughput patterning of antibody binding functionality on surfaces by selectively changing the reactivity of protein-coated surfaces in specific regions of a workpiece with a beam of energetic helium particles. The exposed areas are passivated with bovine serum albumin (BSA) and no longer bind the antigen. We demonstrate that patterns can be formed (1) by using a stencil mask with etched openings that forms a patterned exposure, or (2) by using angled exposure to cast shadows of existing raised microstructures on the surface to form self-aligned patterns. We demonstrate the efficacy of this process through the patterning of anti-lysozyme, anti-Norwalk virus, and anti-Escherichia coli antibodies and the subsequent detection of each of their targets by the enzyme-mediated formation of colored or silver deposits, and also by binding of gold nanoparticles. The process allows for the patterning of three-dimensional structures by inclining the sample relative to the beam so that the shadowed regions remain unaltered. We demonstrate that the resolution of the patterning process is of the order of hundreds of nanometers, and that the approach is well-suited for high throughput patterning. PMID:24706125

Numerical Simulation of Cast Distortion in Gas Turbine Engine Components

NASA Astrophysics Data System (ADS)

Inozemtsev, A. A.; Dubrovskaya, A. S.; Dongauser, K. A.; Trufanov, N. A.

2015-06-01

In this paper the process of multiple airfoilvanes manufacturing through investment casting is considered. The mathematical model of the full contact problem is built to determine stress strain state in a cast during the process of solidification. Studies are carried out in viscoelastoplastic statement. Numerical simulation of the explored process is implemented with ProCASTsoftware package. The results of simulation are compared with the real production process. By means of computer analysis the optimization of technical process parameters is done in order to eliminate the defect of cast walls thickness variation.

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

PubMed

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

1994-06-01

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

Differential gene expression in queen–worker caste determination in bumble-bees

PubMed Central

Pereboom, Jeffrey J. M; Jordan, William C; Sumner, Seirian; Hammond, Robert L; Bourke, Andrew F. G

2005-01-01

Investigating how differential gene expression underlies caste determination in the social Hymenoptera is central to understanding how variation in gene expression underlies adaptive phenotypic diversity. We investigated for the first time the association between differential gene expression and queen–worker caste determination in the bumble-bee Bombus terrestris. Using suppression subtractive hybridization we isolated 12 genes that were differentially expressed in queen- and worker-destined larvae. We found that the sets of genes underlying caste differences in larvae and adults failed to overlap greatly. We also found that B. terrestris shares some of the genes whose differential expression is associated with caste determination in the honeybee, Apis mellifera, but their expression patterns were not identical. Instead, we found B. terrestris to exhibit a novel pattern, whereby most genes upregulated (i.e. showing relatively higher levels of expression) in queen-destined larvae early in development were upregulated in worker-destined larvae late in development. Overall, our results suggest that caste determination in B. terrestris involves a difference not so much in the identity of genes expressed by queen- and worker-destined larvae, but primarily in the relative timing of their expression. This conclusion is of potential importance in the further study of phenotypic diversification via differential gene expression. PMID:16024376

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

NASA Astrophysics Data System (ADS)

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

2018-01-01

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

Precision cast vs. wrought superalloys

NASA Technical Reports Server (NTRS)

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

1986-01-01

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

Thin Gauge Twin-Roll Casting, Process Capabilities and Product Quality

NASA Astrophysics Data System (ADS)

Daaland, O.; Espedal, A. B.; Nedreberg, M. L.; Alvestad, I.

Traditionally industrial twin roll casters have been operated at gauges 6-10 mm, depending on the type of caster and the final product requirements. Over the past few years it has become apparent that a significant increase in productivity can be achieved when the casting gauge is reduced. Hydro Aluminium embarked on an extensive research and development, thin gauge casting programme, in the beginning of the 1990's and this paper presents some results from a five year lasting project (joint programme between Hydro Aluminium a.s. and Lauener Engineering). Based on more than 400 casting trials the major benefits and limitations of casting at reduced gauge and increased speed are outlined. Important aspects related to process development and product quality are discussed including: productivity and limitations, surface defects, microstructural characteristics, cooling rates and dendrite structure, segregation behaviour and mechanical properties after thermo-mechanical processing. Results for casting of several alloys are given. Additionally, numerical modelling results of the strip casting process are included.

Benefit from NASA

NASA Image and Video Library

1998-01-01

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

Adaptive significance of the Indian caste system: an ecological perspective.

PubMed

Gadgil, M; Malhotra, K C

1983-01-01

Indian society is an agglomeration of several thousand endogamous groups or castes each with a restricted geographical range and a hereditarily determined mode of subsistence. These reproductively isolated castes may be compared to biological species, and the society thought of as a biological community with each caste having its specific ecological niche. In this paper we examine the ecological-niche relationships of castes which are directly dependent on natural resources. Evidence is presented to show that castes living together in the same region had so organized their pattern of resource use as to avoid excessive intercaste competition for limiting resources. Furthermore, territorial division of the total range of the caste regulated intra-caste competition. Hence, a particular plant or animal resource in a given locality was used almost exclusively by a given lineage within a caste generation after generation. This favoured the cultural evolution of traditions ensuring sustainable use of natural resources. This must have contributed significantly to the stability of Indian caste society over several thousand years. The collapse of the base of natural resources and increasing monetarization of the economy has, however, destroyed the earlier complementarity between the different castes and led to increasing conflicts between them in recent years.

Emulsion based cast booster - a priming system

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

Gupta, R.N.; Mishra, A.K.

2005-07-01

This paper explores the potential of emulsion based cast booster to be used as primer to initiate bulk delivered emulsion explosives used in mines. An attempt has been made for comparative study between conventional cast booster and emulsion based cast booster in terms of the initiation process developed and their capability to develop and maintain the stable detonation process in the column explosives. The study has been conducted using a continuous velocity of detonation (VOD) measuring instrument. During this study three blasts have been monitored. In each blast two holes have been selected for study, the first hole being initiatedmore » with conventional cast booster while the other one with emulsion based cast booster. The findings of the study advocates that emulsion based cast booster is capable of efficient priming of bulk delivered column explosive with stable detonation process in the column. Further, the booster had advantages over the conventional PETN/TNT based cast booster. 5 refs., 2 figs., 1 tab., 1 photo.« 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

The effects of different types of investments on the alpha-case layer of titanium castings.

PubMed

Guilin, Yu; Nan, Li; Yousheng, Li; Yining, Wang

2007-03-01

Different types of investments affect the formation of the alpha-case (alpha-case) layer on titanium castings. This alpha-case layer may possibly alter the mechanical properties of cast titanium, which may influence the fabrication of removable and fixed prostheses. The formation mechanism for the alpha-case layer is not clear. The aim of this study was to evaluate the effect of 3 types of investments on the microstructure, composition, and microhardness of the alpha-case layer on titanium castings. Fifteen wax columns with a diameter of 5 mm and a length of 40 mm were divided into 3 groups of 5 patterns each. Patterns were invested using 3 types of investment materials, respectively, and were cast in pure titanium. The 3 types of materials tested were SiO(2)-, Al(2)O(3)-, and MgO-based investments. All specimens were sectioned and prepared for metallographic observation. The microstructure and composition of the surface reaction layer of titanium castings were investigated by scanning electron microscopy (SEM) and electron probe microanalysis (EPMA). The surface microhardness (VHN) for all specimens was measured using a hardness testing machine, and a mean value for each group was calculated. The alpha-case layer on titanium castings invested with SiO(2)-, Al(2)O(3)-, and MgO-based investments consisted of 3 layers-namely, the oxide layer, alloy layer, and hardening layer. In this study, the oxide layer and alloy layer were called the reaction layer. The thickness of the reaction layer for titanium castings using SiO(2)-, Al(2)O(3)-, and MgO-based investments was approximately 80 microm, 50 microm, and 14 microm, respectively. The surface microhardness of titanium castings made with SiO(2)-based investments was the highest, and that with MgO-based investments was the lowest. The type of investment affects the microstructure and microhardness of the alpha-case layer of titanium castings. Based on the thickness of the surface reaction layer and the surface microhardness of titanium castings, MgO-based investment materials may be the best choice for casting these materials.

Precision technique for trimming dies using a magnification device.

PubMed

Beck, D B

1980-05-01

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

Aluminum-fly ash metal matrix composites for automotive parts. [Reports for 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

Hyperbolically Patterned 3D Graphene Metamaterial with Negative Poisson's Ratio and Superelasticity.

PubMed

Zhang, Qiangqiang; Xu, Xiang; Lin, Dong; Chen, Wenli; Xiong, Guoping; Yu, Yikang; Fisher, Timothy S; Li, Hui

2016-03-16

A hyperbolically patterned 3D graphene metamaterial (GM) with negative Poisson's ratio and superelasticity is highlighted. It is synthesized by a modified hydrothermal approach and subsequent oriented freeze-casting strategy. GM presents a tunable Poisson's ratio by adjusting the structural porosity, macroscopic aspect ratio (L/D), and freeze-casting conditions. Such a GM suggests promising applications as soft actuators, sensors, robust shock absorbers, and environmental remediation. © 2016 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

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

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

Prof. Alan W. Camb; Prof. Anthony Rollett

2001-08-31

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

Quality Management and Control of Low Pressure Cast Aluminum Alloy

NASA Astrophysics Data System (ADS)

Zhang, Dianxi; Zhang, Yanbo; Yang, Xiufan; Chen, Zhaosong; Jiang, Zelan

2018-01-01

This paper briefly reviews the history of low pressure casting and summarizes the major production processes of low pressure casting. It briefly introduces the quality management and control of low pressure cast aluminum alloy. The main processes include are: preparation of raw materials, Melting, refining, physical and chemical analysis, K-mode inspection, sand core, mold, heat treatment and so on.

Tuning the properties of polyhydroxybutyrate films using acetic acid via solvent casting

PubMed Central

Anbukarasu, Preetam; Sauvageau, Dominic; Elias, Anastasia

2015-01-01

Biodegradable polyhydroxybutyrate (PHB) films were fabricated using acetic acid as an alternative to common solvents such as chloroform. The PHB films were prepared using a solvent casting process at temperatures ranging from 80 °C to 160 °C. The crystallinity, mechanical properties and surface morphology of the films cast at different temperatures were characterized and compared to PHB films cast using chloroform as a solvent. Results revealed that the properties of the PHB film varied considerably with solvent casting temperature. In general, samples processed with acetic acid at low temperatures had comparable mechanical properties to PHB cast using chloroform. This acetic acid based method is environmentally friendly, cost efficient and allows more flexible processing conditions and broader ranges of polymer properties than traditional methods. PMID:26640089

Tuning the properties of polyhydroxybutyrate films using acetic acid via solvent casting

NASA Astrophysics Data System (ADS)

Anbukarasu, Preetam; Sauvageau, Dominic; Elias, Anastasia

2015-12-01

Biodegradable polyhydroxybutyrate (PHB) films were fabricated using acetic acid as an alternative to common solvents such as chloroform. The PHB films were prepared using a solvent casting process at temperatures ranging from 80 °C to 160 °C. The crystallinity, mechanical properties and surface morphology of the films cast at different temperatures were characterized and compared to PHB films cast using chloroform as a solvent. Results revealed that the properties of the PHB film varied considerably with solvent casting temperature. In general, samples processed with acetic acid at low temperatures had comparable mechanical properties to PHB cast using chloroform. This acetic acid based method is environmentally friendly, cost efficient and allows more flexible processing conditions and broader ranges of polymer properties than traditional methods.

Advances in multi-scale modeling of solidification and casting processes

NASA Astrophysics Data System (ADS)

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

2011-04-01

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

[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.

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

PubMed

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

2008-06-01

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

A new method to evaluate the quality of single crystal Cu by an X-ray diffraction butterfly pattern method

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

Xu Zhenming; Guo Zhenqi; Li Jianguo

2004-12-15

A new method for the evaluation of the quality of an Ohno continuous cast (OCC) Cu single crystal by X-ray diffraction (XRD) butterfly pattern was brought forward. Experimental results show that the growth direction of single crystal Cu is inclined from both sides of the single crystal Cu rod to the axis and is axially symmetric. The degree of deviation from the [100] orientation from the crystal axis is less than 5 deg. with a casting speed 10-40 mm/min. The orientation of single crystal Cu does not have a fixed direction but is in a regular range. Moreover, the orientationmore » of stray grains in the single crystal Cu is random from continuous casting.« less

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

PubMed

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

2014-02-01

This study differentiated the mechanical properties of nickel-chromium (Ni-Cr) alloys under various casting techniques (different casting molds and casting atmospheres). These techniques were sampled by a sand mold using a centrifugal machine in ambient air (group I) and electromagnetic induction in an automatic argon castimatic casting machine (group II). The specimen casting used a graphite mold by a castimatic casting machine (group III). The characteristics of the Ni-Cr alloys, yield and ultimate tensile strength, bending modulus, microhardness, diffraction phase, grindability, ability to spring back, as well as ground microstructure and pattern under different casting conditions were evaluated. The group III specimens exhibited the highest values in terms of strength, modulus, hardness, and grindability at a grind rate of 500 rpm. Moreover, group III alloys exhibited smaller grain sizes, higher ability to spring back, and greater ductility than those casted by sand investment (groups I and II). The main factor, "casting mold," significantly influenced all mechanical properties. The graphite mold casting of the Ni-Cr dental alloys in a controlled atmosphere argon casting system provided an excellent combination of high mechanical properties and good ability to spring back, and preserved the ductile properties for application in Ni-Cr porcelain-fused system. The results can offer recommendations to assist a prosthetic technician in selecting the appropriate casting techniques to obtain the desired alloy properties. Copyright © 2013 Elsevier B.V. All rights reserved.

Population differentiation of southern Indian male lineages correlates with agricultural expansions predating the caste system.

PubMed

Arunkumar, Ganeshprasad; Soria-Hernanz, David F; Kavitha, Valampuri John; Arun, Varatharajan Santhakumari; Syama, Adhikarla; Ashokan, Kumaran Samy; Gandhirajan, Kavandanpatti Thangaraj; Vijayakumar, Koothapuli; Narayanan, Muthuswamy; Jayalakshmi, Mariakuttikan; Ziegle, Janet S; Royyuru, Ajay K; Parida, Laxmi; Wells, R Spencer; Renfrew, Colin; Schurr, Theodore G; Smith, Chris Tyler; Platt, Daniel E; Pitchappan, Ramasamy

2012-01-01

Previous studies that pooled Indian populations from a wide variety of geographical locations, have obtained contradictory conclusions about the processes of the establishment of the Varna caste system and its genetic impact on the origins and demographic histories of Indian populations. To further investigate these questions we took advantage that both Y chromosome and caste designation are paternally inherited, and genotyped 1,680 Y chromosomes representing 12 tribal and 19 non-tribal (caste) endogamous populations from the predominantly Dravidian-speaking Tamil Nadu state in the southernmost part of India. Tribes and castes were both characterized by an overwhelming proportion of putatively Indian autochthonous Y-chromosomal haplogroups (H-M69, F-M89, R1a1-M17, L1-M27, R2-M124, and C5-M356; 81% combined) with a shared genetic heritage dating back to the late Pleistocene (10-30 Kya), suggesting that more recent Holocene migrations from western Eurasia contributed <20% of the male lineages. We found strong evidence for genetic structure, associated primarily with the current mode of subsistence. Coalescence analysis suggested that the social stratification was established 4-6 Kya and there was little admixture during the last 3 Kya, implying a minimal genetic impact of the Varna (caste) system from the historically-documented Brahmin migrations into the area. In contrast, the overall Y-chromosomal patterns, the time depth of population diversifications and the period of differentiation were best explained by the emergence of agricultural technology in South Asia. These results highlight the utility of detailed local genetic studies within India, without prior assumptions about the importance of Varna rank status for population grouping, to obtain new insights into the relative influences of past demographic events for the population structure of the whole of modern India.

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

A Recipe for Soft Fluidic Elastomer Robots

PubMed Central

Marchese, Andrew D.; Katzschmann, Robert K.

2015-01-01

Abstract This work provides approaches to designing and fabricating soft fluidic elastomer robots. That is, three viable actuator morphologies composed entirely from soft silicone rubber are explored, and these morphologies are differentiated by their internal channel structure, namely, ribbed, cylindrical, and pleated. Additionally, three distinct casting-based fabrication processes are explored: lamination-based casting, retractable-pin-based casting, and lost-wax-based casting. Furthermore, two ways of fabricating a multiple DOF robot are explored: casting the complete robot as a whole and casting single degree of freedom (DOF) segments with subsequent concatenation. We experimentally validate each soft actuator morphology and fabrication process by creating multiple physical soft robot prototypes. PMID:27625913

A Recipe for Soft Fluidic Elastomer Robots.

PubMed

Marchese, Andrew D; Katzschmann, Robert K; Rus, Daniela

2015-03-01

This work provides approaches to designing and fabricating soft fluidic elastomer robots. That is, three viable actuator morphologies composed entirely from soft silicone rubber are explored, and these morphologies are differentiated by their internal channel structure, namely, ribbed, cylindrical, and pleated. Additionally, three distinct casting-based fabrication processes are explored: lamination-based casting, retractable-pin-based casting, and lost-wax-based casting. Furthermore, two ways of fabricating a multiple DOF robot are explored: casting the complete robot as a whole and casting single degree of freedom (DOF) segments with subsequent concatenation. We experimentally validate each soft actuator morphology and fabrication process by creating multiple physical soft robot prototypes.

Rough case-based reasoning system for continues casting

NASA Astrophysics Data System (ADS)

Su, Wenbin; Lei, Zhufeng

2018-04-01

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

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

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

Sabau, Adrian S

2008-04-01

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

Tracheobronchial cast production and use in an undergraduate human anatomy course.

PubMed

Cope, Lee Anne

2008-01-01

Silastic E RTV silicone was used to produce tracheobronchial cast for use in an undergraduate human anatomy course. Following air-drying, the trachea and lungs were injected with E RTV silicone and allowed to cure for 24 hr. The parenchyma was then removed from the tracheobronchial cast by maceration and boiling and then whitened in a 10% solution of hydrogen peroxide. The result was an anatomical replica that illustrates the branching pattern of the tracheobronchial tree and looks very similar to human even though canine lungs were used. In addition, this cast is very flexible and durable enough to stand up to repeated student handling.

SLIP CASTING METHOD

DOEpatents

Allison, A.G.

1959-09-01

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

Multicomponent micropatterned sol-gel materials by capillary molding

NASA Astrophysics Data System (ADS)

Lochhead, Michael J.; Yager, Paul

1997-10-01

A physically and chemically benign method for patterning multiple sol-gel materials onto a single substrate is described. Structures are demonstrated for potential micro- optical chemical sensor, biosensor, and waveguiding applications. Fabrication is based on the micro molding in capillaries (MIMIC) approach. A novel mold design allows several sols to be cast simultaneously. Closely spaced, organically modified silica ridges containing fluorescent dyes are demonstrated. Ridges have cross sectional dimensions from one to 50 micrometers and are centimeters in length. Processing issues, particularly those related to mold filling, are discussed in detail. Because sol-gel MIMIC avoids the harsh physical and chemical environments normally associated with patterning, the approach allows full exploitation of sol- gel processing advantages, such as the ability to entrap sensitive organic dopant molecules in the sol-gel matrix.

Simulation of the Continuous Casting and Cooling Behavior of Metallic Glasses

PubMed Central

Pei, Zhipu; Ju, Dongying

2017-01-01

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

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

PubMed

Pei, Zhipu; Ju, Dongying

2017-04-17

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

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

NASA Astrophysics Data System (ADS)

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

2015-08-01

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

Indigenous lunar construction materials

NASA Technical Reports Server (NTRS)

Rogers, Wayne; Sture, Stein

1991-01-01

The objectives are the following: to investigate the feasibility of the use of local lunar resources for construction of a lunar base structure; to develop a material processing method and integrate the method with design and construction of a pressurized habitation structure; to estimate specifications of the support equipment necessary for material processing and construction; and to provide parameters for systems models of lunar base constructions, supply, and operations. The topics are presented in viewgraph form and include the following: comparison of various lunar structures; guidelines for material processing methods; cast lunar regolith; examples of cast basalt components; cast regolith process; processing equipment; mechanical properties of cast basalt; material properties and structural design; and future work.

The use of porcine corrosion casts for teaching human anatomy.

PubMed

Eberlova, Lada; Liska, Vaclav; Mirka, Hynek; Tonar, Zbynek; Haviar, Stanislav; Svoboda, Milos; Benes, Jan; Palek, Richard; Emingr, Michal; Rosendorf, Jachym; Mik, Patrik; Leupen, Sarah; Lametschwandtner, Alois

2017-09-01

In teaching and learning human anatomy, anatomical autopsy and prosected specimens have always been indispensable. However, alternative methods must often be used to demonstrate particularly delicate structures. Corrosion casting of porcine organs with Biodur E20 ® Plus is valuable for teaching and learning both gross anatomy and, uniquely, the micromorphology of cardiovascular, respiratory, digestive, and urogenital systems. Assessments of casts with a stereomicroscope and/or scanning electron microscope as well as highlighting cast structures using color coding help students to better understand how the structures that they have observed as two-dimensional images actually exist in three dimensions, and students found using the casts to be highly effective in their learning. Reconstructions of cast hollow structures from (micro-)computed tomography scans and videos facilitate detailed analyses of branching patterns and spatial arrangements in cast structures, aid in the understanding of clinically relevant structures and provide innovative visual aids. The casting protocol and teaching manual we offer can be adjusted to different technical capabilities and might also be found useful for veterinary or other biological science classes. Copyright © 2017 Elsevier GmbH. All rights reserved.

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

Patterns of discoloration and oxidation by direct and scattered fluxes on LDEF, including oxygen on silicon

NASA Technical Reports Server (NTRS)

Frederickson, A. R.; Filz, R. C.; Rich, F. J.; Sagalyn, P. L.

1992-01-01

A number of interesting discoloration patterns are clearly evident on MOOO2-1 which resides on the three faces of the Long Duration Exposure Facility (LDEF). Most interesting is the pattern of blue oxidation on polished single crystal silicon apparently produced by scattered or direct ram oxygen atoms along the earth face. A complete explanation for the patterns has not yet been obtained. All honeycomb outgassing holes have a small discoloration ring around them that varies in color. The shadow cast by a suspended wire on the earth face surface is not easily explained by either solar photons or by ram flux. The shadows and the dark/light regions cannot be explained consistently by the process of solar ultraviolet paint-darkening modulated by ram flux oxygen bleaching of the paint.

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

PubMed

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

2002-03-01

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

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.

Caste-Specific and Sex-Specific Expression of Chemoreceptor Genes in a Termite

PubMed Central

Mikheyev, Alexander; Tin, Mandy M. Y.; Watanabe, Yutaka; Matsuura, Kenji

2016-01-01

The sophisticated colony organization of eusocial insects is primarily maintained through the utilization of pheromones. The regulation of these complex social interactions requires intricate chemoreception systems. The recent publication of the genome of Zootermopsis nevadensis opened a new avenue to study molecular basis of termite caste systems. Although there has been a growing interest in the termite chemoreception system that regulates their sophisticated caste system, the relationship between division of labor and expression of chemoreceptor genes remains to be explored. Using high-throughput mRNA sequencing (RNA-seq), we found several chemoreceptors that are differentially expressed among castes and between sexes in a subterranean termite Reticulitermes speratus. In total, 53 chemoreception-related genes were annotated, including 22 odorant receptors, 7 gustatory receptors, 12 ionotropic receptors, 9 odorant-binding proteins, and 3 chemosensory proteins. Most of the chemoreception-related genes had caste-related and sex-related expression patterns; in particular, some chemoreception genes showed king-biased or queen-biased expression patterns. Moreover, more than half of the genes showed significant age-dependent differences in their expression in female and/or male reproductives. These results reveal a strong relationship between the evolution of the division of labor and the regulation of chemoreceptor gene expression, thereby demonstrating the chemical communication and underlining chemoreception mechanism in social insects. PMID:26760975

Caste-Specific and Sex-Specific Expression of Chemoreceptor Genes in a Termite.

PubMed

Mitaka, Yuki; Kobayashi, Kazuya; Mikheyev, Alexander; Tin, Mandy M Y; Watanabe, Yutaka; Matsuura, Kenji

2016-01-01

The sophisticated colony organization of eusocial insects is primarily maintained through the utilization of pheromones. The regulation of these complex social interactions requires intricate chemoreception systems. The recent publication of the genome of Zootermopsis nevadensis opened a new avenue to study molecular basis of termite caste systems. Although there has been a growing interest in the termite chemoreception system that regulates their sophisticated caste system, the relationship between division of labor and expression of chemoreceptor genes remains to be explored. Using high-throughput mRNA sequencing (RNA-seq), we found several chemoreceptors that are differentially expressed among castes and between sexes in a subterranean termite Reticulitermes speratus. In total, 53 chemoreception-related genes were annotated, including 22 odorant receptors, 7 gustatory receptors, 12 ionotropic receptors, 9 odorant-binding proteins, and 3 chemosensory proteins. Most of the chemoreception-related genes had caste-related and sex-related expression patterns; in particular, some chemoreception genes showed king-biased or queen-biased expression patterns. Moreover, more than half of the genes showed significant age-dependent differences in their expression in female and/or male reproductives. These results reveal a strong relationship between the evolution of the division of labor and the regulation of chemoreceptor gene expression, thereby demonstrating the chemical communication and underlining chemoreception mechanism in social insects.

Genomic Signature of Kin Selection in an Ant with Obligately Sterile Workers

PubMed Central

Warner, Michael R.; Mikheyev, Alexander S.

2017-01-01

Abstract Kin selection is thought to drive the evolution of cooperation and conflict, but the specific genes and genome-wide patterns shaped by kin selection are unknown. We identified thousands of genes associated with the sterile ant worker caste, the archetype of an altruistic phenotype shaped by kin selection, and then used population and comparative genomic approaches to study patterns of molecular evolution at these genes. Consistent with population genetic theoretical predictions, worker-upregulated genes experienced reduced selection compared with genes upregulated in reproductive castes. Worker-upregulated genes included more taxonomically restricted genes, indicating that the worker caste has recruited more novel genes, yet these genes also experienced reduced selection. Our study identifies a putative genomic signature of kin selection and helps to integrate emerging sociogenomic data with longstanding social evolution theory. PMID:28419349

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.

Patterns of Increasing Swiss Needle Cast Impacts on Growth of 20- and 40-year-old Douglas-fir from Tillamook

EPA Science Inventory

Currently, Swiss Needle Cast (SNC) is causing an epidemic west of the Oregon Coast Range from Coos Bay to Astoria. The most severely infected Douglas-fir trees are located on BLM land and Stimson Lumber plantations in Tillamook where environmental conditions are highly favorable ...

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.

Fabrication of silk fibroin film using centrifugal casting technique for corneal tissue engineering.

PubMed

Lee, Min Chae; Kim, Dong-Kyu; Lee, Ok Joo; Kim, Jung-Ho; Ju, Hyung Woo; Lee, Jung Min; Moon, Bo Mi; Park, Hyun Jung; Kim, Dong Wook; Kim, Su Hyeon; Park, Chan Hum

2016-04-01

Films prepared from silk fibroin have shown potential as biomaterials in tissue engineering applications for the eye. Here, we present a novel process for fabrication of silk fibroin films for corneal application. In this work, fabrication of silk fibroin films was simply achieved by centrifugal force. In contrast to the conventional dry casting method, we carried out the new process in a centrifuge with a rotating speed of 4000 rpm, where centrifugal force was imposed on an aluminum tube containing silk fibroin solution. In the present study, we also compared the surface roughness, mechanical properties, transparency, and cell proliferation between centrifugal and dry casting method. In terms of surface morphology, films fabricated by the centrifugal casting have less surface roughness than those by the dry casting. For elasticity and transparency, silk fibroin films obtained from the centrifugal casting had favorable results compared with those prepared by dry casting. Furthermore, primary human corneal keratocytes grew better in films prepared by the centrifugal casting. Therefore, our results suggest that this new fabrication process for silk fibroin films offers important potential benefits for corneal tissue regeneration. © 2015 Wiley Periodicals, Inc.

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

PubMed

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

2017-01-01

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

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

PubMed Central

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

2017-01-01

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

Genetic variation in South Indian castes: evidence from Y-chromosome, mitochondrial, and autosomal polymorphisms

PubMed Central

Watkins, WS; Thara, R; Mowry, BJ; Zhang, Y; Witherspoon, DJ; Tolpinrud, W; Bamshad, MJ; Tirupati, S; Padmavati, R; Smith, H; Nancarrow, D; Filippich, C; Jorde, LB

2008-01-01

Background Major population movements, social structure, and caste endogamy have influenced the genetic structure of Indian populations. An understanding of these influences is increasingly important as gene mapping and case-control studies are initiated in South Indian populations. Results We report new data on 155 individuals from four Tamil caste populations of South India and perform comparative analyses with caste populations from the neighboring state of Andhra Pradesh. Genetic differentiation among Tamil castes is low (RST = 0.96% for 45 autosomal short tandem repeat (STR) markers), reflecting a largely common origin. Nonetheless, caste- and continent-specific patterns are evident. For 32 lineage-defining Y-chromosome SNPs, Tamil castes show higher affinity to Europeans than to eastern Asians, and genetic distance estimates to the Europeans are ordered by caste rank. For 32 lineage-defining mitochondrial SNPs and hypervariable sequence (HVS) 1, Tamil castes have higher affinity to eastern Asians than to Europeans. For 45 autosomal STRs, upper and middle rank castes show higher affinity to Europeans than do lower rank castes from either Tamil Nadu or Andhra Pradesh. Local between-caste variation (Tamil Nadu RST = 0.96%, Andhra Pradesh RST = 0.77%) exceeds the estimate of variation between these geographically separated groups (RST = 0.12%). Low, but statistically significant, correlations between caste rank distance and genetic distance are demonstrated for Tamil castes using Y-chromosome, mtDNA, and autosomal data. Conclusion Genetic data from Y-chromosome, mtDNA, and autosomal STRs are in accord with historical accounts of northwest to southeast population movements in India. The influence of ancient and historical population movements and caste social structure can be detected and replicated in South Indian caste populations from two different geographic regions. PMID:19077280

Influence of Processing Techniques on Microstructure and Mechanical Properties of a Biodegradable Mg-3Zn-2Ca Alloy

PubMed Central

Doležal, Pavel; Zapletal, Josef; Fintová, Stanislava; Trojanová, Zuzanka; Greger, Miroslav; Roupcová, Pavla; Podrábský, Tomáš

2016-01-01

New Mg-3Zn-2Ca magnesium alloy was prepared using different processing techniques: gravity casting as well as squeeze casting in liquid and semisolid states. Materials were further thermally treated; thermal treatment of the gravity cast alloy was additionally combined with the equal channel angular pressing (ECAP). Alloy processed by the squeeze casting in liquid as well as in semisolid state exhibit improved plasticity; the ECAP processing positively influenced both the tensile and compressive characteristics of the alloy. Applied heat treatment influenced the distribution and chemical composition of present intermetallic phases. Influence of particular processing techniques, heat treatment, and intermetallic phase distribution is thoroughly discussed in relation to mechanical behavior of presented alloys. PMID:28774000

Circadian consequences of social organization in the ant species Camponotus compressus

NASA Astrophysics Data System (ADS)

Sharma, Vijay Kumar; Lone, Shahnaz Rahman; Goel, Anubhuthi; Chandrashekaran, M. K.

The locomotor activity rhythm of different castes of the ant species Camponotus compressus was monitored individually under laboratory light/dark (LD) cycles, and under continuous darkness (DD). The colony of this ant species comprises two sexual castes, the queens and the males, and three worker castes, namely the major, media, and minor workers. The virgin males and virgin queens display rhythmic activity patterns, but the mated queens were arrhythmic while laying eggs, with the rhythmicity resuming soon after egg-laying. Under the LD regime, major workers showed nocturnal patterns, while about 75% of the media workers displayed nocturnal patterns and about 25% showed diurnal patterns. Under the DD regime, most major workers exhibited circadian rhythm of activity with a single steady state, whereas media workers displayed two types of activity patterns, with activity patterns changing after 6-9 days in DD (turn-arounds). The pre-turn-around τ of the ants that showed nocturnal activity patterns during LD entrainment was <24 h after release into DD, which then became >24 h, after 6-9 days. On the other hand, the pre-turn-around τ of those ants that exhibited diurnal patterns during LD entrainment was first >24 h after release into DD, and then became <24 h, after 6-9 days. The activity of the minor workers neither entrained to LD cycles nor showed any sign of free-run in DD. It appears that the circadian clocks of the ant species C. compressus are flexible, and may perhaps depend upon the tasks assigned to them in the colony.

Production of permeable cellulose triacetate membranes

DOEpatents

Johnson, B.M.

1986-12-23

A phase inversion process for the preparation of cellulose triacetate (CTA) and regenerated cellulose membranes is disclosed. Such membranes are useful as supports for liquid membranes in facilitated transport processes, as microfiltration membranes, as dialysis or ultrafiltration membranes, and for the preparation of ion-selective electrodes. The process comprises the steps of preparing a casting solution of CTA in a solvent comprising a mixture of cyclohexanone and methylene chloride, casting a film from the casting solution, and immersing the cast film in a methanol bath. The resulting CTA membrane may then be hydrolyzed to regenerated cellulose using conventional techniques.

Production of permeable cellulose triacetate membranes

DOEpatents

Johnson, Bruce M.

1986-01-01

A phase inversion process for the preparation of cellulose triacetate (CTA) and regenerated cellulose membranes is disclosed. Such membranes are useful as supports for liquid membranes in facilitated transport processes, as microfiltration membranes, as dialysis or ultrafiltration membranes, and for the preparation of ion-selective electrodes. The process comprises the steps of preparing a casting solution of CTA in a solvent comprising a mixture of cyclohexanone and methylene chloride, casting a film from the casting solution, and immersing the cast film in a methanol bath. The resulting CTA membrane may then be hydrolyzed to regenerated cellulose using conventional techniques.

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

PubMed

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

2010-10-01

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

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.

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

PubMed

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

2006-12-01

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

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

NASA Technical Reports Server (NTRS)

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

1993-01-01

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

Fabrication of cast particle-reinforced metals via pressure infiltration

NASA Technical Reports Server (NTRS)

Klier, E. M.; Mortensen, A.; Cornie, J. A.; Flemings, M. C.

1991-01-01

A new casting process for fabrication of particle-reinforced metals is presented whereby a composite of particulate reinforcing phase in metal is first produced by pressure infiltration. This composite is then diluted in additional molten metal to obtain the desired reinforcement volume fraction and metal composition. This process produces a pore-free as-cast particulate metal-matrix composite. This process is demonstrated for fabrication of magnesium-matrix composites containing SiC reinforcements of average diameter 30, 10 and 3 microns. It is compared with the compocasting process, which was investigated as well for similar SiC particles in Mg-10 wt pct Al, and resulted in unacceptable levels of porosity in the as-cast composite.

Modern and past periglacial features in Central Asia and their implication for paleoclimate reconstructions

NASA Astrophysics Data System (ADS)

Lehmkuhl, Frank

2017-04-01

In the cold and continental areas of Central and High Asia periglacial landform assembles, sediment structures and processes are mainly influenced and determinated by the existence of soil humidity during the freeze-thaw cycles. This results in cryogenic processes and periglacial landforms such as earth hummocks, patterned ground or solifluction. The distribution of rock glaciers as clear indicators of permafrost is also determined by rock fall or moraine debris composed of large boulders (e.g. granite). Periglacial features and landforms have been used to reconstruct past climatic conditions, e.g. relict involutions and ice-wedge casts provide evidence for the distribution of former permafrost, e.g. for the Last Glacial Maximum. Past temperatures, e.g. mean annual air temperatures, can be estimated from these periglacial features. Examples from late Holocene solifluction activity in the Altai, Khangai, and north-eastern Tibetan Plateau show different intensity of solifluction processes during the Late Holocene and Little Ice Age by decrease of temperature and more soil humidity. The distribution of past permafrost in some regions is still a matter of debate due to different interpretations of sediment structures: Sometimes features described as ice-wedge casts may be caused by roots or desiccation cracks due to drying of clay rich sediments. Seismically deformed unconsolidated deposits (seismites) can also be misinterpreted as periglacial involutions. The lack of certain landform assemblages and sediment structures does not necessarily mean that the area had no permafrost as moisture conditions also to a large degree govern periglacial landform generation and not only temperature. They can be ordered in Central Asia as follows (from highest moisture availability to lowest): solifluction - rock glacier - permafrost involutions - ice-wedge casts - sand wedge casts. Reference: LEHMKUHL, F. (2016): Modern and past periglacial features in Central Asia and their implication for paleoclimate reconstructions. - Progress in Physical Geography 40: 369-391. DOI: 10.1177/0309133315615778

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

NASA Astrophysics Data System (ADS)

Jiang, Chengcan; Rui, Yannian

2017-03-01

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

Fabrication of a negative PMMA master mold for soft-lithography by MeV ion beam lithography

NASA Astrophysics Data System (ADS)

Puttaraksa, Nitipon; Unai, Somrit; Rhodes, Michael W.; Singkarat, Kanda; Whitlow, Harry J.; Singkarat, Somsorn

2012-02-01

In this study, poly(methyl methacrylate) (PMMA) was investigated as a negative resist by irradiation with a high-fluence 2 MeV proton beam. The beam from a 1.7 MV Tandetron accelerator at the Plasma and Beam Physics Research Facility (PBP) of Chiang Mai University is shaped by a pair of computer-controlled L-shaped apertures which are used to expose rectangular pattern elements with 1-1000 μm side length. Repeated exposure of rectangular pattern elements allows a complex pattern to be built up. After subsequent development, the negative PMMA microstructure was used as a master mold for casting poly(dimethylsiloxane) (PDMS) following a standard soft-lithography process. The PDMS chip fabricated by this technique was demonstrated to be a microfluidic device.

Method to prevent/mitigate steam explosions in casting pits

DOEpatents

Taleyarkhan, Rusi P.

1996-01-01

Steam explosions can be prevented or mitigated during a metal casting process by the placement of a perforated flooring system in the casting pit. An upward flow of compressed gas through this perforated flooring system is introduced during the casting process to produce a buffer layer between any spilled molten metal and the cooling water in the reservoir. This buffer layer provides a hydrodynamic layer which acts to prevent or mitigate steam explosions resulting from hot, molten metal being spilled into or onto the cooling water.

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.

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

PubMed

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

2001-06-01

The objectives of this paper were to simulate the casting process of titanium tooth crowns and bridges; to predict and control porosity defect. A casting simulation software, MAGMASOFT, was used. The geometry of the crowns with fine details of the occlusal surface were digitized by means of laser measuring technique, then converted and read in the simulation software. Both mold filling and solidification were simulated, the shrinkage porosity was predicted by a "feeding criterion", and the gas pore sensitivity was studied based on the mold filling and solidification simulations. Two types of dental prostheses (a single-crown casting and a three-unit-bridge) with various sprue designs were numerically "poured", and only one optimal design for each prosthesis was recommended for real casting trial. With the numerically optimized design, real titanium dental prostheses (five replicas for each) were made on a centrifugal casting machine. All the castings endured radiographic examination, and no porosity was detected in the cast prostheses. It indicates that the numerical simulation is an efficient tool for dental casting design and porosity control. Copyright 2001 Kluwer Academic Publishers

Effect of pressure of helium, argon, krypton, and xenon on the porosity, microstructure, and mechanical properties of commercially pure titanium castings.

PubMed

Zinelis, S

2000-11-01

Porosity is a frequently observed casting defect in dental titanium alloys. This study evaluated the effect of pressure of helium, argon, krypton, and xenon on the porosity, microstructure, and mechanical properties of commercially pure titanium (cp Ti) castings. Eight groups (A-H) of 16 rectangular wax patterns each (30 mm in length, 3 mm in width, and 1 mm in depth) were prepared. The wax patterns were invested with a magnesia-based material and cast with cp Ti (grade II). Groups A, C, E, and G were cast under a pressure of 1 atm, and groups B, D, F, and H were cast under a pressure of 0.5 atm of He, Ar, Kr, and Xe, respectively. The extent of the porosity of the cast specimens was determined radiographically and quantified by image analysis. Three specimens of each group and 3 cylinders of the as-received cp Ti used as a reference were embedded in resin and studied metallographically after grinding, polishing, and chemical etching. These surfaces were used for determination of the Vickers hardness (VHN) as well. Eight specimens from each group were fractured in the tensile mode, and the 0.2% yield strength, fracture stress, and percentage elongation were calculated. Porosity was analyzed with 2-way ANOVA and the Newman-Keuls multiple range test. VHN measurements and tensile properties for specimen groups were compared with 1-way ANOVA and the Newman-Keuls multiple range test (95% significance level). The porosity levels per group were (%): A = 5.50 +/- 4.34, B = 0.77 +/- 1.27, C = 2.44 +/- 3.68, D = 0.06 +/- 0.12, E-H = 0. Two-way ANOVA showed that there was no detectable interaction (P<.05) between gas type and applied pressure. Metallographic examination revealed no differences in microstructure among the groups studied. A finer grain size was observed in all cast groups compared with the original cp Ti. The VHN of the as-received cp Ti was significantly greater than all the cast groups tested. Groups cast under He showed the highest VHN, yield strength, and fracture stress. No significant differences were found in percentage elongation values among the groups. Porosity and mechanical properties of cp Ti castings are dependent on the gas type and pressure, whereas the microstructure remains unaffected.

Investigation of Materials Processing Technology

DTIC Science & Technology

1993-07-01

Figure 6: Time-temperature curves of A357 casting in Cu mold ................. 12 Figure 7: Time-temperature curves of 17 -4 casting in ceramic mold...simulation of 17 -4 ................ 17 Figure 12: IHTC from IHEAT simulation of 17 -4 casting ..................... 18 Figure 13: Temperature profiles...mold used for Ti castings .......................... 23 Figure 16: Cooling curves for a Ti casting in ceramic mold .................. 24 Figure 17

[Reliability of three dimensional resin model by rapid prototyping manufacturing and digital modeling].

PubMed

Zeng, Fei-huang; Xu, Yuan-zhi; Fang, Li; Tang, Xiao-shan

2012-02-01

To describe a new technique for fabricating an 3D resin model by 3D reconstruction and rapid prototyping, and to analyze the precision of this method. An optical grating scanner was used to acquire the data of silastic cavity block , digital dental cast was reconstructed with the data through Geomagic Studio image processing software. The final 3D reconstruction was saved in the pattern of Stl. The 3D resin model was fabricated by fuse deposition modeling, and was compared with the digital model and gypsum model. The data of three groups were statistically analyzed using SPSS 16.0 software package. No significant difference was found in gypsum model,digital dental cast and 3D resin model (P>0.05). Rapid prototyping manufacturing and digital modeling would be helpful for dental information acquisition, treatment design, appliance manufacturing, and can improve the communications between patients and doctors.

Geometrical effects of conventional and digital prosthodontic planning wax-ups on lateral occlusal contact number, contact area, and steepness.

PubMed

Abduo, Jaafar

2017-01-01

This study evaluated and compared the effect of conventional and digital wax-ups on three lateral occlusion variables: contact number, contact area, and steepness. Dental casts of 10 patients with Angle Class I relationship were included in the study. All patients required fixed prosthodontic treatment that would affect lateral occlusion. The casts of all patients received conventional and digital wax-ups. For pretreatment, conventional wax-up, and digital wax-up casts, contact number, contact area, and occlusion steepness were measured at four lateral positions, that is, at excursions of 0.5, 1.0, 2.0, and 3.0 mm from maximal intercuspation. Lateral occlusion scheme variables were affected by use of diagnostic wax-ups. For all types of casts, contact number decreased as excursion increased. The two types of wax-ups had similar contact number patterns, and contact number was significantly greater for these casts than for pretreatment casts in the earlier stages of excursion. Similarly, contact area gradually decreased with increasing excursion in the pretreatment and conventional and digital wax-up casts. There was only a minimal decrease in occlusion steepness as excursion increased. However, lateral occlusion was generally steeper for digital wax-up casts.

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

NASA Astrophysics Data System (ADS)

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

2016-07-01

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

OVERALL VIEW OF SOUTHERN DUCTILE'S PATTERN REPAIR SHOP, SHOWING A ...

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

OVERALL VIEW OF SOUTHERN DUCTILE'S PATTERN REPAIR SHOP, SHOWING A SPANISH-MADE FORADIA BORING MACHINE IN THE FOREGROUND. - Southern Ductile Casting Company, Mold Making, 2217 Carolina Avenue, Bessemer, Jefferson County, AL

Lightweight Concrete Produced Using a Two-Stage Casting Process.

PubMed

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

2015-03-25

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

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.

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.

Inkjet-Printed Small-Molecule Organic Light-Emitting Diodes: Halogen-Free Inks, Printing Optimization, and Large-Area Patterning.

PubMed

Zhou, Lu; Yang, Lei; Yu, Mengjie; Jiang, Yi; Liu, Cheng-Fang; Lai, Wen-Yong; Huang, Wei

2017-11-22

Manufacturing small-molecule organic light-emitting diodes (OLEDs) via inkjet printing is rather attractive for realizing high-efficiency and long-life-span devices, yet it is challenging. In this paper, we present our efforts on systematical investigation and optimization of the ink properties and the printing process to enable facile inkjet printing of conjugated light-emitting small molecules. Various factors on influencing the inkjet-printed film quality during the droplet generation, the ink spreading on the substrates, and its solidification processes have been systematically investigated and optimized. Consequently, halogen-free inks have been developed and large-area patterning inkjet printing on flexible substrates with efficient blue emission has been successfully demonstrated. Moreover, OLEDs manufactured by inkjet printing the light-emitting small molecules manifested superior performance as compared with their corresponding spin-cast counterparts.

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.

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

NASA Technical Reports Server (NTRS)

Clarke, A. E., Jr.

1964-01-01

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

Social structure and intracohort variation in physical fitness among elderly males in a traditional Third World society.

PubMed

Beall, C M; Goldstein, M C; Feldman, E S

1985-06-01

This paper examines the relationship between physical fitness and activity among elderly males in the traditional rural community of Chetbesi, Nepal. It takes advantage of the unique character of the Hindu caste system to implement a quasiexperimental research design that approximates random assignment to high and low activity levels. The members of the Sarki caste have lower heart rates and systolic blood pressure, relative to other castes, at each of three submaximal workloads and during recovery from bicycle ergometer exercise. Direct observation and physiologic monitoring show that the Sarkis engage in more frequent and extended periods of heavy labor. Thus intracohort variation in physical fitness and activity patterns among the Chetbesi elderly is a function of birth into a socially defined group rather than of self-selection. This pattern of differential fitness may typify the process of aging in many stratified traditional and modernizing societies where socially delimited segments of the population perform the bulk of the hard work. Intrapopulation differences aside, comparison of Sarkis and non-Sarkis with other samples reveals that both lie within the reported range of variation. The rural, unmechanized, agricultural lifestyle and mountain environment of Chetbesi do not result in exceptional fitness for residents. The Chetbesi data suggest that the popular notion that aging is less debilitating in traditional agrarian societies located in rugged mountain terrains may be a myth. The demonstration of the influence of social forces on physical fitness suggests that future research might concentrate profitably on identifying social structures that produce high levels of physical fitness.

Microstructural Evolution in Intensively Melt Sheared Direct Chill Cast Al-Alloys

NASA Astrophysics Data System (ADS)

Jones, S.; Rao, A. K. Prasada; Patel, J. B.; Scamans, G. M.; Fan, Z.

The work presented here introduces the novel melt conditioned direct chill casting (MC-DC) technology, where intensive melt shearing is applied to the conventional direct-chill casting process. MC-DC casting can successfully produce high quality Al-alloy billets. The results obtained from 80 mm diameter billets cast at speed of 200 mm/min show that MC-DC casting of Al-alloys, substantially refines the microstructure and reduces macro-segregation. In this paper, we present the preliminary results and discuss microstructural evolution during MC-DC casting of Al-alloys.

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.

Experimental Studies of Heat-Transfer Behavior at a Casting/Water-Cooled-Mold Interface and Solution of the Heat-Transfer Coefficient

NASA Astrophysics Data System (ADS)

Zeng, Y. D.; Wang, F.

2018-02-01

In this paper, we propose an experimental model for forming an air gap at the casting/mold interface during the solidification process of the casting, with the size and formation time of the air gap able to be precisely and manually controlled. Based on this model, experiments of gravity casting were performed, and on the basis of the measured temperatures at different locations inside the casting and the mold, the inverse analysis method of heat transfer was applied to solve for the heat-transfer coefficient at the casting/mold interface during the solidification process. Furthermore, the impacts of the width and formation time of the air gap on the interface heat-transfer coefficient (IHTC) were analyzed. The results indicate that the experimental model succeeds in forming an air gap having a certain width at any moment during solidification of the casting, thus allowing us to conveniently and accurately study the impact of the air gap on IHTC using the model. In addition, the casting/mold IHTC is found to first rapidly decrease as the air gap forms and then slowly decrease as the solidification process continues. Moreover, as the width of the air gap and the formation time of the air gap increase, the IHTC decreases.

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

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

DOEpatents

Campbell, Christian X; Thomaidis, Dimitrios

2014-05-13

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

Effect of formulation- and administration-related variables on deposition pattern of nasal spray pumps evaluated using a nasal cast.

PubMed

Kundoor, Vipra; Dalby, Richard N

2011-08-01

To systematically evaluate the effect of formulation- and administration-related variables on nasal spray deposition using a nasal cast. Deposition pattern was assessed by uniformly coating a transparent nose model with Sar-Gel®, which changes from white to purple on contact with water. Sprays were subsequently discharged into the cast, which was then digitally photographed. Images were quantified using Adobe® Photoshop. The effects of formulation viscosity (which influences droplet size), simulated administration techniques (head orientation, spray administration angle, spray nozzle insertion depth), spray pump design and metering volume on nasal deposition pattern were investigated. There was a significant decrease in the deposition area associated with sprays of increasing viscosity. This appeared to be mediated by an increase in droplet size and a narrowing of the spray plume. Administration techniques and nasal spray pump design also had a significant effect on the deposition pattern. This simple color-based method provides quantitative estimates of the effects that different formulation and administration variables may have on the nasal deposition area, and provides a rational basis on which manufacturers of nasal sprays can base their patient instructions or post approval changes when it is impractical to optimize these using a clinical study.

Casting copper to tungsten for high-power arc lamp cathodes

NASA Technical Reports Server (NTRS)

Will, H. A.

1974-01-01

Voids forming at interface when copper is cast onto tungsten can be eliminated by adding wetting agent during casting process. Small amount of copper and nickel are cast onto thoriated tungsten insert, insert is recast with more copper to form electrode. Good thermal conductance results in long-lived cathode.

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

PubMed

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

2013-04-01

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

Morphometric Analysis of Aqueous Humor Outflow Structures with Spectral-Domain Optical Coherence Tomography

PubMed Central

Francis, Andrew W.; Kagemann, Larry; Wollstein, Gadi; Ishikawa, Hiroshi; Folz, Steven; Overby, Darryl R.; Sigal, Ian A.; Wang, Bo; Schuman, Joel S.

2012-01-01

Purpose. To describe morphometric details of the human aqueous humor (AH) outflow microvasculature visualized with 360-degree virtual castings during active AH outflow in cadaver eyes and to compare these structures with corrosion casting studies. Methods. The conventional AH outflow pathways of donor eyes (n = 7) and eyes in vivo (n = 3) were imaged with spectral-domain optical coherence tomography (SD-OCT) and wide-bandwidth superluminescent diode array during active AH outflow. Digital image contrast was adjusted to isolate AH microvasculature, and images were viewed in a 3D viewer. Additional eyes (n = 3) were perfused with mock AH containing fluorescent tracer microspheres to compare microvasculature patterns. Results. Observations revealed components of the conventional outflow pathway from Schlemm's canal (SC) to the superficial intrascleral venous plexus (ISVP). The superficial ISVP in both our study and corrosion casts were composed of interconnected venules (10–50 μm) forming a hexagonal meshwork. Larger radial arcades (50–100 μm) drained the region nearest SC and converged with larger tortuous vessels (>100 μm). A 360-degree virtual casting closely approximated corrosion casting studies. Tracer studies corroborated our findings. Tracer decorated several larger vessels (50–100 μm) extending posteriorly from the limbus in both raw and contrast-enhanced fluorescence images. Smaller tracer-labeled vessels (30–40 μm) were seen branching between larger vessels and exhibited a similar hexagonal network pattern. Conclusions. SD-OCT is capable of detailed morphometric analysis of the conventional outflow pathway in vivo or ex vivo with details comparable to corrosion casting techniques. PMID:22499987

Solidification structures grown under induced flow and continuous casting of steel

NASA Technical Reports Server (NTRS)

Tsavaras, A. A.

1984-01-01

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

Lightweight Concrete Produced Using a Two-Stage Casting Process

PubMed Central

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

2015-01-01

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

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.

Women's health in a rural community in Kerala, India: do caste and socioeconomic position matter?

PubMed Central

Mohindra, K S; Haddad, Slim; Narayana, D

2006-01-01

Objectives To examine the social patterning of women's self‐reported health status in India and the validity of the two hypotheses: (1) low caste and lower socioeconomic position is associated with worse reported health status, and (2) associations between socioeconomic position and reported health status vary across castes. Design Cross‐sectional household survey, age‐adjusted percentages and odds ratios, and multilevel multinomial logistic regression models were used for analysis. Setting A panchayat (territorial decentralised unit) in Kerala, India, in 2003. Participants 4196 non‐elderly women. Outcome measures Self‐perceived health status and reported limitations in activities in daily living. Results Women from lower castes (scheduled castes/scheduled tribes (SC/ST) and other backward castes (OBC) reported a higher prevalence of poor health than women from forward castes. Socioeconomic inequalities were observed in health regardless of the indicators, education, women's employment status or household landholdings. The multilevel multinomial models indicate that the associations between socioeconomic indicators and health vary across caste. Among SC/ST and OBC women, the influence of socioeconomic variables led to a “magnifying” effect, whereas among forward caste women, a “buffering” effect was found. Among lower caste women, the associations between socioeconomic factors and self‐assessed health are graded; the associations are strongest when comparing the lowest and highest ratings of health. Conclusions Even in a relatively egalitarian state in India, there are caste and socioeconomic inequalities in women's health. Implementing interventions that concomitantly deal with caste and socioeconomic disparities will likely produce more equitable results than targeting either type of inequality in isolation. PMID:17108296

Process for manufacturing a lithium alloy electrochemical cell

DOEpatents

Bennett, William R.

1992-10-13

A process for manufacturing a lithium alloy, metal sulfide cell tape casts slurried alloy powders in an organic solvent containing a dissolved thermoplastic organic binder onto casting surfaces. The organic solvent is then evaporated to produce a flexible tape removable adhering to the casting surface. The tape is densified to increase its green strength and then peeled from the casting surface. The tape is laminated with a separator containing a lithium salt electrolyte and a metal sulfide electrode to form a green cell. The binder is evaporated from the green cell at a temperature lower than the melting temperature of the lithium salt electrolyte. Lithium alloy, metal sulfide and separator powders may be tape cast.

Software Analytical Instrument for Assessment of the Process of Casting Slabs

NASA Astrophysics Data System (ADS)

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

2010-06-01

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

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 to prevent/mitigate steam explosions in casting pits

DOEpatents

Taleyarkhan, R.P.

1996-12-24

Steam explosions can be prevented or mitigated during a metal casting process by the placement of a perforated flooring system in the casting pit. An upward flow of compressed gas through this perforated flooring system is introduced during the casting process to produce a buffer layer between any spilled molten metal and the cooling water in the reservoir. This buffer layer provides a hydrodynamic layer which acts to prevent or mitigate steam explosions resulting from hot, molten metal being spilled into or onto the cooling water. 3 figs.

Development of a New Membrane Casting Apparatus for Studying Macrovoid Defects in Low-G

NASA Technical Reports Server (NTRS)

Lee, Hanyong; Hwang, Sun-Tak; Krantz, William B.; Greenberg, Alan R.; Khare, Vivek; Zartman, Jeremiah; Todd, Paul W.

2002-01-01

A new membrane-casting apparatus is developed for studying macrovoid defects in polymeric membranes made by the wet- and dry-casting process in low-gravity. Macrovoids are large (10-50 micron), open cavities interspersed among the smaller pores in the substructure under the gelled skin surface layer of the cast membrane. Although their occurrence is considered endemic to the wet- and dry-casting process since they can lead to compaction or skin rupture in the membrane process, recent studies suggest several useful applications such as transdermal and osmotic drug delivery systems, miniature bioreactors, etc. However, lack of knowledge about the macrovoid formation mechanism is an obstacle to further development of applications using them. An on-going debate is the role of the surface-tension-driven solutocapillary convection during macrovoid formation. The rapid growth of macrovoids within 1-5 seconds and the high polymer concentration in and near macrovoids make it difficult to explain the mechanism of macrovoid growth by diffusion alone, which is the widely accepted hypothesis proposed by Reuvers et al. The hypothesis advanced by our research group can explain this rapid growth via a mechanism that involves diffusion from the casting solution in the meta-stable region to the macrovoid enhanced by solutocapillary convection induced by the steep nonsolvent concentration gradient in the vicinity of the macrovoid. Since macrovoid growth is hypothesized to be the interplay of a solutocapillary-induced driving force counteracted by viscous drag and buoyancy, eliminate the latter provides a means for testing this hypothesis. Moreover, free convection mass transfer in the nonsolvent immersion bath used to cause phase-separation in membrane casting complicates developing a model for both the wet-casting process and macrovoid growth. The low-g environment minimizes gravitationally induced free convection thereby permitting a tractable solution to the ternary diffusion equations that characterize membrane formation. NASA's Parabolic Flight Research Aircraft provides a small window of low-g (approximately 25 s) that can be used to study macrovoid development in both wet- and dry-cast membranes if an appropriate casting apparatus is used. This casting apparatus should be able to cast the membrane in both low- and high-g in a manner so that essential one-dimensional mass transfer conditions are achieved to insure lateral uniformity in the membrane. The apparatus used in previous research on membrane casting in low-gravity was operated with the plunger driven mechanism. The spring-loaded plunger pushes the bottom block containing the polymer casting solution well directly under the absorbent chamber located in the upper stationary block. However, membranes made via this casting apparatus often displayed lateral nonuniformities that precluded obtaining quantitative information on the macrovoid growth process. Thus, it was necessary to determine the reason for these structural irregularities observed in the low-g casting apparatus. Both experimental as well as computer simulation studies of the low-g casting apparatus established that the impulsive action of the plunger caused the undesired structural nonuniformities. The simulation results showed that the width-to-depth aspect ratio of the shallow well that contains the casting solution in this apparatus was not an important factor in minimizing this problem. Even for a 40:1 (width : depth) aspect ratio, any convection induced by the horizontal motion of the interface of the casting solution will be damped out within 6.25x10(exp 4) seconds. However, the experimental studies revealed that the impulsive motion of the plunger caused a 'sloshing' of the casting solution that had to be eliminated. Therefore, the plungerdriven mechanism was changed to a cam-driven mechanism that did not cause any impulsive motion of the casting solution. Other refinements to this new membrane-casting apparatus include provision for removing the membranes from the casting wells in a less destructive manner. This was accomplished by using a slit geometry for the casting well that permitted disassembly for removal of the cast membrane. The materials used in the construction of this casting apparatus were chosen to insure wetting at the side walls and to maintain precise control of the thickness of the polymer solution in the casting well. An additional provision in this new casting apparatus is the ability to carry out both wet- as well as dry-casting. As such, this apparatus permitted the first studies of the wet-casting of polymeric membranes in low-g. Both wet- and dry-casting experiments on NASA's KC-135 research aircraft employing this new membrane-casting apparatus are scheduled in July 2002. The morphology of the resulting membranes will be characterized using an environmental scanning electron microscope (ESEM). The results of these low-g studies will be reported later.

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

PubMed

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

2018-01-01

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

Arteriovenous Patterns in Beaked Whales

DTIC Science & Technology

2015-09-30

flushing of blood clots from the vascular system and injection of casting compound followed by corrosion of soft tissue. Resulting vascular casts were...extensive blood clotting of pulmonary vasculature. These pulmonary pathologies rendered all fresh specimens obtained unusable. Due to these complications...The objective was to describe and better understand the gross morphology of the blood vessels in the heads of beaked whales. Gross anatomical

Mortality Burden and Socioeconomic Status in India

PubMed Central

Po, June Y. T.; Subramanian, S. V.

2011-01-01

Background The dimensions along which mortality is patterned in India remains unclear. We examined the specific contribution of social castes, household income, assets, and monthly per capita consumption to mortality differentials in India. Methods and Findings Cross-sectional data on 217 363 individuals from 41 554 households from the 2004–2005 India Human Development Survey was analyzed using multiple logistic regressions. Mortality differentials across social castes were attenuated after adjusting for household economic factors such as income and assets. Individuals living in the lowest income and assets quintiles had an increased risk of mortality with odds ratio (OR) of 1.66 (95% CI  = 1.23–2.24) in the bottom income quintile and OR of 2.94 (95% CI  = 1.66–5.22) in the bottom asset quintile. Counter-intuitively, individuals living in households with lowest monthly consumption per capita had significantly lower probability of death (OR  = 0.27, 95% CI  = 0.20–0.38). Conclusions Mortality burden in India is largely patterned on economic dimensions as opposed to caste dimensions, though caste may play an important role in predicting economic opportunities. PMID:21347373

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

NASA Astrophysics Data System (ADS)

Lynch, Paul C.

This work describes the initial work on the development of the next generation of ultrahigh strength low alloy (UHSLA) cast steels. These UHSLA cast steels have both ultrahigh strength levels and good impact toughness. The influence of heat treatment, secondary processing using hot isostatic processing (HIP), and chemical composition on the microstructure and properties of UHSLA cast steels have been evaluated. The extent of microsegregation reduction expected during the heat treatment of UHSLA cast steels has also been estimated by diffusion modeling. This new family of UHSLA cast steels is similar in composition and properties to UHSLA wrought steels. However, the heat treatment and secondary processing of the UHSLA cast steels is used to develop microstructures and properties typically developed through thermomechanical processing and heat treatment for wrought UHSLA steels. Two martensitic UHSLA steels, 4340+ (silicon modified 4340) and ES-1 were investigated for this study. For the 4340+ alloy, heat treatment variables evaluated include homogenization temperature and time, tempering temperature, and austempering temperature and time. For the ES-1 alloy, heat treatment variables evaluated include homogenization temperature and time, austenization temperature, cryogenic treatment, and tempering temperature. The effect of high temperature hot isostatic processing (HIP) on the 4340+ and ES- 1 alloys was also investigated. Tensile properties, charpy v-notch impact toughness (CVN), microstructures, and fractographs have all been characterized after heat treatment. The effects of HIP on microporosity reduction in the ES-1 alloy were also investigated. The experiments carried out on the investment cast 4340+ alloy have shown that increasing the homogenization temperature can increase CVN without changing the ultimate tensile strength (UTS) or yield strength (YS) of the cast material. By replacing the homogenization step in the conventional heat treatment process with a high temperature HIP treatment, both the CVN and ductility of the alloy was found to increase while maintaining comparable ultimate tensile strength (UTS) and yield strength (YS) levels as compared to the original homogenization treatment. Austempering the (IC) 4340+ material led to a significant increase in CVN and ductility at the expense of UTS and yield strength as the primarily martensitic microstructure was converted to a mixed martensitic-bainitic structure. An initial heat of induction melted, aluminum deoxidized investment cast ES-1 with 0.06 wt % of aluminum showed that the average -40°F and +72°F impact toughness, % elongation, and UTS and YS of the fully heat treated investment cast + HIP ES-1 material lagged significantly behind that of the vacuum degassed cast + HIP ES-1 ingot material. Even though the % elongation and impact toughness of the investment cast ES-1 material changed between heat treatment conditions, the average UTS and YS values remained relatively unchanged throughout the heat treatments for the investment cast study. Etched micrographs of the investment cast ES-1 material showed evidence of significant differences in microsegregation reduction between the samples homogenized at 2125°F for 4 hours and those not homogenized at 2125°F for 4 hours. SEM fracture surface work performed on the investment cast material clearly showed that the induction melted investment and aluminum killed cast material contained significant amounts of MnS and Al2O3 inclusions that were not discovered in the vacuum degassed cast ingot material. Lastly, the results of a third heat of induction melted, aluminum deoxidized investment cast ES-1 material possessing just 0.01wt% of aluminum showed that the decrease in aluminum content from the first experimental heat did not improve the mechanical properties of the investment cast material. (Abstract shortened by UMI.)

Remelt Ingot Production Technology

NASA Astrophysics Data System (ADS)

Grandfield, J. F.

The technology related to the production of remelt ingots (small ingots, sows and T-Bar) is reviewed. Open mold conveyors, sow casting, wheel and belt casting and VDC and HDC casting are described and compared. Process economics, capacity, product quality and process problems are listed. Trends in casting machine technology such as longer open mold conveyor lines are highlighted. Safety issues related to the operation of these processes are discussed. The advantages and disadvantages of the various machine configurations and options e.g. such as dry filling with the mold out of water and wet filling with the mold in water for open mould conveyors are discussed. The effect of mold design on machine productivity, mold cracking and mold life is also examined.

Population Differentiation of Southern Indian Male Lineages Correlates with Agricultural Expansions Predating the Caste System

PubMed Central

Arun, Varatharajan Santhakumari; Syama, Adhikarla; Ashokan, Kumaran Samy; Gandhirajan, Kavandanpatti Thangaraj; Vijayakumar, Koothapuli; Narayanan, Muthuswamy; Jayalakshmi, Mariakuttikan; Ziegle, Janet S.; Royyuru, Ajay K.; Parida, Laxmi; Wells, R. Spencer; Renfrew, Colin; Schurr, Theodore G.; Smith, Chris Tyler; Platt, Daniel E.; Pitchappan, Ramasamy

2012-01-01

Previous studies that pooled Indian populations from a wide variety of geographical locations, have obtained contradictory conclusions about the processes of the establishment of the Varna caste system and its genetic impact on the origins and demographic histories of Indian populations. To further investigate these questions we took advantage that both Y chromosome and caste designation are paternally inherited, and genotyped 1,680 Y chromosomes representing 12 tribal and 19 non-tribal (caste) endogamous populations from the predominantly Dravidian-speaking Tamil Nadu state in the southernmost part of India. Tribes and castes were both characterized by an overwhelming proportion of putatively Indian autochthonous Y-chromosomal haplogroups (H-M69, F-M89, R1a1-M17, L1-M27, R2-M124, and C5-M356; 81% combined) with a shared genetic heritage dating back to the late Pleistocene (10–30 Kya), suggesting that more recent Holocene migrations from western Eurasia contributed <20% of the male lineages. We found strong evidence for genetic structure, associated primarily with the current mode of subsistence. Coalescence analysis suggested that the social stratification was established 4–6 Kya and there was little admixture during the last 3 Kya, implying a minimal genetic impact of the Varna (caste) system from the historically-documented Brahmin migrations into the area. In contrast, the overall Y-chromosomal patterns, the time depth of population diversifications and the period of differentiation were best explained by the emergence of agricultural technology in South Asia. These results highlight the utility of detailed local genetic studies within India, without prior assumptions about the importance of Varna rank status for population grouping, to obtain new insights into the relative influences of past demographic events for the population structure of the whole of modern India. PMID:23209694

Preliminary study of oxide-dispersion-strengthened B-1900 prepared by mechanical alloys

NASA Technical Reports Server (NTRS)

Glasgow, T. K.; Quatinetz, M.

1975-01-01

An experimental oxide dispersion strengthened (ODS) alloy based on the B-1900 composition was produced by the mechanical alloying process. Without optimization of the processing for the alloy or the alloy for the processing, recrystallization of the extruded product to large elongated grains was achieved. Materials having grain length-width ratios of 3 and 5.5 were tested in tension and stress-rupture. The ODS B-1900 exhibited tensile strength similar to that of cast B-1900. Its stress-rupture life was lower than that of cast B-1900 at 760 C. At 1095 C the ODS B-1900 with the higher grain length-width ratio (5.5) had stress-rupture life superior to that of cast B-1900. It was concluded that, with optimization, oxide dispersion strengthening of B-1900 and other complex cast nickel-base alloys has potential for improving high temperature properties over those of the cast alloy counterparts.

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

PubMed

Laila, Assayidatul; Nanko, Makoto; Takeda, Masatoshi

2014-09-04

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

Development of lead zirconate titanate cantilevers on the micrometer length scale

NASA Astrophysics Data System (ADS)

Martin, Christopher Robert

The objective of this research project was to fabricate a functional ferroelectric microcantilever from patterned lead zirconate titanate (PZT) thin films. Cantilevers fabricated from ferroelectric materials have tremendous potential in sensing applications, particularly due to the increased sensitivity that miniaturized devices offer. This thesis highlights and explores a number of the processing issues that hindered the production of a working prototype. PZT is patterned using soft lithography-inspired techniques from a PZT chemical precursor solution derived by the chelation synthesis route. As the ability to pattern ceramic materials derived from sol-gels on the micrometer scale is a relatively new technology, this thesis aims to expand the scientific understanding of new issues that arise when working with these patterned films. For example, the use of Micromolding in Capillaries (MIMIC) to pattern the PZT thin films results in the evolution of topographical distortions from the shape of the original mold during the shrinkage of patterned thin film during drying and sintering. The factors that contribute to this effect have been explained and a new processing technique called MicroChannel Molding (muCM) was developed. This new process combines the advantages of soft lithography with traditional silicon microfabrication techniques to ensure compatibility with current industrial practices. This work lays the foundation for the future production of working ferroelectric microcantilevers. The proposed microfabrication process is described along with descriptions of each processing difficulty that was encountered. Modifications to the process are proposed along with the descriptions of alternative processing techniques that were attempted for the benefit of future researchers. This dissertation concludes with the electronic characterization of micropattemed PZT thin films. To our knowledge, the ferroelectric properties of patterned PZT thin films have never been directly characterized before. The properties are measured with a commercial ferroelectric test system connected through a conductive Atomic Force Microscope tip. The films patterned by MIMIC and muCM are compared to large-area spin cast films to identify the role that the processing method has on the resulting properties.

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

NASA Technical Reports Server (NTRS)

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

1978-01-01

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

Simulation of cracking cores when molding piston components

NASA Astrophysics Data System (ADS)

Petrenko, Alena; Soukup, Josef

2014-08-01

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

Artificial Bone and Teeth through Controlled Ice Growth in Colloidal Suspensions

NASA Astrophysics Data System (ADS)

Tomsia, Antoni P.; Saiz, Eduardo; Deville, Sylvain

2007-06-01

The formation of regular patterns is a common feature of many solidification processes involving cast materials. We describe here how regular patterns can be obtained in porous alumina and hydroxyapatite (HAP) by controlling the freezing of ceramic slurries followed by subsequent ice sublimation and sintering, leading to multilayered porous ceramic structures with homogeneous and well-defined architecture. These porous materials can be infiltrated with a second phase of choice to yield biomimetic nacre-like composites with improved mechanical properties, which could be used for artificial bone and teeth applications. Proper control of the solidification patterns provides powerful means of control over the final functional properties. We discuss the relationships between the experimental results, ice growth fundamentals, the physics of ice and the interaction between inert particles and the solidification front during directional freezing.

Artificial Bone and Teeth through Controlled Ice Growth in Colloidal Suspensions

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

Tomsia, Antoni P.; Saiz, Eduardo; Deville, Sylvain

2007-06-14

The formation of regular patterns is a common feature of many solidification processes involving cast materials. We describe here how regular patterns can be obtained in porous alumina and hydroxyapatite (HAP) by controlling the freezing of ceramic slurries followed by subsequent ice sublimation and sintering, leading to multilayered porous ceramic structures with homogeneous and well-defined architecture. These porous materials can be infiltrated with a second phase of choice to yield biomimetic nacre-like composites with improved mechanical properties, which could be used for artificial bone and teeth applications. Proper control of the solidification patterns provides powerful means of control over themore » final functional properties. We discuss the relationships between the experimental results, ice growth fundamentals, the physics of ice and the interaction between inert particles and the solidification front during directional freezing.« less

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

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

Development of expert systems for modeling of technological process of pressure casting on the basis of artificial intelligence

NASA Astrophysics Data System (ADS)

Gavarieva, K. N.; Simonova, L. A.; Pankratov, D. L.; Gavariev, R. V.

2017-09-01

In article the main component of expert system of process of casting under pressure which consists of algorithms, united in logical models is considered. The characteristics of system showing data on a condition of an object of management are described. A number of logically interconnected steps allowing to increase quality of the received castings is developed

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.

Spray Deposition: A Fundamental Study of Droplet Impingement, Spreading and Consolidation

DTIC Science & Technology

1989-12-01

low alloy (HSLA) steel. Preforms of HSLA-100, a low carbon bainitic, copper precipitation strengthened HSLA steel...manufacturing process. Specifically, HSLA-100, a copper precipitation strengthened high-strength, low - alloy steel was spray cast via the Osprey’ m process...by spray casting. Preforms of HSLA-100, a low carbon bainitic, copper precipitation strengthened steel, were spray cast under differing conditions

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.

Low-cost single-crystal turbine blades, volume 1

NASA Technical Reports Server (NTRS)

Strangman, T. E.; Heath, B.; Fujii, M.

1983-01-01

The exothermic casting process was successfully developed into a low cost nonproprietary method for producing single crystal (SC) castings. Casting yields were lower than expected, on the order of 20 percent, but it is felt that the casting yield could be significantly improved with minor modifications to the process. Single crystal Mar-M 247 and two derivative SC alloys were developed. NASAIR 100 and SC Alloy 3 were fully characterized through mechanical property testing. SC Mar-M 247 shows no significant improvement in strength over directionally solidified (DS) Mar-M 247, but the derivative alloys, NASAIR 100 and Alloy 3, show significant tensile and fatigue improvements. The 1000 hr/238 MPa (20 ksi) stress rupture capability compared to DS Mar-M 247 was improved over 28 C. Firtree testing, holography, and strain gauge rig testing were used to evaluate the effects of the anisotropic characteristics of single crystal materials. In general, the single crystal material behaved similarly to DS Mar-M 247. Two complete engine sets of SC HP turbine blades were cast using the exothermic casting process and fully machined.

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

Organic materials for ceramic molding processes

NASA Technical Reports Server (NTRS)

Saito, K.

1984-01-01

Ceramic molding processes are examined. Binders, wetting agents, lubricants, plasticizers, surface active agents, dispersants, etc., for pressing, rubber pressing, sip casting, injection casting, taping, extrusion, etc., are described, together with forming machines.

Part I: In-situ fluorometric quantification of microalgal neutral lipids. Part II: Thermal degradation behavior of investment casting polymer patterns

NASA Astrophysics Data System (ADS)

Zhao, Hongfang

Research described in this dissertation covers two topics. Part-I is focused on in-situ determination of neutral lipid content of microalgae using a lipophilic fluorescent dye. The traditional Nile red stain-based method for detecting microalgal intracellular lipids is limited due to varying composition and thickness of rigid cell walls. In this study, the addition of dilute acid and heating of solution, were found to greatly enhance staining efficiency of Nile red for microalgal species evaluated. Oil-in-water (O/W) microemulsion stabilized by a non-ionic surfactant was employed as a pseudo-standard that mimics lipid-bearing microalgal cells suspended in water. The average neutral lipid contents determined were very close to the results obtained by traditional gravimetric method and solid phase extraction. Part II of the dissertation explores thermo-physico-chemical properties of polymeric pattern materials, including expanded polystyrene (EPS) foam, polyurethane foam, and epoxy stereolithography (SLA) patterns, that are used in investment casting. Density, elastic modulus, expansion coefficient, thermal degradation behavior, etc. were experimentally investigated for their effects on metal casting quality. The reduction in toxic hydrogen cyanide (HCN) generated during thermal decomposition of polyurethane pattern was achieved by increasing either oxidant level or residence time in heated zone. Thermal degradation kinetics of the pattern materials were examined with a thermogravimetric analysis and activation energies were determined by Kissinger and Flynn-Wall-Ozawa methods.

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.

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.

HFIR Fuel Casting Support

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

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

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

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

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

Madhav Rao Gonvindaraju

1999-10-18

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

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.

Acute kidney injury and hyperbilirubinemia in a young male after ingestion of Tribulus terrestris.

PubMed

Ryan, Margaret; Lazar, Ira; Nadasdy, Gyongyi M; Nadasdy, Tibor; Satoskar, Anjali A

2015-03-01

Acute tubular necrosis (ATN), especially from toxic injury is frequently accompanied by tubular casts and crystals. Myeloma casts, myoglobin, red blood cell and granular casts are well described. However, bile casts in tubules are rarely seen. We describe a case of Tribulus terrestris toxicity in a young healthy male, presenting with severe hyperbilirubinemia followed by acute renal failure and bile containing casts in the tubules. Tribulus terrestris is an herb often used by athletes as a nutritional supplement for performance enhancement. Although it is thought to be relatively safe, serious side effects have been reported before. Our aim is to increase awareness of the potential toxicities of performance enhancing herbal medications. These are often sold over-the-counter and therefore casually used, especially by young healthy individuals. Beneficial effects are controversial. Under-reporting by patients and infrequent documentation by health-care providers can delay diagnosis. We elaborately describe the kidney biopsy findings in Tribulus terrestris toxicity, and also provide a concise overview of the spectrum of tubular casts and their staining patterns, found in various kidney diseases.

The effect of a ceramic coating on the cpTi-porcelain bond strength.

PubMed

Papadopoulos, Triantafillos D; Spyropoulos, Konstantin D

2009-02-01

To investigate the bond strength between cpTi and low fusing porcelains after different treatments. 72 patterns were covered with a ceramic coating and invested with phosphate-bonded material (group A), another 72 were invested with magnesia material (group B) and all cast with cpTi. 31 solid castings were selected from each group. The castings of group B were ground and sandblasted, while the castings of group A were only sandblasted. Aluminum content of the metal surface was determined by EDS and castings were submitted to a 3-point bending test to determine the modulus of elasticity (E). The porcelains Duceratin Plus, Noritake Ti22 and Triceram were applied respectively and specimens were submitted to a 3-point bending test. The fracture mode and the remaining porcelain were determined by optical microscopy and SEM/EDS. Bond strength and fracture mode were calculated by two-way ANOVA. The E of groups A and B was 98.3 GPa and 98.6 GPa respectively. The bond strength was 26+/-3 MPa (Duceratin Plus), 28+/-3 MPa (Noritake Ti22), 27+/-2 MPa (Triceram) for group A and 24+/-1 MPa, 29+/-2 MPa, 27+/-1 MPa for group B respectively. No significant differences were found for the same porcelain between the two groups (p<0.05). A significant difference was found between Duceratin Plus and Noritake Ti22, for group B (p<0.05). The mode of failure was mainly adhesive for all specimens. A significant reduction in aluminum was recorded in all subgroups. The special coating of patterns makes the Ti casting procedure inexpensive, without reducing the metal-ceramic bond strength.

Application of TRIZ Theory in Patternless Casting Manufacturing Technique

NASA Astrophysics Data System (ADS)

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

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

A new method to acquire 3-D images of a dental cast

NASA Astrophysics Data System (ADS)

Li, Zhongke; Yi, Yaxing; Zhu, Zhen; Li, Hua; Qin, Yongyuan

2006-01-01

This paper introduced our newly developed method to acquire three-dimensional images of a dental cast. A rotatable table, a laser-knife, a mirror, a CCD camera and a personal computer made up of a three-dimensional data acquiring system. A dental cast is placed on the table; the mirror is installed beside the table; a linear laser is projected to the dental cast; the CCD camera is put up above the dental cast, it can take picture of the dental cast and the shadow in the mirror; while the table rotating, the camera records the shape of the laser streak projected on the dental cast, and transmit the data to the computer. After the table rotated one circuit, the computer processes the data, calculates the three-dimensional coordinates of the dental cast's surface. In data processing procedure, artificial neural networks are enrolled to calibrate the lens distortion, map coordinates form screen coordinate system to world coordinate system. According to the three-dimensional coordinates, the computer reconstructs the stereo image of the dental cast. It is essential for computer-aided diagnosis and treatment planning in orthodontics. In comparison with other systems in service, for example, laser beam three-dimensional scanning system, the characteristic of this three-dimensional data acquiring system: a. celerity, it casts only 1 minute to scan a dental cast; b. compact, the machinery is simple and compact; c. no blind zone, a mirror is introduced ably to reduce blind zone.

Space Weather Now-Casting for Area-Denied Locations: Testing All-Sky-Imaging Applications at Geomagnetic Conjugate Points.

NASA Astrophysics Data System (ADS)

Baumgardner, J. L.; Mendillo, M.; Martinis, C. R.; Hickey, D. A.; Wroten, J.

2017-12-01

We explore the concept of using an all-sky-imager (ASI) in one hemisphere to provide now-casting of ionospheric perturbations in the opposite hemisphere. The specific example deals with low-latitude plasma instabilities known as equatorial spread-F (ESF) that depend on geomagnetic field controlled electrodynamics. ASI observations of 630.0 nm airglow from 300 km exhibit regions of low emission ("airglow depletions") that correlate highly with ESF patterns of radiowave disruptions, e.g., from GPS satellites. For both oceanographic and geopolitical reasons, there are vast regions of the globe that cannot be used for ground-based now-casting of local ESF effects. For such area-denied locations, it is possible for observations of airglow depletions from the opposite hemisphere to be used to specify both local and conjugate location environmental impacts. We use fifteen months of ASI observations from the El Leoncito Observatory (Argentina) to predict simultaneous conditions at its trans-equatorial geomagnetic conjugate point in Villa de Leyva (Colombia)—validated by independent ASI observations at that location. We find the success rate of conjugate point now-casting to be greater than 95% for large-scale ESF occurrence patterns. For a different pair of stations at higher magnetic latitudes, three years of observations from the Arecibo Observatory (Puerto Rico) were used to make ESF now-casting at its conjugate point in Mercedes (Argentina) with a 85% success rate.

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

NASA Astrophysics Data System (ADS)

Li, Ben Q.

1995-05-01

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

Designing High Performance Steel Castings Today: Proceedings of the Steel Founders Society of America, Technical and Operating Conference December 7-10, 2016Chicago, IL

DTIC Science & Technology

2016-12-10

will be 2 x failure (critical) depth. G. INSPECTION REQUIREMENTS Either the No- Bake sand or Investment process is selected based on which... Bake sand and the Investment Casting Handbook by the Investment Casting Institute has the tolerance values for investment castings. Typically there

Systems and methods for monitoring a solid-liquid interface

DOEpatents

Stoddard, Nathan G; Lewis, Monte A.; Clark, Roger F

2013-06-11

Systems and methods are provided for monitoring a solid-liquid interface during a casting process. The systems and methods enable determination of the location of a solid-liquid interface during the casting process.

Development of High-Performance Cast Crankshafts. Final Technical Report

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

Bauer, Mark E

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

Photoreactive elastin-like proteins for use as versatile bioactive materials and surface coatings

PubMed Central

Raphel, Jordan; Parisi-Amon, Andreina; Heilshorn, Sarah

2012-01-01

Photocrosslinkable, protein-engineered biomaterials combine a rapid, controllable, cytocompatible crosslinking method with a modular design strategy to create a new family of bioactive materials. These materials have a wide range of biomedical applications, including the development of bioactive implant coatings, drug delivery vehicles, and tissue engineering scaffolds. We present the successful functionalization of a bioactive elastin-like protein with photoreactive diazirine moieties. Scalable synthesis is achieved using a standard recombinant protein expression host followed by site-specific modification of lysine residues with a heterobifunctional N-hydroxysuccinimide ester-diazirine crosslinker. The resulting biomaterial is demonstrated to be processable by spin coating, drop casting, soft lithographic patterning, and mold casting to fabricate a variety of two- and three-dimensional photocrosslinked biomaterials with length scales spanning the nanometer to millimeter range. Protein thin films proved to be highly stable over a three-week period. Cell-adhesive functional domains incorporated into the engineered protein materials were shown to remain active post-photo-processing. Human adipose-derived stem cells achieved faster rates of cell adhesion and larger spread areas on thin films of the engineered protein compared to control substrates. The ease and scalability of material production, processing versatility, and modular bioactive functionality make this recombinantly engineered protein an ideal candidate for the development of novel biomaterial coatings, films, and scaffolds. PMID:23015764

Photoreactive elastin-like proteins for use as versatile bioactive materials and surface coatings.

PubMed

Raphel, Jordan; Parisi-Amon, Andreina; Heilshorn, Sarah

2012-10-07

Photocrosslinkable, protein-engineered biomaterials combine a rapid, controllable, cytocompatible crosslinking method with a modular design strategy to create a new family of bioactive materials. These materials have a wide range of biomedical applications, including the development of bioactive implant coatings, drug delivery vehicles, and tissue engineering scaffolds. We present the successful functionalization of a bioactive elastin-like protein with photoreactive diazirine moieties. Scalable synthesis is achieved using a standard recombinant protein expression host followed by site-specific modification of lysine residues with a heterobifunctional N-hydroxysuccinimide ester-diazirine crosslinker. The resulting biomaterial is demonstrated to be processable by spin coating, drop casting, soft lithographic patterning, and mold casting to fabricate a variety of two- and three-dimensional photocrosslinked biomaterials with length scales spanning the nanometer to millimeter range. Protein thin films proved to be highly stable over a three-week period. Cell-adhesive functional domains incorporated into the engineered protein materials were shown to remain active post-photo-processing. Human adipose-derived stem cells achieved faster rates of cell adhesion and larger spread areas on thin films of the engineered protein compared to control substrates. The ease and scalability of material production, processing versatility, and modular bioactive functionality make this recombinantly engineered protein an ideal candidate for the development of novel biomaterial coatings, films, and scaffolds.

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

Determination of Coherency and Rigidity Temperatures in Al-Cu Alloys Using In Situ Neutron Diffraction During Casting

NASA Astrophysics Data System (ADS)

Drezet, Jean-Marie; Mireux, Bastien; Szaraz, Zoltan; Pirling, Thilo

2014-08-01

The rigidity temperature of a solidifying alloy is the temperature at which the solid phase is sufficiently coalesced to transmit tensile stress. It is a major input parameter in numerical modeling of solidification processes as it defines the point at which thermally induced deformations start to generate internal stresses in a casting. This temperature has been determined for an Al-13 wt.% Cu alloy using in situ neutron diffraction during casting in a dog-bone-shaped mold. This setup allows the sample to build up internal stress naturally as its contraction is not possible. The cooling on both sides of the mold induces a hot spot at the middle of the sample that is irradiated by neutrons. Diffraction patterns are recorded every 11 s using a large detector, and the very first change of diffraction angles allows for the determination of the rigidity temperature. We measured rigidity temperatures equal to 557°C and 548°C depending on the cooling rate for grain refined Al-13 wt.% Cu alloys. At a high cooling rate, rigidity is reached during the formation of the eutectic phase. In this case, the solid phase is not sufficiently coalesced to sustain tensile load and thus cannot avoid hot tear formation.

After aesthetic rhinoplasty: new looks and psychological outlooks on post-surgical satisfaction.

PubMed

Moses, S; Last, U; Mahler, D

1984-01-01

Thirty-four female patients who underwent rhinoplasty were followed through assessment of post-surgical satisfaction (pss), perception of subjective improvement, objective improvement (surgeon's ratings), and objective post-surgical nasal deformity. Assessments of pss and subjective improvement were obtained on 3 occasions: T1, 1 week after surgery, on cast removal; T2, 1 month after cast removal; and T3, 3 months after cast removal. The investigation was aimed at examination of the relationship of patients' subjective post-surgical appraisals of the operation with objective indices of outcome of rhinoplasty. Results indicated that at T1, pss is totally dissociated from objective outcome or its appraisal by the patient. At T2 an association between objective outcome and pss and subjective appraisal of outcome is evident, but seems to reflect the total reliance of the patients' judgment on surgeons' appraisals. At T3 a paradoxical trend is indicated: slim objective favorable outcomes correlate with high pss, while a considerable share of patients with whom a highly favorable outcome has been attained express relatively low pss. This paradoxical trend may be well understood when applying Cognitive Dissonance Theory. The whole pattern of results point again at highly complex and powerful psychological processes, some of them seemingly irrational, operating within patients when relating to rhinoplasty, a simple superficial surgical procedure.

Diversity of Glycosyl Hydrolases from Cellulose-Depleting Communities Enriched from Casts of Two Earthworm Species▿ †

PubMed Central

Beloqui, Ana; Nechitaylo, Taras Y.; López-Cortés, Nieves; Ghazi, Azam; Guazzaroni, María-Eugenia; Polaina, Julio; Strittmatter, Axel W.; Reva, Oleg; Waliczek, Agnes; Yakimov, Michail M.; Golyshina, Olga V.; Ferrer, Manuel; Golyshin, Peter N.

2010-01-01

The guts and casts of earthworms contain microbial assemblages that process large amounts of organic polymeric substrates from plant litter and soil; however, the enzymatic potential of these microbial communities remains largely unexplored. In the present work, we retrieved carbohydrate-modifying enzymes through the activity screening of metagenomic fosmid libraries from cellulose-depleting microbial communities established with the fresh casts of two earthworm species, Aporrectodea caliginosa and Lumbricus terrestris, as inocula. Eight glycosyl hydrolases (GHs) from the A. caliginosa-derived community were multidomain endo-β-glucanases, β-glucosidases, β-cellobiohydrolases, β-galactosidase, and β-xylosidases of known GH families. In contrast, two GHs derived from the L. terrestris microbiome had no similarity to any known GHs and represented two novel families of β-galactosidases/α-arabinopyranosidases. Members of these families were annotated in public databases as conserved hypothetical proteins, with one being structurally related to isomerases/dehydratases. This study provides insight into their biochemistry, domain structures, and active-site architecture. The two communities were similar in bacterial composition but significantly different with regard to their eukaryotic inhabitants. Further sequence analysis of fosmids and plasmids bearing the GH-encoding genes, along with oligonucleotide usage pattern analysis, suggested that those apparently originated from Gammaproteobacteria (pseudomonads and Cellvibrio-like organisms), Betaproteobacteria (Comamonadaceae), and Alphaproteobacteria (Rhizobiales). PMID:20622123

VIEW OF INTERIOR OF SOUTHERN DUCTILE CASTING COMPANY, CENTERVILLE FOUNDRY ...

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

VIEW OF INTERIOR OF SOUTHERN DUCTILE CASTING COMPANY, CENTERVILLE FOUNDRY SHOWING MOLD MAKING WITH PNEWMATIC JOLT SQUEEZE COPE AND DRAG MOLDING MACHINES THAT INDIVIDUALLY MADE EITHER A COPE OR DRAG AND A SMALL WHEELED MATCHPLATE JOLT-SQUEEZE MACHINE THAT COMPRESSED AN ENTIRE MOLD AT A SINGLE TIME USING A DOUBLE-SIDED PATTERN (MATCHPLATE). ALSO SHOWN ARE RAILED PALLET CAR CONVEYORS THAT CARRIED COMPLETED MOLDS FROM MOLDING MACHINES TO POURING AREAS WHERE WORKERS USED SMALL OVERHEAD CRANE TO LIFT JACKETS AND WEIGHTS ONTO THE MOLDS TO HOLD THEM TOGETHER WHILE POURING. - Southern Ductile Casting Company, Centerville Foundry, 101 Airport Road, Centreville, Bibb County, AL

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.

Development of a New Ferrous Aluminosilicate Refractory Material for Investment Casting of Aluminum Alloys

NASA Astrophysics Data System (ADS)

Yuan, Chen; Jones, Sam; Blackburn, Stuart

2012-12-01

Investment casting is a time-consuming, labour intensive process, which produces complex, high value-added components for a variety of specialised industries. Current environmental and economic pressures have resulted in a need for the industry to improve current casting quality, reduce manufacturing costs and explore new markets for the process. Alumino-silicate based refractories are commonly used as both filler and stucco materials for ceramic shell production. A new ceramic material, norite, is now being produced based on ferrous aluminosilicate chemistry, having many potential advantages when used for the production of shell molds for casting aluminum alloy. This paper details the results of a direct comparison made between the properties of a ceramic shell system produced with norite refractories and a typical standard refractory shell system commonly used in casting industry. A range of mechanical and physical properties of the systems was measured, and a full-scale industrial casting trial was also carried out. The unique properties of the norite shell system make it a promising alternative for casting aluminum based alloys in the investment foundry.

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

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

Gastaldo, R.A.; Demko, T.M.; Liu, Yuejin

1989-08-01

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

Structural and compositional analysis of a casting mold sherd from ancient China.

PubMed

Zong, Yunbing; Yao, Shengkun; Lang, Jianfeng; Chen, Xuexiang; Fan, Jiadong; Sun, Zhibin; Duan, Xiulan; Li, Nannan; Fang, Hui; Zhou, Guangzhao; Xiao, Tiqiao; Li, Aiguo; Jiang, Huaidong

2017-01-01

Casting had symbolic significance and was strictly controlled in the Shang dynasty of ancient China. Vessel casting was mainly distributed around the Shang capital, Yin Ruins, which indicates a rigorous centralization of authority. Thus, for a casting mold to be excavated far from the capital region is rare. In addition to some bronze vessel molds excavated at the Buyao Village site, another key discovery of a bronze vessel mold occurred at Daxinzhuang. The Daxinzhuang site was a core area in the east of Shang state and is an important site to study the eastward expansion of the Shang. Here, combining synchrotron X-rays and other physicochemical analysis methods, nondestructive three-dimensional structure imaging and different elemental analyses were conducted on this mold sherd. Through high penetration X-ray tomography, we obtained insights on the internal structure and discovered some pores. We infer that the generation of pores inside the casting mold sherd was used to enhance air permeability during casting. Furthermore, we suppose that the decorative patterns on the surface were carved and not pasted onto it. Considering the previous compositional studies of bronze vessels, the copper and iron elements were analyzed by different methods. Unexpectedly, a larger amount of iron than of copper was detected on the surface. According to the data analysis and archaeological context, the source of iron on the casting mold sherd could be attributed to local soil contamination. A refined compositional analysis confirms that this casting mold was fabricated locally and used for bronze casting.

Effect of pressure difference on the quality of titanium casting.

PubMed

Watanabe, I; Watkins, J H; Nakajima, H; Atsuta, M; Okabe, T

1997-03-01

In casting titanium using a two-compartment casting machine, Herø et al. (1993) reported that the pressure difference between the melting chamber and the mold chamber affected the soundness of the castings. This study tested the hypothesis that differences in pressure produce castings with various amounts of porosity and different mechanical properties values. Plastic dumbbell-shaped patterns were invested with an alumina-based, phosphate-bonded investment material. Both chambers of the casting machine were evacuated to 6 x 10(-2) torr; the argon pressure difference was then adjusted to either 50, 150, 300, or 450 torr. The porosity of the cast specimens was determined by x-ray radiography and quantitative image analysis. Tensile strength and elongation were measured by means of a universal testing machine at a strain rate of 1.7 x 10(-4)/s. The fractured surfaces were examined by SEM. Changes in Vickers hardness with depth from the cast surface were measured on polished cross-sections of the specimens. Raising the argon pressure difference to 300 and 450 torr caused a significant increase in internal porosity and a resultant decrease in the engineering tensile strength and elongation. The highest tensile strength (approximately 540 MPa), elongation (approximately 10%), bulk hardness (HV50g 209), and lowest porosity level (approximately 0.8%) occurred in the specimens cast at 150 torr. Turbulence of the metal during casting was thought to be responsible for the increase in porosity levels with the increase in argon pressure difference. By choosing an argon pressure difference (around 150 torr) suitable for this geometry, we could produce castings which have adequate mechanical properties and low porosity levels.

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

DOT National Transportation Integrated Search

2015-11-01

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

Cast dielectric composite linear accelerator

DOEpatents

Sanders, David M [Livermore, CA; Sampayan, Stephen [Manteca, CA; Slenes, Kirk [Albuquerque, NM; Stoller, H M [Albuquerque, NM

2009-11-10

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

Evolution of A-Type Macrosegregation in Large Size Steel Ingot After Multistep Forging and Heat Treatment

NASA Astrophysics Data System (ADS)

Loucif, Abdelhalim; Ben Fredj, Emna; Harris, Nathan; Shahriari, Davood; Jahazi, Mohammad; Lapierre-Boire, Louis-Philippe

2018-03-01

A-type macrosegregation refers to the channel chemical heterogeneities that can be formed during solidification in large size steel ingots. In this research, a combination of experiment and simulation was used to study the influence of open die forging parameters on the evolution of A-type macrosegregation patterns during a multistep forging of a 40 metric ton (MT) cast, high-strength steel ingot. Macrosegregation patterns were determined experimentally by macroetch along the longitudinal axis of the forged and heat-treated ingot. Mass spectroscopy, on more than 900 samples, was used to determine the chemical composition map of the entire longitudinal sectioned surface. FORGE NxT 1.1 finite element modeling code was used to predict the effect of forging sequences on the morphology evolution of A-type macrosegregation patterns. For this purpose, grain flow variables were defined and implemented in a large scale finite element modeling code to describe oriented grains and A-type segregation patterns. Examination of the A-type macrosegregation showed four to five parallel continuous channels located nearly symmetrical to the axis of the forged ingot. In some regions, the A-type patterns became curved or obtained a wavy form in contrast to their straight shape in the as-cast state. Mass spectrometry analysis of the main alloying elements (C, Mn, Ni, Cr, Mo, Cu, P, and S) revealed that carbon, manganese, and chromium were the most segregated alloying elements in A-type macrosegregation patterns. The observed differences were analyzed using thermodynamic calculations, which indicated that changes in the chemical composition of the liquid metal can affect the primary solidification mode and the segregation intensity of the alloying elements. Finite element modeling simulation results showed very good agreement with the experimental observations, thereby allowing for the quantification of the influence of temperature and deformation on the evolution of the shape of the macrosegregation channels during the open die forging process.

Evolution of A-Type Macrosegregation in Large Size Steel Ingot After Multistep Forging and Heat Treatment

NASA Astrophysics Data System (ADS)

Loucif, Abdelhalim; Ben Fredj, Emna; Harris, Nathan; Shahriari, Davood; Jahazi, Mohammad; Lapierre-Boire, Louis-Philippe

2018-06-01

A-type macrosegregation refers to the channel chemical heterogeneities that can be formed during solidification in large size steel ingots. In this research, a combination of experiment and simulation was used to study the influence of open die forging parameters on the evolution of A-type macrosegregation patterns during a multistep forging of a 40 metric ton (MT) cast, high-strength steel ingot. Macrosegregation patterns were determined experimentally by macroetch along the longitudinal axis of the forged and heat-treated ingot. Mass spectroscopy, on more than 900 samples, was used to determine the chemical composition map of the entire longitudinal sectioned surface. FORGE NxT 1.1 finite element modeling code was used to predict the effect of forging sequences on the morphology evolution of A-type macrosegregation patterns. For this purpose, grain flow variables were defined and implemented in a large scale finite element modeling code to describe oriented grains and A-type segregation patterns. Examination of the A-type macrosegregation showed four to five parallel continuous channels located nearly symmetrical to the axis of the forged ingot. In some regions, the A-type patterns became curved or obtained a wavy form in contrast to their straight shape in the as-cast state. Mass spectrometry analysis of the main alloying elements (C, Mn, Ni, Cr, Mo, Cu, P, and S) revealed that carbon, manganese, and chromium were the most segregated alloying elements in A-type macrosegregation patterns. The observed differences were analyzed using thermodynamic calculations, which indicated that changes in the chemical composition of the liquid metal can affect the primary solidification mode and the segregation intensity of the alloying elements. Finite element modeling simulation results showed very good agreement with the experimental observations, thereby allowing for the quantification of the influence of temperature and deformation on the evolution of the shape of the macrosegregation channels during the open die forging process.

The Surales, Self-Organized Earth-Mound Landscapes Made by Earthworms in a Seasonal Tropical Wetland.

PubMed

Zangerlé, Anne; Renard, Delphine; Iriarte, José; Suarez Jimenez, Luz Elena; Adame Montoya, Kisay Lorena; Juilleret, Jérôme; McKey, Doyle

2016-01-01

The formation, functioning and emergent properties of patterned landscapes have recently drawn increased attention, notably in semi-arid ecosystems. We describe and analyze a set of similarly spectacular landforms in seasonal tropical wetlands. Surales landscapes, comprised of densely packed, regularly spaced mounds, cover large areas of the Orinoco Llanos. Although descriptions of surales date back to the 1940's, their ecology is virtually unknown. From data on soil physical and chemical properties, soil macrofauna, vegetation and aerial imagery, we provide evidence of the spatial extent of surales and how they form and develop. Mounds are largely comprised of earthworm casts. Recognizable, recently produced casts account for up to one-half of total soil mass. Locally, mounds are relatively constant in size, but vary greatly across sites in diameter (0.5-5 m) and height (from 0.3 m to over 2 m). This variation appears to reflect a chronosequence of surales formation and growth. Mound shape (round to labyrinth) varies across elevational gradients. Mounds are initiated when large earthworms feed in shallowly flooded soils, depositing casts that form 'towers' above water level. Using permanent galleries, each earthworm returns repeatedly to the same spot to deposit casts and to respire. Over time, the tower becomes a mound. Because each earthworm has a restricted foraging radius, there is net movement of soil to the mound from the surrounding area. As the mound grows, its basin thus becomes deeper, making initiation of a new mound nearby more difficult. When mounds already initiated are situated close together, the basin between them is filled and mounds coalesce to form larger composite mounds. Over time, this process produces mounds up to 5 m in diameter and 2 m tall. Our results suggest that one earthworm species drives self-organizing processes that produce keystone structures determining ecosystem functioning and development.

The Surales, Self-Organized Earth-Mound Landscapes Made by Earthworms in a Seasonal Tropical Wetland

PubMed Central

Iriarte, José; Suarez Jimenez, Luz Elena; Adame Montoya, Kisay Lorena; Juilleret, Jérôme; McKey, Doyle

2016-01-01

The formation, functioning and emergent properties of patterned landscapes have recently drawn increased attention, notably in semi-arid ecosystems. We describe and analyze a set of similarly spectacular landforms in seasonal tropical wetlands. Surales landscapes, comprised of densely packed, regularly spaced mounds, cover large areas of the Orinoco Llanos. Although descriptions of surales date back to the 1940’s, their ecology is virtually unknown. From data on soil physical and chemical properties, soil macrofauna, vegetation and aerial imagery, we provide evidence of the spatial extent of surales and how they form and develop. Mounds are largely comprised of earthworm casts. Recognizable, recently produced casts account for up to one-half of total soil mass. Locally, mounds are relatively constant in size, but vary greatly across sites in diameter (0.5–5 m) and height (from 0.3 m to over 2 m). This variation appears to reflect a chronosequence of surales formation and growth. Mound shape (round to labyrinth) varies across elevational gradients. Mounds are initiated when large earthworms feed in shallowly flooded soils, depositing casts that form ‘towers’ above water level. Using permanent galleries, each earthworm returns repeatedly to the same spot to deposit casts and to respire. Over time, the tower becomes a mound. Because each earthworm has a restricted foraging radius, there is net movement of soil to the mound from the surrounding area. As the mound grows, its basin thus becomes deeper, making initiation of a new mound nearby more difficult. When mounds already initiated are situated close together, the basin between them is filled and mounds coalesce to form larger composite mounds. Over time, this process produces mounds up to 5 m in diameter and 2 m tall. Our results suggest that one earthworm species drives self-organizing processes that produce keystone structures determining ecosystem functioning and development. PMID:27168157

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

NASA Astrophysics Data System (ADS)

Hadadzadeh, Amir; Wells, Mary

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

Data Package for Secondary Waste Form Down-Selection—Cast Stone

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

Serne, R. Jeffrey; Westsik, Joseph H.

2011-09-05

Available literature on Cast Stone and Saltstone was reviewed with an emphasis on determining how Cast Stone and related grout waste forms performed in relationship to various criteria that will be used to decide whether a specific type of waste form meets acceptance criteria for disposal in the Integrated Disposal Facility (IDF) at Hanford. After the critical review of the Cast Stone/Saltstone literature, we conclude that Cast Stone is a good candidate waste form for further consideration. Cast stone meets the target IDF acceptance criteria for compressive strength, no free liquids, TCLP leachate are below the UTS permissible concentrations andmore » leach rates for Na and Tc-99 are suiteably low. The cost of starting ingredients and equipment necessary to generate Cast Stone waste forms with secondary waste streams are low and the Cast Stone dry blend formulation can be tailored to accommodate variations in liquid waste stream compositions. The database for Cast Stone short-term performance is quite extensive compared to the other three candidate waste solidification processes. The solidification of liquid wastes in Cast Stone is a mature process in comparison to the other three candidates. Successful production of Cast Stone or Saltstone has been demonstrated from lab-scale monoliths with volumes of cm3 through m3 sized blocks to 210-liter sized drums all the way to the large pours into vaults at Savannah River. To date over 9 million gallons of low activity liquid waste has been solidified and disposed in concrete vaults at Savannah River.« less

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

PubMed

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

2000-12-01

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

Understanding How Processing Additives Tune the Nanoscale Morphology of High Efficiency Organic Photovoltaic Blends: From Casting Solution to Spun-Cast Thin Film

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

Shao, Ming; Keum, Jong Kahk; Kumar, Rajeev

2014-08-26

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

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

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

Shao, Ming; Keum, Jong Kahk; Kumar, Rajeev

2014-01-01

Adding a small amount of a processing additive to the casting solution of organic blends has been demonstrated to be an effective method for achieving improved power conversion efficiency (PCE) in organic photovoltaics (OPVs). However, an understanding of the nano-structural evolution occurring in the transformation from casting solution to thin photoactive films is still lacking. In this report, we investigate the effects of the processing additive diiodooctane (DIO) on the morphology of OPV blend of PBDTTT-C-T and fullerene derivative, PC71BM in a casting solution and in spun-cast thin films by using neutron/x-ray scattering, neutron reflectometry and other characterization techniques. Themore » results reveal that DIO has no effect on the solution structures of PBDTTT-C-T and PC71BM. In the spun-cast films, however, DIO is found to promote significantly the molecular ordering of PBDTTT-C-T and PC71BM, and phase segregation, resulting in the improved PCE. Thermodynamic analysis based on Flory-Huggins theory provides a rationale for the effects of DIO on different characteristics of phase segregation as a solvent and due to evaporationg during the film formation. Such information may enable improved rational design of ternary blends to more consistently achieve improved PCE for OPVs.« less

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.

A work study of the CAD/CAM method and conventional manual method in the fabrication of spinal orthoses for patients with adolescent idiopathic scoliosis.

PubMed

Wong, M S; Cheng, J C Y; Wong, M W; So, S F

2005-04-01

A study was conducted to compare the CAD/CAM method with the conventional manual method in fabrication of spinal orthoses for patients with adolescent idiopathic scoliosis. Ten subjects were recruited for this study. Efficiency analyses of the two methods were performed from cast filling/ digitization process to completion of cast/image rectification. The dimensional changes of the casts/ models rectified by the two cast rectification methods were also investigated. The results demonstrated that the CAD/CAM method was faster than the conventional manual method in the studied processes. The mean rectification time of the CAD/CAM method was shorter than that of the conventional manual method by 108.3 min (63.5%). This indicated that the CAD/CAM method took about 1/3 of the time of the conventional manual to finish cast rectification. In the comparison of cast/image dimensional differences between the conventional manual method and the CAD/CAM method, five major dimensions in each of the five rectified regions namely the axilla, thoracic, lumbar, abdominal and pelvic regions were involved. There were no significant dimensional differences (p < 0.05) in 19 out of the 25 studied dimensions. This study demonstrated that the CAD/CAM system could save the time in the rectification process and offer a relatively high resemblance in cast rectification as compared with the conventional manual method.

Simulation of Channel Segregation During Directional Solidification of In—75 wt pct Ga. Qualitative Comparison with In Situ Observations

NASA Astrophysics Data System (ADS)

Saad, Ali; Gandin, Charles-André; Bellet, Michel; Shevchenko, Natalia; Eckert, Sven

2015-11-01

Freckles are common defects in industrial casting. They result from thermosolutal convection due to buoyancy forces generated from density variations in the liquid. The present paper proposes a numerical analysis for the formation of channel segregation using the three-dimensional (3D) cellular automaton (CA)—finite element (FE) model. The model integrates kinetics laws for the nucleation and growth of a microstructure with the solution of the conservation equations for the casting, while introducing an intermediate modeling scale for a direct representation of the envelope of the dendritic grains. Directional solidification of a cuboid cell is studied. Its geometry, the alloy chosen as well as the process parameters are inspired from experimental observations recently reported in the literature. Snapshots of the convective pattern, the solute distribution, and the morphology of the growth front are qualitatively compared. Similitudes are found when considering the coupled 3D CAFE simulations. Limitations of the model to reach direct simulation of the experiments are discussed.

The evidence of the rugoscopy effectiveness as a human identification method in patients submitted to rapid palatal expansion.

PubMed

Barbieri, Ana A; Scoralick, Raquel A; Naressi, Suely C M; Moraes, Mari E L; Daruge, Eduardo; Daruge, Eduardo

2013-01-01

The objective of this study was to demonstrate the effectiveness of rugoscopy as a human identification method, even when the patient is submitted to rapid palatal expansion, which in theory would introduce doubt. With this intent, the Rugoscopic Identity was obtained for each subject using the classification formula proposed by Santos based on the intra-oral casts made before and after treatment from patients who were subjected to palatal expansion. The casts were labeled with the patients' initials and randomly arranged for studying. The palatine rugae kept the same patterns in every case studied. The technical error of the intra-evaluator measurement provided a confidence interval of 95%, making rugoscopy a reliable identification method for patients who were submitted to rapid palatal expansion, because even in the presence of intra-oral changes owing to the use of palatal expanders, the palatine rugae retained the biological and technical requirements for the human identification process. © 2012 American Academy of Forensic Sciences.

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.

Hydroxyapatite scaffolds processed using a TBA-based freeze-gel casting/polymer sponge technique.

PubMed

Yang, Tae Young; Lee, Jung Min; Yoon, Seog Young; Park, Hong Chae

2010-05-01

A novel freeze-gel casting/polymer sponge technique has been introduced to fabricate porous hydroxyapatite scaffolds with controlled "designer" pore structures and improved compressive strength for bone tissue engineering applications. Tertiary-butyl alcohol (TBA) was used as a solvent in this work. The merits of each production process, freeze casting, gel casting, and polymer sponge route were characterized by the sintered microstructure and mechanical strength. A reticulated structure with large pore size of 180-360 microm, which formed on burn-out of polyurethane foam, consisted of the strut with highly interconnected, unidirectional, long pore channels (approximately 4.5 microm in dia.) by evaporation of frozen TBA produced in freeze casting together with the dense inner walls with a few, isolated fine pores (<2 microm) by gel casting. The sintered porosity and pore size generally behaved in an opposite manner to the solid loading, i.e., a high solid loading gave low porosity and small pore size, and a thickening of the strut cross section, thus leading to higher compressive strengths.

In vivo Study of the Accuracy of Dual-arch Impressions.

PubMed

de Lima, Luciana Martinelli Santayana; Borges, Gilberto Antonio; Junior, Luiz Henrique Burnett; Spohr, Ana Maria

2014-06-01

This study evaluated in vivo the accuracy of metal (Smart®) and plastic (Triple Tray®) dual-arch trays used with vinyl polysiloxane (Flexitime®), in the putty/wash viscosity, as well as polyether (Impregum Soft®) in the regular viscosity. In one patient, an implant-level transfer was screwed on an implant in the mandibular right first molar, serving as a pattern. Ten impressions were made with each tray and impression material. The impressions were poured with Type IV gypsum. The width and height of the pattern and casts were measured in a profile projector (Nikon). The results were submitted to Student's t-test for one sample (α = 0.05). For the width distance, the plastic dual-arch trays with vinyl polysiloxane (4.513 mm) and with polyether (4.531 mm) were statistically wider than the pattern (4.489 mm). The metal dual-arch tray with vinyl polysiloxane (4.504 mm) and with polyether (4.500 mm) did not differ statistically from the pattern. For the height distance, only the metal dual-arch tray with polyether (2.253 mm) differed statistically from the pattern (2.310 mm). The metal dual-arch tray with vinyl polysiloxane, in the putty/wash viscosities, reproduced casts with less distortion in comparison with the same technique with the plastic dual-arch tray. The plastic or metal dual-arch trays with polyether reproduced cast with greater distortion. How to cite the article: Santayana de Lima LM, Borges GA, Burnett LH Jr, Spohr AM. In vivo study of the accuracy of dual-arch impressions. J Int Oral Health 2014;6(3):50-5.

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.

Casting for infantile scoliosis: the pitfall of increased peak inspiratory pressure.

PubMed

Dhawale, Arjun A; Shah, Suken A; Reichard, Samantha; Holmes, Laurens; Brislin, Robert; Rogers, Kenneth; Mackenzie, William G

2013-01-01

Serial cast correction is a popular treatment option for progressive infantile scoliosis. Body casting can lead to chest and abdominal expansion restriction and result in decreased chest wall compliance. There are no studies evaluating the effects of casting on ventilation in infantile scoliosis. This study examines changes in peak inspiratory pressure (PIP) during serial casting for infantile scoliosis. We retrospectively reviewed data obtained from 37 serial Cotrel elongation, derotation, and flexion cast corrections in patients with infantile scoliosis. Patient demographics, radiographic measurements, and anesthesia data were recorded. Anesthesia technique was standardized: children were intubated with rigid endotracheal tubes (ETTs); tidal volume was held constant at 8 to 10 cm(3)/kg using volume control ventilation; and PIP was recorded at baseline, after cast application before window cutout, and after window cutout before extubation. Any complications were documented. We assessed the PIP changes with a repeated measures analysis of variance (ANOVA). The mean age at first casting was 21.8 months (range, 12 to 42 mo) and mean follow-up since first casting was 22.4 months (range, 13 to 40 mo) with mean major Cobb angle of 53±15 degrees. The mean PIP was 15.5±4.9 cm H(2)O before casting, 31.9±7.9 cm H(2)O after cast application, and 20.4±5.6 cm H2O after making windows. There was a 106% increase after casting and 32% increase after window cutout from the baseline PIP levels. There was a significant difference in PIP on repeated measures ANOVA (P<0.0001). Intraoperatively, there was difficulty in maintaining ventilation during 2 procedures and 1 hypotensive episode. One patient developed hypoxemia after casting and another had delayed difficulty in breathing. Casting resulted in an increased PIP due to transient restrictive pulmonary process; after windows were cut out, the PIP reduced but not to baseline. In patients with underlying pulmonary disease, the casting process may induce respiratory complications, and a proper period of observation after casting is necessary. Case series, level 4.

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

PubMed

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

2006-08-07

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

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

PubMed Central

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

2006-01-01

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

Fracture Analysis of Cast Steel Sling

NASA Astrophysics Data System (ADS)

Li, Xinghui

2018-02-01

The fracture reasons of ZG270-500 cast steel sling are analyzed through such means as macroscopic morphology analysis, chemical composition analysis, and microscopic metallography analysis. Results: coarse Widmanstatten structure and casting defects occurring in casting and subsequent heat treatment process reduce the strength, plasticity and toughness of the steel, which is the main reason of brittle fracture of the sling during work, and corresponding improvement suggestions are proposed herein.

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.

Nonaqueous slip casting of YBa2Cu3O(7-x) superconductive ceramics. Ph.D. Thesis - 1993

NASA Technical Reports Server (NTRS)

Hooker, Matthew W.; Taylor, Theodore D.

1994-01-01

This study investigates the slip casting of YBa2Cu3O(7-x) powders using nonaqueous carrier liquids and fired ceramic molds. The parameters of the process examined here include the rheological properties of YBa2Cu3O(7-x) powder dispersed in various solvent/dispersant systems, the combination of nonaqueous slips with fired ceramic molds to form the superconductive ceramics, the process-property relationships using a four-factor factorial experiment, and the applicability of magnetic fields to align the YBa2Cu3O(7-x) grains during the casting process.

Low-cost single-crystal turbine blades, volume 2

NASA Technical Reports Server (NTRS)

Strangman, T. E.; Dennis, R. E.; Heath, B. R.

1984-01-01

The overall objectives of Project 3 were to develop the exothermic casting process to produce uncooled single-crystal (SC) HP turbine blades in MAR-M 247 and higher strength derivative alloys and to validate the materials process and components through extensive mechanical property testing, rig testing, and 200 hours of endurance engine testing. These Program objectives were achieved. The exothermic casting process was successfully developed into a low-cost nonproperietary method for producing single-crystal castings. Single-crystal MAR-M 247 and two derivatives DS alloys developed during this project, NASAIR 100 and SC Alloy 3, were fully characterized through mechanical property testing. SC MAR-M 247 shows no significant improvement in strength over directionally solidified (DS) MAR-M 247, but the derivative alloys, NASAIR 100 and Alloy 3, show significant tensile and fatigue improvements. Firtree testing, holography, and strain-gauge rig testing were used to determine the effects of the anisotropic characteristics of single-crystal materials. No undesirable characteristics were found. In general, the single-crystal material behaved similarly to DS MAR-M 247. Two complete engine sets of SC HP turbine blades were cast using the exothermic casting process and fully machined. These blades were successfully engine-tested.

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

DTIC Science & Technology

1974-08-31

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

Hanford's Simulated Low Activity Waste Cast Stone Processing

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

Kim, Young

2013-08-20

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

Fabrication of a Bronze Age Sword using Ancient Techniques

NASA Astrophysics Data System (ADS)

Sapiro, David; Webler, Bryan

2016-12-01

A khopesh was cast and forged for the TMS 2016 Bladesmithing Symposium. The khopesh was the first sword style, originating during the Bronze Age in the Near East. The manufacturing process used in this study closely followed Bronze Age techniques to determine the plausibility of open mold casting coupled with cold work and annealing cycles. Forging and annealing cycles substantially increased blade strength and diminished intergranular δ-phase inclusions. While a functional blade was not completed due to casting defects, the process gives valuable insight into the effort required to fabricate a khopesh during the Bronze Age. Forging and annealing cycles following casting were necessary to produce the mechanical properties desired in a sword.

Mapping sleeping bees within their nest: spatial and temporal analysis of worker honey bee sleep.

PubMed

Klein, Barrett Anthony; Stiegler, Martin; Klein, Arno; Tautz, Jürgen

2014-01-01

Patterns of behavior within societies have long been visualized and interpreted using maps. Mapping the occurrence of sleep across individuals within a society could offer clues as to functional aspects of sleep. In spite of this, a detailed spatial analysis of sleep has never been conducted on an invertebrate society. We introduce the concept of mapping sleep across an insect society, and provide an empirical example, mapping sleep patterns within colonies of European honey bees (Apis mellifera L.). Honey bees face variables such as temperature and position of resources within their colony's nest that may impact their sleep. We mapped sleep behavior and temperature of worker bees and produced maps of their nest's comb contents as the colony grew and contents changed. By following marked bees, we discovered that individuals slept in many locations, but bees of different worker castes slept in different areas of the nest relative to position of the brood and surrounding temperature. Older worker bees generally slept outside cells, closer to the perimeter of the nest, in colder regions, and away from uncapped brood. Younger worker bees generally slept inside cells and closer to the center of the nest, and spent more time asleep than awake when surrounded by uncapped brood. The average surface temperature of sleeping foragers was lower than the surface temperature of their surroundings, offering a possible indicator of sleep for this caste. We propose mechanisms that could generate caste-dependent sleep patterns and discuss functional significance of these patterns.

Novel Applications of Rapid Prototyping in Gamma-ray and X-ray Imaging

PubMed Central

Miller, Brian W.; Moore, Jared W.; Gehm, Michael E.; Furenlid, Lars R.; Barrett, Harrison H.

2010-01-01

Advances in 3D rapid-prototyping printers, 3D modeling software, and casting techniques allow for the fabrication of cost-effective, custom components in gamma-ray and x-ray imaging systems. Applications extend to new fabrication methods for custom collimators, pinholes, calibration and resolution phantoms, mounting and shielding components, and imaging apertures. Details of the fabrication process for these components are presented, specifically the 3D printing process, cold casting with a tungsten epoxy, and lost-wax casting in platinum. PMID:22984341

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

EPA Science Inventory

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

Structural and compositional analysis of a casting mold sherd from ancient China

PubMed Central

Zong, Yunbing; Yao, Shengkun; Lang, Jianfeng; Chen, Xuexiang; Fan, Jiadong; Sun, Zhibin; Duan, Xiulan; Li, Nannan; Fang, Hui; Zhou, Guangzhao; Xiao, Tiqiao; Li, Aiguo; Jiang, Huaidong

2017-01-01

Casting had symbolic significance and was strictly controlled in the Shang dynasty of ancient China. Vessel casting was mainly distributed around the Shang capital, Yin Ruins, which indicates a rigorous centralization of authority. Thus, for a casting mold to be excavated far from the capital region is rare. In addition to some bronze vessel molds excavated at the Buyao Village site, another key discovery of a bronze vessel mold occurred at Daxinzhuang. The Daxinzhuang site was a core area in the east of Shang state and is an important site to study the eastward expansion of the Shang. Here, combining synchrotron X-rays and other physicochemical analysis methods, nondestructive three-dimensional structure imaging and different elemental analyses were conducted on this mold sherd. Through high penetration X-ray tomography, we obtained insights on the internal structure and discovered some pores. We infer that the generation of pores inside the casting mold sherd was used to enhance air permeability during casting. Furthermore, we suppose that the decorative patterns on the surface were carved and not pasted onto it. Considering the previous compositional studies of bronze vessels, the copper and iron elements were analyzed by different methods. Unexpectedly, a larger amount of iron than of copper was detected on the surface. According to the data analysis and archaeological context, the source of iron on the casting mold sherd could be attributed to local soil contamination. A refined compositional analysis confirms that this casting mold was fabricated locally and used for bronze casting. PMID:28296963

The effect and complication of botulinum toxin type a injection with serial casting for the treatment of spastic equinus foot.

PubMed

Lee, Sook Joung; Sung, In Young; Jang, Dae Hyun; Yi, Jin Hwa; Lee, Jin Ho; Ryu, Ju Seok

2011-06-01

To identify the effect of serial casting combined with Botulinum toxin type A (BTX-A) injection on spastic equinus foot. Twenty-nine children with cerebral palsy who had equinus foot were recruited from the outpatient clinic of Rehabilitation Medicine. The children were divided into 2 groups, one of which received serial casting after BTX-A injection, and the other which only received BTX-A injection. Serial casting started 3 weeks after the BTX-A injection, and was changed weekly for 3 times. Spasticity of the ankle joint was evaluated using the modified Ashworth scale (MAS), and the modified Tardieu scale (MTS). Gait pattern was measured using the physician's rating scale (PRS). The degree of ankle dorsiflexion and the MAS improved significantly until 12 weeks following the BTX-A injection in the serial casting group (p<0.001), while the BTX-A injection-only group improved until 6 weeks following injection (p<0.05). The combined group showed a significantly greater increase in the degree of dorsiflexion compared to the BTX-A injection-only group at post-injection weeks 6 and 12 (p<0.05). Three children (11.5%) suffered from foot ulcers as a complication caused by the serial casting. Our study demonstrated that the effect of BTX-A injection with serial casting was superior and lasted longer than the effect of BTX-A injection only in patients with spastic equinus foot. We therefore recommend BTX-A injection with serial casting for the treatment of equinus foot. However, physicians must also consider the possible complications associated with serial casting.

Influence of processing factors over concrete strength.

NASA Astrophysics Data System (ADS)

Kara, K. A.; Dolzhenko, A. V.; Zharikov, I. S.

2018-03-01

Construction of facilities of cast in-situ reinforced concrete poses additional requirements to quality of material, peculiarities of the construction process may sometimes lead to appearance of lamination planes and inhomogeneity of concrete, which reduce strength of the material and structure as a whole. Technology compliance while working with cast in-situ concrete has a significant impact onto the concrete strength. Such process factors as concrete curing, vibration and compaction of the concrete mixture, temperature treatment, etc., when they are countered or inadequately followed lead to a significant reduction in concrete strength. Here, the authors experimentally quantitatively determine the loss of strength in in-situ cast concrete structures due to inadequate following of process requirements, in comparison with full compliance.

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.

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.

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

NASA Astrophysics Data System (ADS)

Jin, Chul Kyu; Kang, Chung Gil

2011-10-01

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

Ultrasonic Substrate Vibration-Assisted Drop Casting (SVADC) for the Fabrication of Photovoltaic Solar Cell Arrays and Thin-Film Devices.

PubMed

Eslamian, Morteza; Zabihi, Fatemeh

2015-12-01

A simple, low-cost, versatile, and potentially scalable casting method is proposed for the fabrication of micro- and nano-thin films, herein termed as ultrasonic "substrate vibration-assisted drop casting" (SVADC). The impingement of a solution drop onto a substrate in a simple process called drop casting, usually results in spreading of the liquid solution and the formation of a non-uniform thin solid film after solvent evaporation. Our previous and current supporting results, as well as few similar reports by others, confirm that imposing ultrasonic vibration on the substrate can simply convert the uncontrollable drop casting method into a controllable coating technique. Therefore, the SVADC may be used to fabricate an array of emerging thin-film solar cells, such as polymer, perovskite, and quantum-dot solar cells, as well as other small thin-film devices, in a roll-to-roll and automated fabrication process. The preliminary results demonstrate a ten-fold increase in electrical conductivity of PSS made by SVADC compared with the film made by conventional drop casting. Also, simple planar perovskite solar cells made here using SVADC show promising performance with an efficiency of over 3 % for a simple structure without performing process optimization or using expensive materials and treatments.

Computation material science of structural-phase transformation in casting aluminium alloys

NASA Astrophysics Data System (ADS)

Golod, V. M.; Dobosh, L. Yu

2017-04-01

Successive stages of computer simulation the formation of the casting microstructure under non-equilibrium conditions of crystallization of multicomponent aluminum alloys are presented. On the basis of computer thermodynamics and heat transfer during solidification of macroscale shaped castings are specified the boundary conditions of local heat exchange at mesoscale modeling of non-equilibrium formation the solid phase and of the component redistribution between phases during coalescence of secondary dendrite branches. Computer analysis of structural - phase transitions based on the principle of additive physico-chemical effect of the alloy components in the process of diffusional - capillary morphological evolution of the dendrite structure and the o of local dendrite heterogeneity which stochastic nature and extent are revealed under metallographic study and modeling by the Monte Carlo method. The integrated computational materials science tools at researches of alloys are focused and implemented on analysis the multiple-factor system of casting processes and prediction of casting microstructure.

Scale Rules for Macrosegregation during Direct-Chill Casting of Aluminum Alloys

NASA Astrophysics Data System (ADS)

Eskin, Dmitry G.; Du, Qiang; Katgerman, Laurens

2008-05-01

An analysis of published experimental and numerical results shows that there is a scaling relationship between the magnitude and direction of centerline segregation in direct-chill (DC) cast billets from aluminum alloys and the process parameters, i.e., billet diameter and casting speed. It seems that there is always a range of these process parameters where the centerline segregation is positive, and there is a threshold when the centerline segregation vanishes. Numerical simulations of macrosegregation during DC casting of a binary Al-Cu alloy were performed at different ratios of casting speed and billet diameter. The macrosegregation model takes into account only two mechanisms of macrosegregation, i.e., thermosolutal convection and shrinkage-induced flow. The results of these computer simulations fit well to the dependence obtained using numerous reference data. The results are discussed in terms of the contribution of different mechanisms of macrosegregation and the shape of the billet sump.

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

NASA Astrophysics Data System (ADS)

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

2017-02-01

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

Fuzzy control strategy for secondary cooling of continuous steel casting

NASA Astrophysics Data System (ADS)

Tirian, G. O.; Gheorghiu, C. A.; Hepuţ, T.; Rob, R.

2017-05-01

The purpose of this paper is to create an original fuzzy solution on the existing structure of the control system of continuous casting that eliminates fissures in the poured material from the secondary cooling of steel. For this purpose a system was conceived with three fuzzy database decision rules, which by analyzing a series of measurements taken from the process produces adjustments in the rate of flow of the cooling water and the speed of casting and determine the degree of risk of the wire. In the specialized literature on the national plan and the world, there is no intelligent correction in the rate of flow of the cooling water and the speed of casting in the secondary cooling of steel. The database of rules was made using information collected directly from the installation process of continuous casting of the Arcelor Mittal Hunedoara.

Effects of Process Parameters on Solidification Structure of A390 Aluminum Alloy Hollow Billet

NASA Astrophysics Data System (ADS)

Zuo, Kesheng; Zhang, Haitao; Qin, Ke; Cui, Jianzhong; Chen, Qingzhang

2017-08-01

The effects of process parameters on the solidification structure of A390 aluminum alloy hollow billets prepared by direct-chill casting were investigated. The decrease of casting temperature deteriorated the homogeneity and increased the size of primary Si particles in the hollow billet. Although the average size of primary Si particles was not obviously affected by the increase of casting speed, the thickness of Si-depleted layer at the inner wall increased with the higher casting speed. The tensile strength of A390 alloy is a function of the percentage of coarse Si particles (larger than 35 μm) and the average size of primary Si particles. Higher and more stable tensile strength can be received in the hollow billet with the casting temperature of 1050 K (777 °C), because the fine and uniformly distributed primary Si particles were obtained in the hollow billet.

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

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

Noise Reduction to Reduce Patient Anxiety During Cast Removal: Can We Decrease Patient Anxiety With Cast Removal by Wearing Noise Reduction Headphones During Cast Saw Use?

PubMed

Mahan, Susan T; Harris, Marie S; Lierhaus, Anneliese M; Miller, Patricia E; DiFazio, Rachel L

Noise reduction headphones decrease the sound during cast removal. Their effectiveness in decreasing anxiety has not been studied. Compare pediatric patients' anxiety levels during cast removal with and without utilization of noise reduction headphones combined with use of a personal electronic device. Quality improvement project. Patients randomly assigned to noise reduction headphone group or standard care group during cast removal. Faces, Legs, Activity, Cry, and Consolability Scale and heart rate were evaluated prior to, during, and after cast removal. Data were compared across groups. Fifty patients were included; 25 per group. No difference detected between the 2 groups in Faces, Legs, Activity, Cry, and Consolability Scale score prior to (p = .05) or after cast removal (p = .30). During cast removal, the headphone group had lower FLACC Scale scores (p = .03). Baseline heart rate was lower in the headphone group prior to (p = .02) and after (p = .005) cast removal with no difference during cast removal (p = .24). Utilizing noise reduction headphones and a personal electronic device during the cast removal process decreases patient anxiety.

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

Obtaining of High Cr Content Cast Iron Materials

NASA Astrophysics Data System (ADS)

Florea, C.; Bejinariu, C.; Carcea, I.; Cimpoesu, N.; Chicet, D. L.; Savin, C.

2017-06-01

We have obtained, through the classic casting process, 3 highly chromium-based experimental alloys proposed for replacing the FC 250 classical cast iron in braking applications. Casting was carried out in an induction furnace and cast into moulds made of KALHARTZ 8500 resin casting mixture and HARTER hardener at SC RanCon SRL Iasi. It is known that the microstructure of the cast iron is a combination of martensite with a small amount of residual austenite after the heat treatment of the ingot. In the case of high-alloy chromium alloys, the performance of the material is due to the presence of M7C3 carbides distributed in the iron matrix Resistance to machining and deformation is based on alloy composition and microstructure, while abrasion resistance will depend on properties and wear conditions.

The role of water in slip casting

NASA Technical Reports Server (NTRS)

Mccauley, R. A.; Phelps, G. W.

1984-01-01

Slips and casting are considered in terms of physical and colloidal chemistry. Casting slips are polydisperse suspensions of lyophobic particles in water, whose degree of coagulation is controlled by interaction of flocculating and deflocculating agents. Slip casting rate and viscosity are functions of temperature. Slip rheology and response to deflocculating agents varies significantly as the kinds and amounts of colloid modifiers change. Water is considered as a raw material. Various concepts of water/clay interactions and structures are discussed. Casting is a de-watering operation in which water moves from slip to cast to mold in response to a potential energy termed moisture stress. Drying is an evaporative process from a free water surface.

Silicon solar cell process development, fabrication and analysis

NASA Technical Reports Server (NTRS)

Yoo, H. I.; Iles, P. A.; Leung, D. C.

1981-01-01

Solar cells were fabricated from EFG ribbons dendritic webs, cast ingots by heat exchanger method, and cast ingots by ubiquitous crystallization process. Baseline and other process variations were applied to fabricate solar cells. EFG ribbons grown in a carbon-containing gas atmosphere showed significant improvement in silicon quality. Baseline solar cells from dendritic webs of various runs indicated that the quality of the webs under investigation was not as good as the conventional CZ silicon, showing an average minority carrier diffusion length of about 60 um versus 120 um of CZ wafers. Detail evaluation of large cast ingots by HEM showed ingot reproducibility problems from run to run and uniformity problems of sheet quality within an ingot. Initial evaluation of the wafers prepared from the cast polycrystalline ingots by UCP suggested that the quality of the wafers from this process is considerably lower than the conventional CZ wafers. Overall performance was relatively uniform, except for a few cells which showed shunting problems caused by inclusions.

Computational Multi-Scale Modeling of the Microstructure and Segregation of Cast Mg Alloys at Low Superheat

NASA Astrophysics Data System (ADS)

Nastac, Laurentiu; El-Kaddah, Nagy

It is well known that casting at low superheat has a strong influence on the solidification structures of the cast alloy. Recent studies on casting magnesium AZ alloys at low superheat using the Magnetic Suspension Melting (MSM) process have shown that the cast alloy exhibit a fine globular grain structure, and the grain size depend on the cooling rate. This paper describes a stochastic mesoscopic model for predicting the grain structure and segregation in cast alloys at low superheat. This model was applied to predict the globular solidification morphology and solute redistribution of Al in cast Mg AZ31B alloy at different cooling rates. The predictions were found to be in good agreement with the observed grain structure and Al segregation. This makes the model a very useful tool for optimizing the solidification structure of cast magnesium alloys.

Coming out of the woods: do termites need a specialized worker caste to search for new food sources?

NASA Astrophysics Data System (ADS)

Rupf, Thomas; Roisin, Yves

2008-09-01

Most small-colony termites live confined within a single piece of wood on which they feed and do not possess permanent workers: Tasks are done by developmentally flexible immatures (pseudergates). By contrast, large-colony termites possess a specialized (true) worker caste and forage outside their nest for food. To shed light on possible transitional steps between these contrasting patterns of social organization, we studied an atypical Rhinotermitidae, Prorhinotermes inopinatus. In this species, despite the absence of a true worker caste, soldiers, pseudergates, and neotenic reproductives may leave the nest and explore their surroundings. Although evidence presented in this study indicates that termites recognize unknown areas, there is no directional recruitment toward them. The discovery of a food source, i.e., a piece of wood, is followed by the establishment of a long-lasting trail between the nest and the food source. A large fraction of the colony, including neotenic reproductives, ultimately migrates into the piece of wood. Our results thus demonstrate that multiple features of external foraging behavior can evolve independently of the existence of a true worker caste in termites. We suggest that large colonies with true workers, like those of most Rhinotermitidae, may easily have evolved from a Prorhinotermes-like pattern if submitted to increasing selective pressures for worker efficiency in a stable environment.

Control system of water flow and casting speed in continuous steel casting

NASA Astrophysics Data System (ADS)

Tirian, G. O.; Gheorghiu, C. A.; Hepuţ, T.; Chioncel, C.

2017-05-01

This paper presents the results of research based on real data taken from the installation process at Arcelor Mittal Hunedoara. Using Matlab Simulink an intelligent system is made that takes in data from the process and makes real time adjustments in the rate of flow of the cooling water and the speed of casting that eliminates fissures in the poured material from the secondary cooling of steel. Using Matlab Simulink simulation environment allowed for qualitative analysis for various real world situations. Thus, compared to the old method of approach for the problem of cracks forming in the crust of the steel in the continuous casting, this new method, proposed and developed, brings safety and precision in this complex process, thus removing any doubt on the existence or non-existence of cracks and takes the necessary steps to prevent and correct them.

Parallel volume ray-casting for unstructured-grid data on distributed-memory architectures

NASA Technical Reports Server (NTRS)

Ma, Kwan-Liu

1995-01-01

As computing technology continues to advance, computational modeling of scientific and engineering problems produces data of increasing complexity: large in size and unstructured in shape. Volume visualization of such data is a challenging problem. This paper proposes a distributed parallel solution that makes ray-casting volume rendering of unstructured-grid data practical. Both the data and the rendering process are distributed among processors. At each processor, ray-casting of local data is performed independent of the other processors. The global image composing processes, which require inter-processor communication, are overlapped with the local ray-casting processes to achieve maximum parallel efficiency. This algorithm differs from previous ones in four ways: it is completely distributed, less view-dependent, reasonably scalable, and flexible. Without using dynamic load balancing, test results on the Intel Paragon using from two to 128 processors show, on average, about 60% parallel efficiency.

Liquid Metal Engineering by Application of Intensive Melt Shearing

NASA Astrophysics Data System (ADS)

Patel, Jayesh; Zuo, Yubo; Fan, Zhongyun

In all casting processes, liquid metal treatment is an essential step in order to produce high quality cast products. A new liquid metal treatment technology has been developed which comprises of a rotor/stator set-up that delivers high shear rate to the liquid melt. It generates macro-flow in a volume of melt for distributive mixing and intensive shearing for dispersive mixing. The high shear device exhibits significantly enhanced kinetics for phase transformations, uniform dispersion, distribution and size reduction of solid particles and gas bubbles, improved homogenisation of chemical composition and temperature fields and also forced wetting of usually difficult-to-wet solid particles in the liquid metal. Hence, it can benefit various casting processes to produce high quality cast products with refined microstructure and enhanced mechanical properties. Here, we report an overview on the application of the new high shear technology to the processing of light metal alloys.

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.

Technique Incorporating Cooling & Contraction / Expansion Analysis to Illustrate Shrinkage Tendency in Cast Irons

NASA Astrophysics Data System (ADS)

Stan, S.; Chisamera, M.; Riposan, I.; Neacsu, L.; Cojocaru, A. M.; Stan, I.

2017-06-01

With the more widespread adoption of thermal analysis testing, thermal analysis data have become an indicator of cast iron quality. The cooling curve and its first derivative display patterns that can be used to predict the characteristics of a cast iron. An experimental device was developed with a technique to simultaneously evaluate cooling curves and expansion or contraction of cast metals during solidification. Its application is illustrated with results on shrinkage tendency of ductile iron treated with FeSiMgRECa master alloy and inoculated with FeSi based alloys, as affected by mould rigidity (green sand and resin sand moulds). Undercooling at the end of solidification relative to the metastable (carbidic) equilibrium temperature and the expansion within the solidification sequence appear to have a strong influence on the susceptibility to macro - and micro - shrinkage in ductile iron castings. Green sand moulds, as less rigid moulds, encourage the formation of contraction defects, not only because of high initial expansion values, but also because of a higher cooling rate during solidification, and consequently, increased undercooling below the metastable equilibrium temperature up to the end of solidification.

Effect of flask vibration time on casting integrity, Surface Penetration and Coating Inclusion in lost foam casting of Al-Si Alloy

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

Karimian, Majid; Idris, M. H.; Ourdjini, A.

2011-01-17

The paper presents the result of an experimental investigation conducted on medium aluminum silicon alloy casting- LM6, using no-vacuum assisted lost foam casting process. The study is directed for establishing the relationship between the flask vibrations times developed for molded sample on the casting integrity, surface penetration and coating inclusion defects of the casting. Four different flask vibration times namely 180, 120, 90 and 60 sec. were investigated. The casting integrity was investigated in terms of fulfilling in all portions and edges. The surface penetration was measured using optical microscope whilst image analyzer was used to quantify the percentage ofmore » coating inclusion in the casting. The results show that vibration time has significant influence on the fulfilling as well as the internal integrity of the lost foam casting. It was found that the lower vibration time produced comparatively sound casing.« less

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.

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.;

Development of a CFD code for casting simulation

NASA Technical Reports Server (NTRS)

Murph, Jesse E.

1993-01-01

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

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.

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

NASA Astrophysics Data System (ADS)

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

2014-07-01

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

Contact angle control of sessile drops on a tensioned web

NASA Astrophysics Data System (ADS)

Park, Janghoon; Kim, Dongguk; Lee, Changwoo

2018-04-01

In this study, the influence of the change of tension applied to flexible and thin web substrate on the contact angle of sessile drop in roll-to-roll system was investigated. Graphene oxide and deionized water solutions were used in the experiments. Tension was changed to 29, 49, and 69 N, and the casting distance of the micropipette and the material was set to 10, 20, and 40 mm, and the droplet volume was set to 10, 20, and 30 μL, respectively. Statistical analysis of three variables and analysis of the variance methodology showed that the casting distance was most significant for the contact angle change, and the most interesting tension variable was also affected. The change in tension caused the maximum contact angle to change by 5.5°. The tension was not uniform in the width direction. When the droplet was applied in the same direction in the width direction, it was confirmed that the tension unevenness had great influence on the contact angle up to 11°. Finally, the casting distance, which has a large effect on the contact angle, was calibrated in the width direction to reduce the width direction contact angle deviation to 1%. This study can be applied to fine patterning research using continuous inkjet printing and aerosol jet printing, which are roll-to-roll processes based on droplet handling.

Fabrication of titanium removable dental prosthesis frameworks with a 2-step investment coating method.

PubMed

Koike, Mari; Hummel, Susan K; Ball, John D; Okabe, Toru

2012-06-01

Although pure titanium is known to have good biocompatibility, a titanium alloy with better strength is needed for fabricating clinically acceptable, partial removable dental prosthesis (RDP) frameworks. The mechanical properties of an experimental Ti-5Al-5Cu alloy cast with a 2-step investment technique were examined for RDP framework applications. Patterns for tests for various properties and denture frameworks for a preliminary trial casting were invested with a 2-step coating method using 2 types of mold materials: a less reactive spinel compound (Al(2)O(3)·MgO) and a less expensive SiO(2)-based material. The yield and tensile strength (n=5), modulus of elasticity (n=5), elongation (n=5), and hardness (n=8) of the cast Ti-5Al-5Cu alloy were determined. The external appearance and internal porosities of the preliminary trial castings of denture frameworks (n=2) were examined with a conventional dental radiographic unit. Cast Ti-6Al-4V alloy and commercially pure titanium (CP Ti) were used as controls. The data for the mechanical properties were statistically analyzed with 1-way ANOVA (α=.05). The yield strength of the cast Ti-5Al-5Cu alloy was 851 MPa and the hardness was 356 HV. These properties were comparable to those of the cast Ti-6Al-4V and were higher than those of CP Ti (P<.05). One of the acrylic resin-retention areas of the Ti-5Al-5Cu frameworks was found to have been incompletely cast. The cast biocompatible experimental Ti-5Al-5Cu alloy exhibited high strength when cast with a 2-step coating method. With a dedicated study to determine the effect of sprue design on the quality of castings, biocompatible Ti-5Al-5Cu RDP frameworks for a clinical trial can be produced. Copyright © 2012 The Editorial Council of the Journal of Prosthetic Dentistry. Published by Mosby, Inc. All rights reserved.

Inclusion behaviour in the liquid core during continuous casting

NASA Astrophysics Data System (ADS)

Jiang, Guang S.

Water models using perspex have been built to study the fluid flow and recirculation patterns developed in the sump of a steel continuous casting machine and the influences these have on the behaviour of inclusions. An experimental method has been devised to simulate the behaviour of inclusions in the sump and to study the apportionment of the input flux of inclusions between the molten mould powder layer and the strand. The method entails the uses of finely dispersed coloured paraffin oil in the inlet stream together with a floating colourless paraffin layer on the top of the water in the model mould to simulate the molten powder layer on top of the molten steel.A theoretical model has been formulated which relates the inclusion separation in the sump to the fluid flow there. The inclusion removal ratio in the sump for a given continuous casting machine can be predicted using this theoretical model. The model, using the properties of liquid steel and practicable casting speeds, demonstrates that the removal of inclusions of small size (<40 um) from the mould sump is less than 5% efficient.Inclusion agglomeration plays an important role in inclusion removal. It has been shown that deep submersion of the SEN enhances the agglomeration of inclusion particle. Under certain conditions, for example, the average particle diameter in the meniscus region has been found to be as much as three times its value at the SEN nozzle.The use of fine alumina flakes or small air bubbles, together with a plane light source, has been found to be very successful in studying the fluid flow patterns developed in three-dimensional models. Employing this method, the fluid flow patterns developed on different planes within the model mould have been viewed and recorded photographically. The photographs so obtained have helped to explain the results obtained for the removal of inclusions. The fluid flow patterns developed when small outside diameter nozzles with deep SEN submerged depths are used have been found to be of benefit to the removal of inclusions.Increasing the SEN submerged depth promotes inclusion agglomeration and hence increases the inclusion removal ratio. Reducing the nozzle outside diameter and the casting speed increases the inclusion removal ratio in the sump. But the infleunces of these latter changes are not very strong, so that inclusion removal consideration need not influence the design strategies used for the casting speed and nozzle outside diameter. The SEN port angle has a little effect on the inclusion removal when using deep SEN submerged depth.Although argon stream introduced into the tundish nozzle stream can protect the nozzle blockage, it is not beneficial to the inclusion removal in the sump.

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

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

PubMed

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

2013-09-01

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

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

PubMed Central

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

2013-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2017-02-01

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

3D printing in X-ray and Gamma-Ray Imaging: A novel method for fabricating high-density imaging apertures☆

PubMed Central

Miller, Brian W.; Moore, Jared W.; Barrett, Harrison H.; Fryé, Teresa; Adler, Steven; Sery, Joe; Furenlid, Lars R.

2011-01-01

Advances in 3D rapid-prototyping printers, 3D modeling software, and casting techniques allow for cost-effective fabrication of custom components in gamma-ray and X-ray imaging systems. Applications extend to new fabrication methods for custom collimators, pinholes, calibration and resolution phantoms, mounting and shielding components, and imaging apertures. Details of the fabrication process for these components, specifically the 3D printing process, cold casting with a tungsten epoxy, and lost-wax casting in platinum are presented. PMID:22199414

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.

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

NASA Astrophysics Data System (ADS)

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

2018-01-01

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

Detecting novel SNPs and breed-specific haplotypes at calpastatin gene in Iranian fat- and thin-tailed sheep breeds and their effects on protein structure.

PubMed

Aali, Mohsen; Moradi-Shahrbabak, Mohammad; Moradi-Shahrbabak, Hosein; Sadeghi, Mostafa

2014-03-01

Calpastatin has been introduced as a potential candidate gene for growth and meat quality traits. In this study, genetic variability was investigated in the exon 6 and its intron boundaries of ovine CAST gene by PCR-SSCP analysis and DNA sequencing. Also a protein sequence and structural analysis were performed to predict the possible impact of amino acid substitutions on physicochemical properties and structure of the CAST protein. A total of 487 animals belonging to four ancient Iranian sheep breeds with different fat metabolisms, Lori-Bakhtiari and Chall (fat-tailed), Zel-Atabay cross-bred (medium fat-tailed) and Zel (thin-tailed), were analyzed. Eight unique SSCP patterns, representing eight different sequences or haplotypes, CAST-1, CAST-2 and CAST-6 to CAST-11, were identified. Haplotypes CAST-1 and CAST-2 were most common with frequency of 0.365 and 0.295. The novel haplotype CAST-8 had considerable frequency in Iranian sheep breeds (0.129). All the consensus sequences showed 98-99%, 94-98%, 92-93% and 82-83% similarity to the published ovine, caprine, bovine and porcine CAST locus sequences, respectively. Sequence analysis revealed four SNPs in intron 5 (C24T, G62A, G65T and T69-) and three SNPs in exon 6 (c.197A>T, c.282G>T and c.296C>G). All three SNPs in exon 6 were missense mutations which would result in p.Gln 66 Leu, p.Glu 94 Asp and p.Pro 99 Arg substitutions, respectively, in CAST protein. All three amino acid substitutions affected the physicochemical properties of ovine CAST protein including hydrophobicity, amphiphilicity and net charge and subsequently might influence its structure and effect on the activity of Ca2+ channels; hence, they might regulate calpain activity and afterwards meat tenderness and growth rate. The Lori-Bakhtiari population showed the highest heterozygosity in the ovine CAST locus (0.802). Frequency difference of haplotypes CAST-10 and CAST-8 between Lori-Bakhtiari (fat-tailed) and Zel (thin-tailed) breeds was highly significant (P<0.001), indicating that these two haplotypes might be breed-specific haplotypes that distinguish between fat-tailed and thin-tailed sheep breeds. Copyright © 2013 Elsevier B.V. All rights reserved.

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.

The Effect and Complication of Botulinum Toxin Type A Injection with Serial Casting for the Treatment of Spastic Equinus Foot

PubMed Central

Lee, Sook Joung; Jang, Dae Hyun; Yi, Jin Hwa; Lee, Jin Ho; Ryu, Ju Seok

2011-01-01

Objective To identify the effect of serial casting combined with Botulinum toxin type A (BTX-A) injection on spastic equinus foot. Method Twenty-nine children with cerebral palsy who had equinus foot were recruited from the outpatient clinic of Rehabilitation Medicine. The children were divided into 2 groups, one of which received serial casting after BTX-A injection, and the other which only received BTX-A injection. Serial casting started 3 weeks after the BTX-A injection, and was changed weekly for 3 times. Spasticity of the ankle joint was evaluated using the modified Ashworth scale (MAS), and the modified Tardieu scale (MTS). Gait pattern was measured using the physician's rating scale (PRS). Results The degree of ankle dorsiflexion and the MAS improved significantly until 12 weeks following the BTX-A injection in the serial casting group (p<0.001), while the BTX-A injection-only group improved until 6 weeks following injection (p<0.05). The combined group showed a significantly greater increase in the degree of dorsiflexion compared to the BTX-A injection-only group at post-injection weeks 6 and 12 (p<0.05). Three children (11.5%) suffered from foot ulcers as a complication caused by the serial casting. Conclusion Our study demonstrated that the effect of BTX-A injection with serial casting was superior and lasted longer than the effect of BTX-A injection only in patients with spastic equinus foot. We therefore recommend BTX-A injection with serial casting for the treatment of equinus foot. However, physicians must also consider the possible complications associated with serial casting. PMID:22506143

An Investigation into the Effects of Sprue Attachment Design on Porosity and Castability

DTIC Science & Technology

1990-12-01

of a dental alloy: sprue design, mold temperature, fusing and casting temperature of the alloy, type of casting machine, casting force, burnout time... Student at: University of Texas, San Antonio AFIT/CI/CIA-90-119 AFIT/CI Wright-Patterson AFB OH 45433-6583 Approved for Public Release IAW AFR 190-1...Supervising Professor: E. Steven Duke, D.D.S., M.S.D. Many variables are involved in the process of fabricating a dense dental casting which accurately

Rapidly solidified titanium alloys by melt overflow

NASA Technical Reports Server (NTRS)

Gaspar, Thomas A.; Bruce, Thomas J., Jr.; Hackman, Lloyd E.; Brasmer, Susan E.; Dantzig, Jonathan A.; Baeslack, William A., III

1989-01-01

A pilot plant scale furnace was designed and constructed for casting titanium alloy strips. The furnace combines plasma arc skull melting techniques with melt overflow rapid solidification technology. A mathematical model of the melting and casting process was developed. The furnace cast strip of a suitable length and width for use with honeycomb structures. Titanium alloys Ti-6Al-4V and Ti-14Al-21 Nb were successfully cast into strips. The strips were evaluated by optical metallography, microhardness measurements, chemical analysis, and cold rolling.

Grain refinement of cast zinc through magnesium inoculation: Characterisation and mechanism

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

Liu, Zhilin; Qiu, Dong; Wang, Feng

2015-08-15

It was previously found that peritectic-forming solutes are more favourable for the grain refinement of cast Al alloys than eutectic-forming solutes. In this work, we report that the eutectic-forming solute, Mg, can also significantly grain refine cast Zn. Differential thermal analysis (DTA) of a Zn–Mg alloy, in which efficient grain refinement occurred, evidenced an unexpected peak that appeared before the nucleation of η-Zn grains on the DTA spectrum. Based on extensive examination using X-ray diffraction, high resolution SEM and EDS, it was found that: (a) some faceted Zn–Mg intermetallic particles were reproducibly observed; (b) the particles were located at ormore » near grain centres; (c) the atomic ratio of Mg to Zn in the intermetallic compound was determined to be around 1/2. Using tilting selected area diffraction (SAD) and convergent beam Kikuchi line diffraction pattern (CBKLDP) techniques, these faceted particles were identified as MgZn{sub 2} and an orientation relationship between such grain-centred MgZn{sub 2} particles and the η-Zn matrix was determined. Hence, the unexpected peak on the DTA spectrum is believed to correspond to the formation of MgZn{sub 2} particles, which act as effective heterogeneous nucleation sites in the alloy. Together with the effect of Mg solute on restricting grain growth, such heterogeneous nucleation is cooperatively responsible for the grain size reduction in Zn–Mg alloys. - Highlights: • A new eutectic-based grain refiner for the cast Zn was found. • The formation process of an intermetallic compound (MgZn{sub 2}) was characterised. • MgZn{sub 2} can act as potent heterogeneous nucleation sites above the liquidus. • A new OR between MgZn{sub 2} and η-Zn was determined using the CBKLDP technique.« less

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

Using a micro-molding process to fabricate polymeric wavelength filters

NASA Astrophysics Data System (ADS)

Chuang, Wei-Ching; Lee, An-Chen; Ho, Chi-Ting

2008-08-01

A procedure for fabricating a high aspect ratio periodic structure on a UV polymer at submicron order using holographic interferometry and molding processes is described. First, holographic interferometry using a He-Cd (325 nm) laser was used to create the master of the periodic line structure on an i-line sub-micron positive photoresist film. A 20 nm nickel thin film was then sputtered on the photoresist. The final line pattern on a UV polymer was obtained from casting against the master mold. Finally, a SU8 polymer was spun on the polymer grating to form a planar waveguide or a channel waveguide. The measurement results show that the waveguide length could be reduced for the waveguide having gratings with a high aspect ratio.

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Performance Steel Castings

DTIC Science & Technology

2012-09-30

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

Comparative Evaluation of Marginal and Internal Gap of Co-Cr Copings Fabricated from Conventional Wax Pattern, 3D Printed Resin Pattern and DMLS Tech: An In Vitro Study.

PubMed

Bhaskaran, Eswaran; Azhagarasan, N S; Miglani, Saket; Ilango, T; Krishna, G Phani; Gajapathi, B

2013-09-01

Accuracy of the fit of the restoration has always remained as one of the primary factors in determining success of the restoration. A well fitting restoration needs to be accurate both along its margins and internal surface. This study was conducted to comparatively evaluate the marginal gap and internal gap of cobalt-chromium (Co-Cr) copings fabricated by conventional casting procedures and with direct metal laser sintering (DMLS) technique. Among the total of 30 test samples 10 cast copings were made from inlay casting wax and 10 from 3D printed resin pattern. 10 copings were obtained from DMLS technique. All the 30 test samples were then cemented sequentially on stainless steel model using pressure indicating paste and evaluated for vertical marginal gap in 8 predetermined reference areas. All copings were then removed and partially sectioned and cemented sequentially on same master model for evaluation of internal gap at 4 predetermined reference areas. Both marginal gap and internal gap were measured in microns using video measuring system (VMS2010F). The results obtained for both marginal and internal gap were statistically analyzed and the values fall within the clinically acceptable range. The DMLS technique had an edge over the other two techniques used, as it exhibited minimal gap in the marginal region which is an area of chief concern.

The Effect of Multiple Firings on the Shear Bond Strength of Porcelain to a New Millable Alloy and a Conventional Casting Alloy

PubMed Central

Farzin, Mitra; Giti, Rashin; Asalforush-Rezaiye, Amin

2018-01-01

This study compared the effect of multiple firings on the shear bond strength (SBS) of porcelain to the new millable alloy (Ceramill Sintron) and a conventional casting alloy (4-all). Thirty-six cylindrical cores (6.8 × 9 mm) were made of millable and castable alloy through CAD/CAM and casting techniques, respectively (n = 18). In the center of each bar, a 4 × 4 × 2-mm shot of porcelain was fused. Having divided each group into 3 subgroups based on the number of firing cycles (3, 5, 7), the specimens were fixed in a universal testing machine and underwent a shear force test (1.5 mm/min crosshead speed) until fractured. Then the SBS values (MPa) were calculated, and the failure patterns were microscopically characterized as adhesive, cohesive, or mixed. Two-way ANOVA statistical test revealed that the number of porcelain firings had no significant effect on the SBS of any of the metal groups (p = 0.1); however, it was statistically higher in the millable group than the castable group (p < 0.05). Moreover, detecting the mixed failure pattern in all the specimens implied that the multiple firings had no significant effect on the failure pattern. The multiple porcelain firings had no significant effect on the SBS of porcelain to neither the millable nor castable alloys. PMID:29565827

Small queens and big-headed workers in a monomorphic ponerine ant

NASA Astrophysics Data System (ADS)

Kikuchi, Tomonori; Miyazaki, Satoshi; Ohnishi, Hitoshi; Takahashi, Junichi; Nakajima, Yumiko; Tsuji, Kazuki

2008-10-01

Evolution of caste is a central issue in the biology of social insects. Comparative studies on their morphology so far suggest the following three patterns: (1) a positive correlation between queen worker size dimorphism and the divergence in reproductive ability between castes, (2) a negative correlation among workers between morphological diversity and reproductive ability, and (3) a positive correlation between queen worker body shape difference and the diversity in worker morphology. We conducted morphological comparisons between castes in Pachycondyla luteipes, workers of which are monomorphic and lack their reproductive ability. Although the size distribution broadly overlapped, mean head width, head length, and scape length were significantly different between queens and workers. Conversely, in eye length, petiole width, and Weber’s length, the size differences were reversed. The allometries (head length/head width, scape length/head width, and Weber’s length/head width) were also significantly different between queens and workers. Morphological examinations showed that the body shape was different between queens and workers, and the head part of workers was disproportionately larger than that of queens. This pattern of queen worker dimorphism is novel in ants with monomorphic workers and a clear exception to the last pattern. This study suggests that it is possible that the loss of individual-level selection, the lack of reproductive ability, influences morphological modification in ants.

Proteome Analysis of Human Sebaceous Follicle Infundibula Extracted from Healthy and Acne-Affected Skin

PubMed Central

Bek-Thomsen, Malene; Lomholt, Hans B.; Scavenius, Carsten; Enghild, Jan J.; Brüggemann, Holger

2014-01-01

Acne vulgaris is a very common disease of the pilosebaceous unit of the human skin. The pathological processes of acne are not fully understood. To gain further insight sebaceous follicular casts were extracted from 18 healthy and 20 acne-affected individuals by cyanoacrylate-gel biopsies and further processed for mass spectrometry analysis, aiming at a proteomic analysis of the sebaceous follicular casts. Human as well as bacterial proteins were identified. Human proteins enriched in acne and normal samples were detected, respectively. Normal follicular casts are enriched in proteins such as prohibitins and peroxiredoxins which are involved in the protection from various stresses, including reactive oxygen species. By contrast, follicular casts extracted from acne-affected skin contained proteins involved in inflammation, wound healing and tissue remodeling. Among the most distinguishing proteins were myeloperoxidase, lactotransferrin, neutrophil elastase inhibitor and surprisingly, vimentin. The most significant biological process among all acne-enriched proteins was ‘response to a bacterium’. Identified bacterial proteins were exclusively from Propionibacterium acnes. The most abundant P. acnes proteins were surface-exposed dermatan sulphate adhesins, CAMP factors, and a so far uncharacterized lipase in follicular casts extracted from normal as well as acne-affected skin. This is a first proteomic study that identified human proteins together with proteins of the skin microbiota in sebaceous follicular casts. PMID:25238151

Tongue prints in biometric authentication: A pilot study

PubMed Central

Jeddy, Nadeem; Radhika, T; Nithya, S

2017-01-01

Background and Objectives: Biometric authentication is an important process for the identification and verification of individuals for security purposes. There are many biometric systems that are currently in use and also being researched. Tongue print is a new biometric authentication tool that is unique and cannot be easily forged because no two tongue prints are similar. The present study aims to evaluate the common morphological features of the tongue and its variations in males and females. The usefulness of alginate impression and dental cast in obtaining the lingual impression was also evaluated. Materials and Methods: The study sample included twenty participants. The participants were subjected to visual examination following which digital photographs of the dorsal surface of the tongue were taken. Alginate impressions of the tongue were made, and casts were prepared using dental stone. The photographs and the casts were analyzed by two observers separately for the surface morphology including shape, presence or absence of fissures and its pattern of distribution. Three reference points were considered to determine the shape of the tongue. Results: The most common morphological feature on the dorsum of the tongue was the presence of central fissures. Multiple vertical fissures were observed in males whereas single vertical fissure was a common finding in females. The fissures were predominantly shallow in males and deep in females. The tongue was predominantly U shaped in males and females. V-shaped tongue was observed in 25% of females. Conclusion: Tongue prints are useful in biometric authentication. The methodology used in the study is simple, easy and can be adopted by dentists on a regular basis. However, large-scale studies are required to validate the results and also identify other features of the tongue that can be used in forensics and biometric authentication process. PMID:28479712

Tongue prints in biometric authentication: A pilot study.

PubMed

Jeddy, Nadeem; Radhika, T; Nithya, S

2017-01-01

Biometric authentication is an important process for the identification and verification of individuals for security purposes. There are many biometric systems that are currently in use and also being researched. Tongue print is a new biometric authentication tool that is unique and cannot be easily forged because no two tongue prints are similar. The present study aims to evaluate the common morphological features of the tongue and its variations in males and females. The usefulness of alginate impression and dental cast in obtaining the lingual impression was also evaluated. The study sample included twenty participants. The participants were subjected to visual examination following which digital photographs of the dorsal surface of the tongue were taken. Alginate impressions of the tongue were made, and casts were prepared using dental stone. The photographs and the casts were analyzed by two observers separately for the surface morphology including shape, presence or absence of fissures and its pattern of distribution. Three reference points were considered to determine the shape of the tongue. The most common morphological feature on the dorsum of the tongue was the presence of central fissures. Multiple vertical fissures were observed in males whereas single vertical fissure was a common finding in females. The fissures were predominantly shallow in males and deep in females. The tongue was predominantly U shaped in males and females. V-shaped tongue was observed in 25% of females. Tongue prints are useful in biometric authentication. The methodology used in the study is simple, easy and can be adopted by dentists on a regular basis. However, large-scale studies are required to validate the results and also identify other features of the tongue that can be used in forensics and biometric authentication process.

Mapping Sleeping Bees within Their Nest: Spatial and Temporal Analysis of Worker Honey Bee Sleep

PubMed Central

Klein, Barrett Anthony; Stiegler, Martin; Klein, Arno; Tautz, Jürgen

2014-01-01

Patterns of behavior within societies have long been visualized and interpreted using maps. Mapping the occurrence of sleep across individuals within a society could offer clues as to functional aspects of sleep. In spite of this, a detailed spatial analysis of sleep has never been conducted on an invertebrate society. We introduce the concept of mapping sleep across an insect society, and provide an empirical example, mapping sleep patterns within colonies of European honey bees (Apis mellifera L.). Honey bees face variables such as temperature and position of resources within their colony's nest that may impact their sleep. We mapped sleep behavior and temperature of worker bees and produced maps of their nest's comb contents as the colony grew and contents changed. By following marked bees, we discovered that individuals slept in many locations, but bees of different worker castes slept in different areas of the nest relative to position of the brood and surrounding temperature. Older worker bees generally slept outside cells, closer to the perimeter of the nest, in colder regions, and away from uncapped brood. Younger worker bees generally slept inside cells and closer to the center of the nest, and spent more time asleep than awake when surrounded by uncapped brood. The average surface temperature of sleeping foragers was lower than the surface temperature of their surroundings, offering a possible indicator of sleep for this caste. We propose mechanisms that could generate caste-dependent sleep patterns and discuss functional significance of these patterns. PMID:25029445

An Investigation of the Mold-Flux Performance for the Casting of Cr12MoV Steel Using a Mold Simulator Technique

NASA Astrophysics Data System (ADS)

Zhou, Lejun; Wang, Wanlin; Xu, Chao; Zhang, Chen

2017-08-01

Mold flux plays important roles in the process of continuous casting. In this article, the performance of mold flux for the casting of Cr12MoV steel was investigated by using a mold simulator. The results showed that the slag film formed in the gap between the initial shell and mold hot surface is thin and discontinuous during the casting process with the Flux BM, due to the absorption of chromic oxide inclusions into the liquid slag, while the slag film formed in the case of the optimized Flux NEW casting process is uniform. The main precipitated crystals in Flux BM slag film are cuspidine (Ca4Si2O7F2) and Cr3O4, but only Ca4Si2O7F2 precipitated in the Flux NEW case. Besides, both the responding temperature and heat flux in the case of Flux BM are relatively higher and fluctuate in a larger amplitude. The surface of the shell obtained in the case of the Flux BM experiment is quite uneven, and many severe depressions, cracks, and entrapped slags are observed in the surface due to the lack of lubrication. However, the obtained shell surface in the case of the Flux NEW shows good surface quality due to the addition of B2O3 and the adjustment of basicity, which can compensate for the negative effects of the mold-flux properties caused by the absorption of chromic oxide during the casting process.

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.

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

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

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

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

Case and Administrative Support Tools

EPA Pesticide Factsheets

Case and Administrative Support Tools (CAST) is the secure portion of the Office of General Counsel (OGC) Dashboard business process automation tool used to help reduce office administrative labor costs while increasing employee effectiveness. CAST supports business functions which rely on and store Privacy Act sensitive data (PII). Specific business processes included in CAST (and respective PII) are: -Civil Rights Cast Tracking (name, partial medical history, summary of case, and case correspondance). -Employment Law Case Tracking (name, summary of case). -Federal Tort Claims Act Incident Tracking (name, summary of incidents). -Ethics Program Support Tools and Tracking (name, partial financial history). -Summer Honors Application Tracking (name, home address, telephone number, employment history). -Workforce Flexibility Initiative Support Tools (name, alternative workplace phone number). -Resource and Personnel Management Support Tools (name, partial employment and financial history).

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.

Development of chloride-induced corrosion in pre-cracked RC beams under sustained loading: Effect of load-induced cracks, concrete cover, and exposure conditions

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

Yu, Linwen; Université de Sherbrooke, Quebec; François, Raoul, E-mail: raoul.francois@insa-toulouse.fr

2015-01-15

This paper deals with corrosion initiation and propagation in pre-cracked reinforced concrete beams under sustained loading during exposure to a chloride environment. Specimen beams that were cast in 2010 were compared to specimens cast in 1984. The only differences between the two sets of beams were the casting direction in relation to tensile reinforcement and the exposure conditions in the salt-fog chamber. The cracking maps, corrosion maps, chloride profiles, and cross-sectional loss of one group of two beams cast in 2010 were studied and their calculated corrosion rates were compared to that of beams cast in 1984 in order tomore » investigate the factors influencing the natural corrosion process. Experimental results show that, after rapid initiation of corrosion at the crack tip, the corrosion process practically halted and the time elapsing before corrosion resumed depended on the exposure conditions and cover depth.« less

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.

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

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

Aikin, Jr., Robert M.

2017-10-04

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

A Winning Cast

NASA Technical Reports Server (NTRS)

2001-01-01

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

Interface Effects of the Properties and Processing of Graded Composite Aluminum Alloys

DTIC Science & Technology

2015-08-31

diffuse interface. Produced by the Alcoa sequential casting process, the material has a gradient in composition from a stronger, precipitation...strengthened alloy (7055) to a softer, strain-hardenable alloy (5456) [1], [2]. Alcoa donated material, 30x30x2 cm3 in volume. The material was cast, rolled

Vacuum casting of thick polymeric films

NASA Technical Reports Server (NTRS)

Cuddihy, E. F.; Moacanin, J.

1979-01-01

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

Microstructural and mechanical investigation of aluminium alloy (Al 1050) melted by microwave hybrid heating

NASA Astrophysics Data System (ADS)

Shashank Lingappa, M.; Srinath, M. S.; Amarendra, H. J.

2017-07-01

Microwave processing of metals is an emerging area. Melting of bulk metallic materials through microwave irradiation is still immature. In view of this, the present paper discusses the melting of bulk Al 1050 metallic material through microwave irradiation. The melting process is carried out successfully in a domestic microwave oven with 900 W power at 2450 MHz frequency. Metallurgical and mechanical characterization of the processed and as-received material is carried out. Aluminium phase is found to be dominant in processed material when tested through x-ray diffraction (XRD). Microstructure study of as-cast metal through scanning electron microscopy (SEM) reveals the formation of uniform hexagonal grain structure free from pores and cavities. The average tensile strength of the cast material is found to be around 21% higher, when compared to as-received material. Vickers’ microhardness of the as-cast metal is measured and is 10% higher than that of the as-received metal. Radiography on as-cast metal shows no significant defects. Al 1050 material melted through microwave irradiation has exhibited superior properties than the as-received Al 1050.

Casting materials and their application in research and teaching.

PubMed

Haenssgen, Kati; Makanya, Andrew N; Djonov, Valentin

2014-04-01

From a biological point of view, casting refers to filling of anatomical and/or pathological spaces with extraneous material that reproduces a three-dimensional replica of the space. Casting may be accompanied by additional procedures such as corrosion, in which the soft tissue is digested out, leaving a clean cast, or the material may be mixed with radiopaque substances to allow x-ray photography or micro computed topography (µCT) scanning. Alternatively, clearing of the surrounding soft tissue increases transparency and allows visualization of the casted cavities. Combination of casting with tissue fixation allows anatomical dissection and didactic surgical procedures on the tissue. Casting materials fall into three categories namely, aqueous substances (India ink, Prussian blue ink), pliable materials (gelatins, latex, and silicone rubber), or hard materials (methyl methacrylates, polyurethanes, polyesters, and epoxy resins). Casting has proved invaluable in both teaching and research and many phenomenal biological processes have been discovered through casting. The choice of a particular material depends inter alia on the targeted use and the intended subsequent investigative procedures, such as dissection, microscopy, or µCT. The casting material needs to be pliable where anatomical and surgical manipulations are intended, and capillary-passable for ultrastructural investigations.

The influence of cooling parameters on the speed of continuous steel casting

NASA Astrophysics Data System (ADS)

Tirian, G. O.; Gheorghiu, C. A.; Hepuţ, T.; Chioncel, C. P.

2018-01-01

This paper analyzes the cooling parameters of the continuous casting speed. In the researches carried out we aimed to establish some correlation equations between the parameters characterizing the continuous casting process, the temperature of the steel at the entrance to the crystallizer, the superheating of the steel and the flow of the cooling water in the crystallizer and different zones of the secondary cooling. Parallel to these parameters were also the values for the casting speed. The research was made for the casting of round ϕ270mm semi-finished steel products. The steel was developed in an electric EBT furnace with a capacity of 100t, treated in L.F. (Ladle - Furnace) and VD (Vacuum-Degassing) and poured in a 5-wire continuous casting plant. The obtained data was processed in MATLAB using three types of correlation equations. The obtained results are presented both in the analytical and graphical form, each correlation being analyzed from the technological point of view, indicating the optimal values for the independent parameters monitored. In the analysis we present a comparison between the results obtained after the three types of equations for each correlation.

Genome-wide and caste-specific DNA methylomes of the ants Camponotus floridanus and Harpegnathos saltator

PubMed Central

Bonasio, Roberto; Li, Qiye; Lian, Jinmin; Mutti, Navdeep S.; Jin, Lijun; Zhao, Hongmei; Zhang, Pei; Wen, Ping; Xiang, Hui; Ding, Yun; Jin, Zonghui; Shen, Steven S.; Wang, Zongji; Wang, Wen; Wang, Jun; Berger, Shelley L.; Liebig, Jürgen; Zhang, Guojie; Reinberg, Danny

2012-01-01

SUMMARY Background Ant societies comprise individuals belonging to different castes characterized by specialized morphologies and behaviors. Because ant embryos can follow different developmental trajectories, epigenetic mechanisms must play a role in caste determination. Ants have a full set of DNA methyltransferase and their genomes contain methylcytosine. To determine the relationship between DNA methylation and phenotypic plasticity in ants, we obtained and compared the genome-wide methylomes of different castes and developmental stages of Camponotus floridanus and Harpegnathos saltator. Results In the ant genomes, methylcytosines are found both in CpG and non-CpG contexts and are strongly enriched at exons of active genes. Changes in exonic DNA methylation correlate with alternative splicing events such as exon skipping and alternative splice site selection. Several genes exhibit caste-specific and developmental changes in DNA methylation that are conserved between the two species, including genes involved in reproduction, telomere maintenance, and noncoding RNA metabolism. Several loci are methylated and expressed monoallelically, and in some cases the choice of methylated allele depends on the caste. Conclusions These first ant methylomes and their intra- and inter-species comparison reveal an exonic methylation pattern that points to a connection between DNA methylation and splicing. The presence of monoallelic DNA methylation and the methylation of non-CpG sites in all samples suggest roles in genome regulation in these social insects, including the intriguing possibility of parental or caste-specific genomic imprinting. PMID:22885060

Caste-, sex-, and age-dependent expression of immune-related genes in a Japanese subterranean termite, Reticulitermes speratus

PubMed Central

Kobayashi, Kazuya; Matsuura, Kenji

2017-01-01

Insects protect themselves from microbial infections through innate immune responses, including pathogen recognition, phagocytosis, the activation of proteolytic cascades, and the synthesis of antimicrobial peptides. Termites, eusocial insects inhabiting microbe-rich wood, live in closely-related family groups that are susceptible to shared pathogen infections. To resist pathogenic infection, termite families have evolved diverse immune adaptations at both individual and societal levels, and a strategy of trade-offs between reproduction and immunity has been suggested. Although termite immune-inducible genes have been identified, few studies have investigated the differential expression of these genes between reproductive and neuter castes, and between sexes in each caste. In this study, we compared the expression levels of immune-related genes among castes, sexes, and ages in a Japanese subterranean termite, Reticulitermes speratus. Using RNA-seq, we found 197 immune-related genes, including 40 pattern recognition proteins, 97 signalling proteins, 60 effectors. Among these genes, 174 showed differential expression among castes. Comparing expression levels between males and females in each caste, we found sexually dimorphic expression of immune-related genes not only in reproductive castes, but also in neuter castes. Moreover, we identified age-related differential expression of 162 genes in male and/or female reproductives. In addition, although R. speratus is known to use the antibacterial peptide C-type lysozyme as an egg recognition pheromone, we determined that R. speratus has not only C-type, but also P-type and I-type lysozymes, as well as other termite species. Our transcriptomic analyses revealed immune response plasticity among all castes, and sex-biased expression of immune genes even in neuter castes, suggesting a sexual division of labor in the immune system of R. speratus. This study heightens the understanding of the evolution of antimicrobial strategies in eusocial insects, and of sexual roles in insect societies as a whole. PMID:28410430

Caste-, sex-, and age-dependent expression of immune-related genes in a Japanese subterranean termite, Reticulitermes speratus.

PubMed

Mitaka, Yuki; Kobayashi, Kazuya; Matsuura, Kenji

2017-01-01

Insects protect themselves from microbial infections through innate immune responses, including pathogen recognition, phagocytosis, the activation of proteolytic cascades, and the synthesis of antimicrobial peptides. Termites, eusocial insects inhabiting microbe-rich wood, live in closely-related family groups that are susceptible to shared pathogen infections. To resist pathogenic infection, termite families have evolved diverse immune adaptations at both individual and societal levels, and a strategy of trade-offs between reproduction and immunity has been suggested. Although termite immune-inducible genes have been identified, few studies have investigated the differential expression of these genes between reproductive and neuter castes, and between sexes in each caste. In this study, we compared the expression levels of immune-related genes among castes, sexes, and ages in a Japanese subterranean termite, Reticulitermes speratus. Using RNA-seq, we found 197 immune-related genes, including 40 pattern recognition proteins, 97 signalling proteins, 60 effectors. Among these genes, 174 showed differential expression among castes. Comparing expression levels between males and females in each caste, we found sexually dimorphic expression of immune-related genes not only in reproductive castes, but also in neuter castes. Moreover, we identified age-related differential expression of 162 genes in male and/or female reproductives. In addition, although R. speratus is known to use the antibacterial peptide C-type lysozyme as an egg recognition pheromone, we determined that R. speratus has not only C-type, but also P-type and I-type lysozymes, as well as other termite species. Our transcriptomic analyses revealed immune response plasticity among all castes, and sex-biased expression of immune genes even in neuter castes, suggesting a sexual division of labor in the immune system of R. speratus. This study heightens the understanding of the evolution of antimicrobial strategies in eusocial insects, and of sexual roles in insect societies as a whole.

Apparatus and method for a light direction sensor

NASA Technical Reports Server (NTRS)

Leviton, Douglas B. (Inventor)

2011-01-01

The present invention provides a light direction sensor for determining the direction of a light source. The system includes an image sensor; a spacer attached to the image sensor, and a pattern mask attached to said spacer. The pattern mask has a slit pattern that as light passes through the slit pattern it casts a diffraction pattern onto the image sensor. The method operates by receiving a beam of light onto a patterned mask, wherein the patterned mask as a plurality of a slit segments. Then, diffusing the beam of light onto an image sensor and determining the direction of the light source.

Reusability of contaminated seed crystal for cast quasi-single crystalline silicon ingots

NASA Astrophysics Data System (ADS)

Li, Zaoyang; Liu, Lijun; Zhou, Genshu

2015-04-01

Reusing seed crystal is beneficial for reducing the production costs for cast quasi-single crystalline (QSC) silicon ingots. We numerically investigate the reusability of seed crystal in the casting processes with quartz crucible and silicon feedstock of different purities. The reused seed crystal is recycled from the standard QSC ingot and has been highly contaminated by iron impurity. Transient simulations of iron transport are carried out and special attention is paid to the diffusion and distribution characteristics of iron impurity at the ingot bottom. The heights of the bottom iron contaminated region are compared for silicon ingots grown from normal and recycled seed crystals. The results show that the purity of quartz crucible can influence the reusability of seed crystal more significantly than that of the feedstock. The recycled seed crystal with high iron concentration can be reused for casting processes with standard crucible, whereas it is not recommended for reusing for processes with pure crucible.

The casting of semi-permeable membranes in a microgravity environment

NASA Technical Reports Server (NTRS)

Vera, I.

1986-01-01

The experiment is to study polymeric membranes. Presently, semipermeable membranes are being manufactured from several different kinds of polymers all over the world and specific applications have been identified in fluid separation processes such as reverse osmosis, ultrafiltration and electrodialysis. Although, the ultrastructure of asymmetric and composite membranes have been under intensive study, still there are many questions about the factors affecting this structure and their degree of correlation. Nevertheless, there is indication that the entire morphological structure of polymeric membranes could be affected by the difference in specific gravity between the cast solution and the coagulation liquid normally used in the membranes preparation process. The casting of semipermeable membranes in space might help to identify the effect of gravity upon the structure of these membranes. It is important to recognize that the casting process involves changes of state and that in a microgravity environment, there will be a reduction on buoyancy-driven natural convection and density gradients.

Rheology and stability kinetics of bare silicon nanoparticle inks for low-cost direct printing

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

More, Priyesh V.; Jeong, Sunho; Seo, Yeong-Hui

2013-12-16

Highly dispersed and stable silicon nanoparticles ink is formulated for its application in direct printing or printable electronics. These dispersions are prepared from free-standing silicon nanoparticles which are not capped with any organic ligand, making it suitable for electronic applications. Silicon nanoparticles dispersions are prepared by suspending the nanoparticles in benzonitrile or ethanol by using polypropylene glycol (PPG) as a binder. All the samples show typical shear thinning behavior while the dispersion samples show low viscosities signifying good quality dispersion. Such thinning behavior favors in fabrication of dense films with spin-coating or patterns with drop casting. The dispersion stability ismore » monitored by turbiscan measurements showing good stability for one week. A low-cost direct printing method for dispersion samples is also demonstrated to obtain micro-sized patterns. Low electrical resistivity of resulting patterns, adjustable viscosity and good stability makes these silicon nanoparticles dispersions highly applicable for direct printing process.« less

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

NASA Astrophysics Data System (ADS)

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

2014-05-01

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

Biomimetic Materials by Freeze Casting

NASA Astrophysics Data System (ADS)

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

2013-06-01

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

CENTRIFUGAL CASTING MACHINE

DOEpatents

Shuck, A.B.

1958-04-01

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

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.

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

NASA Technical Reports Server (NTRS)

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

2002-01-01

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

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

NASA Technical Reports Server (NTRS)

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

2003-01-01

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

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

Evaluation of Uranium-235 Measurement Techniques

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

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

2017-05-23

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

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

NASA Astrophysics Data System (ADS)

Pan, Dong; Xu, Qingyan; Liu, Baicheng

2011-05-01

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

Evaluation of the microstructure, secondary dendrite arm spacing, and mechanical properties of Al-Si alloy castings made in sand and Fe-Cr slag molds

NASA Astrophysics Data System (ADS)

Narasimha Murthy, I.; Babu Rao, J.

2017-07-01

The microstructure and mechanical properties of as-cast A356 (Al-Si) alloy castings were investigated. A356 alloy was cast into three different molds composed of sand, ferrochrome (Fe-Cr) slag, and a mixture of sand and Fe-Cr. A sodium silicate-CO2 process was used to make the necessary molds. Cylindrical-shaped castings were prepared. Cast products with no porosity and a good surface finish were achieved in all of the molds. These castings were evaluated for their metallography, secondary dendrite arm spacing (SDAS), and mechanical properties, including hardness, compression, tensile, and impact properties. Furthermore, the tensile and impact samples were analyzed by fractography. The results show that faster heat transfer in the Fe-Cr slag molds than in either the silica sand or mixed molds led to lower SDAS values with a refined microstructure in the products cast in Fe-Cr slag molds. Consistent and enhanced mechanical properties were observed in the slag mold products than in the castings obtained from either sand or mixed molds. The fracture surface of the slag mold castings shows a dimple fracture morphology with a transgranular fracture nature. However, the fracture surfaces of the sand mold castings display brittle fracture. In conclusion, products cast in Fe-Cr slag molds exhibit an improved surface finish and enhanced mechanical properties compared to those of products cast in sand and mixed molds.

The endocranial cast of an early miocene edentate, Hapalops indifferens Ameghino (Mammalia, Edentata, Tardigrada, Megatheriidae). Comparative study with brains of recent sloths.

PubMed

Dozo, M T

1987-01-01

A natural endocranial cast which represents a complete brain of a specimen of Hapalops indifferens is described. Comparing this cast to brains of actual Tardigrada, it shows a telencephalic morphology and a pattern of neocortical sulci that resemble more the brain of Bradypus rather than that of Choloepus. The neocortical sulci homologate the lateral or corono-lateral, suprasylvian and pseudosylvian sulci. Taking into account the studies of cortical maps in Bradypus and the notable similitude of the pattern of neocortical sulci between Bradypus and H. indifferens, the possible representation of the primary sensitive and motor somatic areas, secondary sensitive somatic area, visual and auditory areas are inferred. As in Bradypus, the primary sensitive and motor somatotopic organizations would be overlapped and would not be mirror images; they would show a predominance of the area of the forelimb. The relative brain size of H. indifferens is similar or higher than that of sloths of the genus Bradypus. The close resemblance between Bradypus and Hapalops, with respect to its brain morphology and relative brain size. is congruent with the current hypothesis of the phylogenetic relations between fossil and recent Tardigrada.

Anatomical variations of the right hepatic veins and their relevance to surgery.

PubMed

Hribernik, Marija; de Cecchis, Lucio; Trotovsek, Blaz; Gadzijev, Eldar M; Ravnik, Dean

2003-01-01

In a morphological study of the right hepatic veins anatomical characteristics of surgical importance were looked for. 110 cadaveric human livers were prepared by the corrosion casts method. The confluence patterns of the superior right hepatic vein, the hepatocaval confluence, the accessory right hepatic veins and the anastomoses between hepatic veins in the right hemiliver were examined. Four types of the superior right hepatic vein, based on the length of its trunk and the confluence pattern of its main tributaries were determined and their frequency was calculated. Type I was found in 20%, type II in 40%, type III in 25% and type IV in 15%. Accessory right hepatic veins with a minimal caliber of 0.4 cm, which were always present in type IV, were also found in other types, all together in 27% of the casts. The tributary-free part of the superior right hepatic vein at hepatocaval confluence was longer than 1 cm in 77%. In the right hemiliver 109 anastomoses were found in 29/110 liver casts. Knowing the characteristics of different superior right hepatic vein types and of the accessory right hepatic veins may be useful in segment-oriented liver resections and in right side living donor resections.

High-throughput preparation of complex multi-scale patterns from block copolymer/homopolymer blend films

NASA Astrophysics Data System (ADS)

Park, Hyungmin; Kim, Jae-Up; Park, Soojin

2012-02-01

A simple, straightforward process for fabricating multi-scale micro- and nanostructured patterns from polystyrene-block-poly(2-vinylpyridine) (PS-b-P2VP)/poly(methyl methacrylate) (PMMA) homopolymer in a preferential solvent for PS and PMMA is demonstrated. When the PS-b-P2VP/PMMA blend films were spin-coated onto a silicon wafer, PS-b-P2VP micellar arrays consisting of a PS corona and a P2VP core were formed, while the PMMA macrodomains were isolated, due to the macrophase separation caused by the incompatibility between block copolymer micelles and PMMA homopolymer during the spin-coating process. With an increase of PMMA composition, the size of PMMA macrodomains increased. Moreover, the P2VP blocks have a strong interaction with a native oxide of the surface of the silicon wafer, so that the P2VP wetting layer was first formed during spin-coating, and PS nanoclusters were observed on the PMMA macrodomains beneath. Whereas when a silicon surface was modified with a PS brush layer, the PS nanoclusters underlying PMMA domains were not formed. The multi-scale patterns prepared from copolymer micelle/homopolymer blend films are used as templates for the fabrication of gold nanoparticle arrays by incorporating the gold precursor into the P2VP chains. The combination of nanostructures prepared from block copolymer micellar arrays and macrostructures induced by incompatibility between the copolymer and the homopolymer leads to the formation of complex, multi-scale surface patterns by a simple casting process.A simple, straightforward process for fabricating multi-scale micro- and nanostructured patterns from polystyrene-block-poly(2-vinylpyridine) (PS-b-P2VP)/poly(methyl methacrylate) (PMMA) homopolymer in a preferential solvent for PS and PMMA is demonstrated. When the PS-b-P2VP/PMMA blend films were spin-coated onto a silicon wafer, PS-b-P2VP micellar arrays consisting of a PS corona and a P2VP core were formed, while the PMMA macrodomains were isolated, due to the macrophase separation caused by the incompatibility between block copolymer micelles and PMMA homopolymer during the spin-coating process. With an increase of PMMA composition, the size of PMMA macrodomains increased. Moreover, the P2VP blocks have a strong interaction with a native oxide of the surface of the silicon wafer, so that the P2VP wetting layer was first formed during spin-coating, and PS nanoclusters were observed on the PMMA macrodomains beneath. Whereas when a silicon surface was modified with a PS brush layer, the PS nanoclusters underlying PMMA domains were not formed. The multi-scale patterns prepared from copolymer micelle/homopolymer blend films are used as templates for the fabrication of gold nanoparticle arrays by incorporating the gold precursor into the P2VP chains. The combination of nanostructures prepared from block copolymer micellar arrays and macrostructures induced by incompatibility between the copolymer and the homopolymer leads to the formation of complex, multi-scale surface patterns by a simple casting process. Electronic supplementary information (ESI) available: AFM images of PS-b-P2VP/PMMA blend films and cross-sectional line scans. See DOI: 10.1039/c2nr11792d

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

NASA Astrophysics Data System (ADS)

Li, Yu; Milbourn, David

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

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

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…

Implementation Analysis of Cutting Tool Carbide with Cast Iron Material S45 C on Universal Lathe

NASA Astrophysics Data System (ADS)

Junaidi; hestukoro, Soni; yanie, Ahmad; Jumadi; Eddy

2017-12-01

Cutting tool is the tools lathe. Cutting process tool CARBIDE with Cast Iron Material Universal Lathe which is commonly found at Analysiscutting Process by some aspects numely Cutting force, Cutting Speed, Cutting Power, Cutting Indication Power, Temperature Zone 1 and Temperatur Zone 2. Purpose of this Study was to determine how big the cutting Speed, Cutting Power, electromotor Power,Temperatur Zone 1 and Temperatur Zone 2 that drives the chisel cutting CARBIDE in the Process of tur ning Cast Iron Material. Cutting force obtained from image analysis relationship between the recommended Component Cuting Force with plane of the cut and Cutting Speed obtained from image analysis of relationships between the recommended Cutting Speed Feed rate.

The Role of Diesel Engines in Early Submarine Development

DTIC Science & Technology

2010-04-26

advantage of advances in metallurgical technology, could not match the superior technology in casting processes, alloy development, and heat treatments...metallurgical technology. NELSECO had the German plans and assistance from German engineers, but the foundries could not duplicate the casting to German...that the Germans and other European countries possessed. The U.S. commercial foundries did not want to undertake the risky development casting of low

Maximizing Modern Distribution of Complex Anatomical Spatial Information: 3D Reconstruction and Rapid Prototype Production of Anatomical Corrosion Casts of Human Specimens

ERIC Educational Resources Information Center

Li, Jianyi; Nie, Lanying; Li, Zeyu; Lin, Lijun; Tang, Lei; Ouyang, Jun

2012-01-01

Anatomical corrosion casts of human specimens are useful teaching aids. However, their use is limited due to ethical dilemmas associated with their production, their lack of perfect reproducibility, and their consumption of original specimens in the process of casting. In this study, new approaches with modern distribution of complex anatomical…

Embedding Optical Fibers In Cast Metal Parts

NASA Technical Reports Server (NTRS)

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

1995-01-01

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

Subsurface earthworm casts can be important soil microsites specifically influencing the growth of grassland plants.

PubMed

Zaller, Johann G; Wechselberger, Katharina F; Gorfer, Markus; Hann, Patrick; Frank, Thomas; Wanek, Wolfgang; Drapela, Thomas

Earthworms (Annelida: Oligochaeta) deposit several tons per hectare of casts enriched in nutrients and/or arbuscular mycorrhizal fungi (AMF) and create a spatial and temporal soil heterogeneity that can play a role in structuring plant communities. However, while we begin to understand the role of surface casts, it is still unclear to what extent plants utilize subsurface casts. We conducted a greenhouse experiment using large mesocosms (volume 45 l) to test whether (1) soil microsites consisting of earthworm casts with or without AMF (four Glomus taxa) affect the biomass production of 11 grassland plant species comprising the three functional groups grasses, forbs, and legumes, (2) different ecological groups of earthworms (soil dwellers- Aporrectodea caliginosa vs. vertical burrowers- Lumbricus terrestris ) alter potential influences of soil microsites (i.e., four earthworms × two subsurface microsites × two AMF treatments). Soil microsites were artificially inserted in a 25-cm depth, and afterwards, plant species were sown in a regular pattern; the experiment ran for 6 months. Our results show that minute amounts of subsurface casts (0.89 g kg -1 soil) decreased the shoot and root production of forbs and legumes, but not that of grasses. The presence of earthworms reduced root biomass of grasses only. Our data also suggest that subsurface casts provide microsites from which root AMF colonization can start. Ecological groups of earthworms did not differ in their effects on plant production or AMF distribution. Taken together, these findings suggest that subsurface earthworm casts might play a role in structuring plant communities by specifically affecting the growth of certain functional groups of plants.

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.

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

PubMed

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

2013-01-01

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

Modeling and simulation of clutch pressure plate casting using alternate materials

NASA Astrophysics Data System (ADS)

Madhuraj, H. N.; Bharath, M. R.

2018-04-01

Clutch Pressure Plate is a stress bearing component in the clutch assembly. Cast iron alloys like FG300, G2500 are commonly used for clutch pressure plate castings. These materials have high compressive strength, low tensile strength & no ductility but these cost high for the manufacturers. There is a need for alternate material so as to reduce cost, defects in castings without losing the life and effectiveness of the clutch plate. The work carried out here is modeling the clutch pressure plate using CAD tool. And then the casting process is simulated by casting simulation for fluid flow and solidification analysis by trying alternate material. Here the castability of the alternate material En-Gjs-400-15 and the commonly used material FG300 for the clutch pressure plate component is analyzed by designing and optimizing a proper gating system.

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

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.

Nanowire–quantum-dot lasers on flexible membranes

NASA Astrophysics Data System (ADS)

Tatebayashi, Jun; Ota, Yasutomo; Ishida, Satomi; Nishioka, Masao; Iwamoto, Satoshi; Arakawa, Yasuhiko

2018-06-01

We demonstrate lasing in a single nanowire with quantum dots as an active medium embedded on poly(dimethylsiloxane) membranes towards application in nanowire-based flexible nanophotonic devices. Nanowire laser structures with 50 quantum dots are grown on patterned GaAs(111)B substrates and then transferred from the as-grown substrates on poly(dimethylsiloxane) transparent flexible organosilicon membranes, by means of spin-casting and curing processes. We observe lasing oscillation in the transferred single nanowire cavity with quantum dots at 1.425 eV with a threshold pump pulse fluence of ∼876 µJ/cm2, which enables the realization of high-performance multifunctional NW-based flexible photonic devices.

Fabrication of submicron structures in nanoparticle/polymer composite by holographic lithography and reactive ion etching

NASA Astrophysics Data System (ADS)

Zhang, A. Ping; He, Sailing; Kim, Kyoung Tae; Yoon, Yong-Kyu; Burzynski, Ryszard; Samoc, Marek; Prasad, Paras N.

2008-11-01

We report on the fabrication of nanoparticle/polymer submicron structures by combining holographic lithography and reactive ion etching. Silica nanoparticles are uniformly dispersed in a (SU8) polymer matrix at a high concentration, and in situ polymerization (cross-linking) is used to form a nanoparticle/polymer composite. Another photosensitive SU8 layer cast upon the nanoparticle/SU8 composite layer is structured through holographic lithography, whose pattern is finally transferred to the nanoparticle/SU8 layer by the reactive ion etching process. Honeycomb structures in a submicron scale are experimentally realized in the nanoparticle/SU8 composite.

Implementation and Validation of 3-D Ice Accretion Measurement Methodology

NASA Technical Reports Server (NTRS)

Lee, Sam; Broeren, Andy P.; Kreeger, Richard E.; Potapczuk, Mark; Utt, Lloyd

2014-01-01

A research program has been implemented to develop and validate the use of a commercial 3-D laser scanning system to record ice accretion geometry in the NASA Icing Research Tunnel. A main component of the program was the geometric assessment of the 3- D laser scanning system on a 2-D (straight wing) and a 3-D (swept wing) airfoil geometries. This exercise consisted of comparison of scanned ice accretion to castings of the same ice accretion. The scan data were also used to create rapid prototype artificial ice shapes that were scanned and compared to the original ice accretion. The results from geometric comparisons on the straight wing showed that the ice shape models generated through the scan/rapid prototype process compared reasonably well with the cast shapes. Similar results were obtained with the geometric comparisons on the swept wing. It was difficult to precisely compare the scans of the cast shapes to the original ice accretion scans because the cast shapes appear to have shrunk during the mold/casting process by as much as 0.10-inch. However the comparison of the local ice-shape features were possible and produced better results. The rapid prototype manufacturing process was shown to reproduce the original ice accretion scan normally within 0.01-inch.

Microstructure and Corrosion Characterization of Squeeze Cast AM50 Magnesium Alloys

NASA Astrophysics Data System (ADS)

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

2010-12-01

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

Cerebral Aneurysm Clipping Surgery Simulation Using Patient-Specific 3D Printing and Silicone Casting.

PubMed

Ryan, Justin R; Almefty, Kaith K; Nakaji, Peter; Frakes, David H

2016-04-01

Neurosurgery simulator development is growing as practitioners recognize the need for improved instructional and rehearsal platforms to improve procedural skills and patient care. In addition, changes in practice patterns have decreased the volume of specific cases, such as aneurysm clippings, which reduces the opportunity for operating room experience. The authors developed a hands-on, dimensionally accurate model for aneurysm clipping using patient-derived anatomic data and three-dimensional (3D) printing. Design of the model focused on reproducibility as well as adaptability to new patient geometry. A modular, reproducible, and patient-derived medical simulacrum was developed for medical learners to practice aneurysmal clipping procedures. Various forms of 3D printing were used to develop a geometrically accurate cranium and vascular tree featuring 9 patient-derived aneurysms. 3D printing in conjunction with elastomeric casting was leveraged to achieve a patient-derived brain model with tactile properties not yet available from commercial 3D printing technology. An educational pilot study was performed to gauge simulation efficacy. Through the novel manufacturing process, a patient-derived simulacrum was developed for neurovascular surgical simulation. A follow-up qualitative study suggests potential to enhance current educational programs; assessments support the efficacy of the simulacrum. The proposed aneurysm clipping simulator has the potential to improve learning experiences in surgical environment. 3D printing and elastomeric casting can produce patient-derived models for a dynamic learning environment that add value to surgical training and preparation. Copyright © 2016 Elsevier Inc. All rights reserved.

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.

Effect of Heating Time on Hardness Properties of Laser Clad Gray Cast Iron Surface

NASA Astrophysics Data System (ADS)

Norhafzan, B.; Aqida, S. N.; Mifthal, F.; Zulhishamuddin, A. R.; Ismail, I.

2018-03-01

This paper presents effect of heating time on cladded gray cast iron. In this study, the effect of heating time on cladded gray cast iron and melted gray cast iron were analysed. The gray cast iron sample were added with mixed Mo-Cr powder using laser cladding technique. The mixed Mo and Cr powder was pre-placed on gray cast iron surface. Modified layer were sectioned using diamond blade cutter and polish using SiC abrasive paper before heated. Sample was heated in furnace for 15, 30 and 45 minutes at 650 °C and cool down in room temperature. Metallographic study was conduct using inverted microscope while surface hardness properties were tested using Wilson hardness test with Vickers scale. Results for metallographic study showed graphite flakes within matrix of pearlite. The surface hardness for modified layer decreased when increased heating time process. These findings are significant to structure stability of laser cladded gray cast iron with different heating times.

Length dependence of a halo orthosis on cervical immobilization.

PubMed

Triggs, K J; Ballock, R T; Byrne, T; Garfin, S R

1993-02-01

This study was designed to observe the length dependence of a well-molded fiberglass body cast attached to a halo on motion restriction in an unstable cadaveric cervical spine. Also, by using this technique, comparison between the immobilization provided by a body cast and that provided by a standard premolded polyethylene halo vest could be made. Extreme cervical instability was created on adult cadavers. A halo ring was applied and then attached to a fiberglass body cast or to a polyethylene halo vest. Sequential lateral cervical radiographs were obtained during maximum flexion as the body cast was shortened from the level of the iliac crests to the level of the xiphoid process. Radiographic motion was also assessed within the polyethylene halo vest. Results revealed minimal motion difference as the fiberglass body cast was sequentially shortened. In contrast, motions within the polyethylene halo vest were variable. These results suggest that cervical immobilization may be relatively independent of support structure length and that immobilization can be maintained by a well-fitting halo vest extending to the level of the xiphoid process.

Striation patterns in serrated blade stabs to cartilage.

PubMed

Pounder, Derrick J; Reeder, Francesca D

2011-05-20

Stab wounds were made in porcine cartilage with 13 serrated knives, amongst which 4 were drop-point and 9 straight-spine; 9 coarsely serrated, 3 finely serrated and 1 with mixed pattern serrations. The walls of the stab tracks were cast with dental impression material, and the casts photographed together with the knife blades for comparison. All 13 serrated blades produced an "irregularly regular" pattern of striations on cartilage in all stabbings. Unusual and distinctive blade serration patterns produced equally distinctive wound striation patterns. A reference collection of striation patterns and corresponding blades might prove useful for striation pattern analysis. Drop-point blades produced similar striations to straight-spine blades except that the striations were not parallel but rather fan-shaped, converging towards the wound exit. The fan-shaped striation pattern characteristic of drop-point blades is explained by the initial lateral movement of the blade through the cartilage imposed by the presence of the drop point shape. It appears that the greater the overall angle of the drop point, the shorter the blade length over which the drop point occurs, and the closer the first serration is to the knife tip, the more obvious is the fan-shaped pattern. We anticipate that micro-irregularities producing individualising characteristics in non-serrated drop point blades, provided they were located at the tip opposite the drop point, should also show a fan-shaped pattern indicative of a drop point blade. The examination of the walls of stab wounds to cartilage represents an under-utilised source of forensic information to assist in knife identification. Copyright © 2010 Elsevier Ireland Ltd. All rights reserved.

Microstructure-Texture-Mechanical Properties in Hot Rolling of a Centrifugal Casting Ring Blank

NASA Astrophysics Data System (ADS)

Qin, Fang-cheng; Li, Yong-tang; Qi, Hui-ping; Ju, Li

2016-03-01

Deformation characteristic of centrifugal casting 25Mn steel was investigated by compression tests, and then processing maps were established. According to the deformation parameters identified from the established processing maps and hot ring rolling (HRR) process, the industrial test for the 25Mn ring blank was performed. Optical microscope (OM) and electron backscatter diffraction (EBSD) techniques were used for detecting grain boundary features and textures of deformation structures. The morphologies and mechanisms of tensile and impact fracture were revealed. The results show that softening effect plays a dominant role in higher temperatures of 1050-1150 °C and strain rates lower than 0.1 s-1. The average grain size of the rolled 25Mn ring is about 28 μm, but the grains are more coarse and inhomogeneous on the middle layer than that on rest of the areas. The texture on the outer layer is characterized by strong {110} <112> and weak {112} <111>, followed by {001} <100> and {001} <110> on the inner layer and {110} <110> on the center layer, which is mainly associated with the shear deformation. The rolled ring with precise geometrical dimensions and sound mechanical properties is fabricated by HRR. Tensile fracture is composed of clear river-shaped pattern and a little dimple near the inner layer and outer layer, and the fracture mechanism is mainly quasi-cleavage fracture, accompanied by dimple fracture. The morphologies of impact fracture consist of tear ridge and cleavage platform.

Electroactive poly(vinylidene fluoride)-based structures for advanced applications.

PubMed

Ribeiro, Clarisse; Costa, Carlos M; Correia, Daniela M; Nunes-Pereira, João; Oliveira, Juliana; Martins, Pedro; Gonçalves, Renato; Cardoso, Vanessa F; Lanceros-Méndez, Senentxu

2018-04-01

Poly(vinylidene fluoride) (PVDF) and its copolymers are the polymers with the highest dielectric constants and electroactive responses, including piezoelectric, pyroelectric and ferroelectric effects. This semicrystalline polymer can crystallize in five different forms, each related to a different chain conformation. Of these different phases, the β phase is the one with the highest dipolar moment and the highest piezoelectric response; therefore, it is the most interesting for a diverse range of applications. Thus, a variety of processing methods have been developed to induce the formation of the polymer β phase. In addition, PVDF has the advantage of being easily processable, flexible and low-cost. In this protocol, we present a number of reproducible and effective methods to produce β-PVDF-based morphologies/structures in the form of dense films, porous films, 3D scaffolds, patterned structures, fibers and spheres. These structures can be fabricated by different processing techniques, including doctor blade, spin coating, printing technologies, non-solvent-induced phase separation (NIPS), temperature-induced phase separation (TIPS), solvent-casting particulate leaching, solvent-casting using a 3D nylon template, freeze extraction with a 3D poly(vinyl alcohol) (PVA) template, replica molding, and electrospinning or electrospray, with the fabrication method depending on the desired characteristics of the structure. The developed electroactive structures have shown potential to be used in a wide range of applications, including the formation of sensors and actuators, in biomedicine, for energy generation and storage, and as filtration membranes.

Use of Friction Stir Processing for Improving Heat-Affected Zone Liquation Cracking Resistance of a Cast Magnesium Alloy AZ91D

NASA Astrophysics Data System (ADS)

Karthik, G. M.; Janaki Ram, G. D.; Kottada, Ravi Sankar

2017-12-01

In this work, a cast magnesium alloy AZ91D was friction stir processed. Detailed microstructural studies and Gleeble hot ductility tests were conducted on the as-cast and the FSPed samples to comparatively assess their heat-affected zone liquation cracking behavior. The results show that the use of FSP as a pretreatment to fusion welding can strikingly improve the heat-affected zone liquation cracking resistance of alloy AZ91D by reducing the amount and size of the low-melting eutectic β (Mg17Al12) as well as by refining the matrix grain size.

[Effect of fluoride concentration on the corrosion behavior of cobalt-chromium alloy fabricated by two different technology processes].

PubMed

Qiuxia, Yang; Ying, Yang; Han, Xu; Di, Wu; Ke, Guo

2016-02-01

This study aims to determine the effect of fluoride concentration on the corrosion behavior of cobalt-chromium alloy fabricated by two different technology processes in a simulated oral environment. A total of 15 specimens were employed with selective laser melting (SLM) and another 15 for traditional casting (Cast) in cobalt-chromium alloy powders and blocks with the same material composition. The corrosion behavior of the specimens was studied by potentiodynamic polarization test under different oral environments with varying solubilities of fluorine (0, 0.05%, and 0.20% for each) in acid artificial saliva (pH = 5.0). The specimens were soaked in fluorine for 24 h, and the surface microstructure was observed under a field emission scanning electron microscope after immersing the specimens in the test solution at constant temperature. The corrosion potential (Ecorr) value of the cobalt-chromium alloy cast decreased with increasing fluoride concentration in acidic artificial saliva. The Ecorr, Icorr, and Rp values of the cobalt-chromium alloy fabricated by two different technology processes changed significantly when the fluoride concentration was 0.20% (P < 0.05). The Ecorr, Icorr, and Rp values of the cobalt-chromium alloy fabricated by two different technology processes exhibited a statistically significant difference. The Icorr value of the cobalt-chromium alloy cast was higher than that in the SLM group cobalt-chromium alloy when the fluoride concentration was 0.20% (P < 0.05). The Ecorr, tRp alues of the cobalt-chromium alloy cast were lower htan those of the SLM group cobalt-chromium alloy when the fluoride concentration was 0.20% (P< 0 .05). Fluoride ions adversely affected the corrosion resistance of the cobalt-chromium alloy fabricated by two different technology processes. The corrosion resistance of the cobalt-chromium alloy cast was worse than that of the SLM group cobalt-chromium alloy when the fluoride concentration was 0.20%.

Space Technology for Palate Surgery

NASA Technical Reports Server (NTRS)

1980-01-01

University of Miami utilized NASA's spacecraft viewing technology to develop the optical profilometer provides more accurate measurements of cleft palate casts than has heretofore been possible, enabling better planning of corrective surgery. Lens like instrument electronically scans a palate cast precisely measuring its irregular contours by detecting minute differences in the intensity of a light beam reflected off the cast. Readings are computer processed and delivered to the surgeon by a teleprinter.

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

NASA Astrophysics Data System (ADS)

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

2017-09-01

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

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.

Visualization and Quantification of Nasal and Olfactory Deposition in a Sectional Adult Nasal Airway Cast.

PubMed

Xi, Jinxiang; Yuan, Jiayao Eddie; Zhang, Yu; Nevorski, Dannielle; Wang, Zhaoxuan; Zhou, Yue

2016-06-01

To compare drug deposition in the nose and olfactory region with different nasal devices and administration techniques. A Sar-Gel based colorimetry method will be developed to quantify local deposition rates. A sectional nasal airway cast was developed based on an MRI-based nasal airway model to visualize deposition patterns and measure regional dosages. Four nasal spray pumps and four nebulizers were tested with both standard and point-release administration techniques. Delivered dosages were measured using a high-precision scale. The colorimetry correlation for deposited mass was developed via image processing in Matlab and its performance was evaluated through comparison to experimental measurements. Results show that the majority of nasal spray droplets deposited in the anterior nose while only a small fraction (less than 4.6%) reached the olfactory region. For all nebulizers considered, more droplets went beyond the nasal valve, leading to distinct deposition patterns as a function of both the nebulizer type (droplet size and initial speed) and inhalation flow rate. With the point-release administration, up to 9.0% (±1.9%) of administered drugs were delivered to the olfactory region and 15.7 (±2.4%) to the upper nose using Pari Sinus. Standard nasal devices are inadequate to deliver clinically significant olfactory dosages without excess drug losses in other nasal epitheliums. The Sar-Gel based colorimetry method appears to provide a simple and practical approach to visualize and quantify regional deposition.

The multisensory body revealed through its cast shadows.

PubMed

Pavani, Francesco; Galfano, Giovanni

2015-01-01

One key issue when conceiving the body as a multisensory object is how the cognitive system integrates visible instances of the self and other bodies with one's own somatosensory processing, to achieve self-recognition and body ownership. Recent research has strongly suggested that shadows cast by our own body have a special status for cognitive processing, directing attention to the body in a fast and highly specific manner. The aim of the present article is to review the most recent scientific contributions addressing how body shadows affect both sensory/perceptual and attentional processes. The review examines three main points: (1) body shadows as a special window to investigate the construction of multisensory body perception; (2) experimental paradigms and related findings; (3) open questions and future trajectories. The reviewed literature suggests that shadows cast by one's own body promote binding between personal and extrapersonal space and elicit automatic orienting of attention toward the body-part casting the shadow. Future research should address whether the effects exerted by body shadows are similar to those observed when observers are exposed to other visual instances of their body. The results will further clarify the processes underlying the merging of vision and somatosensation when creating body representations.

The multisensory body revealed through its cast shadows

PubMed Central

Pavani, Francesco; Galfano, Giovanni

2015-01-01

One key issue when conceiving the body as a multisensory object is how the cognitive system integrates visible instances of the self and other bodies with one’s own somatosensory processing, to achieve self-recognition and body ownership. Recent research has strongly suggested that shadows cast by our own body have a special status for cognitive processing, directing attention to the body in a fast and highly specific manner. The aim of the present article is to review the most recent scientific contributions addressing how body shadows affect both sensory/perceptual and attentional processes. The review examines three main points: (1) body shadows as a special window to investigate the construction of multisensory body perception; (2) experimental paradigms and related findings; (3) open questions and future trajectories. The reviewed literature suggests that shadows cast by one’s own body promote binding between personal and extrapersonal space and elicit automatic orienting of attention toward the body-part casting the shadow. Future research should address whether the effects exerted by body shadows are similar to those observed when observers are exposed to other visual instances of their body. The results will further clarify the processes underlying the merging of vision and somatosensation when creating body representations. PMID:26042079

The Cannabis Abuse Screening Test and the DSM-5 in the general population: Optimal thresholds and underlying common structure using multiple factor analysis.

PubMed

Legleye, Stéphane

2018-06-01

The Cannabis Abuse Screening Test (CAST) aims at screening the problematic use of cannabis. It has never been validated against the Diagnostic and Statistical Manual of Mental Disorders (DSM)-5 and its relationships with this latter have never been studied. We used a probabilistic telephone survey collected in 2014 (1351 past-year cannabis users aged 15-64) implementing the CAST and a DSM-5 adaptation of the Munich Composite International Diagnostic Interview assessing cannabis use disorders. Data were weighted, and CAST items were considered categorical. Factorial structures were assessed with confirmatory factor analyses; the relationships between the instruments were studied with multiple factor analysis (MFA). One factor for the DSM-5 and two correlated factors for the CAST were the best confirmatory factor analyses solutions. The CAST thresholds for screening moderate/severe and severe cannabis use disorders were 5 (sensitivity = 78.2% and specificity = 79.6%) and 8 (sensitivity = 86.0% and specificity = 86.7%), respectively. The MFA identified two orthogonal dimensions: The first was equally shared by both instruments; the second was the second CAST dimension (extreme frequencies of use before midday and alone, memory problems, and reproaches from friends/family). The CAST structure and screening properties were confirmed. The MFA explains its screening performances by its first dimension and identified the problematic patterns (the second dimension) that are not captured by the DSM-5. Copyright © 2017 John Wiley & Sons, Ltd.

Rheology of composite solid propellants during motor casting

NASA Technical Reports Server (NTRS)

Rogers, C. J.; Smith, P. L.; Klager, K.

1978-01-01

In a study conducted to evaluate flow parameters of uncured solid composite propellants during motor casting, two motors (1.8M-lb grain wt) were cast with a PBAN propellant exhibiting good flow characteristics in a 260-in. dia solid rocket motor. Attention is given to the effects of propellant compositional and processing variables on apparent viscosity as they pertain to rheological behavior and grain defect formation during casting. It is noted that optimized flow behavior is impaired with solid propellant loading. Non-Newtonian pseudoplastic flow is observed, which is dependent upon applied shear stress and the age of the uncured propellant.

Demonstration of the Impact of Thermomagnetic Processing on Cast Aluminum Alloys

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

Ludtka, Gerard Michael; Murphy, Bart L.; Rios, Orlando

2017-10-01

This project builds on an earlier Manufacturing Demonstration Facility Technical Collaboration phase 1 project to investigate application of high magnetic fields during solution heat treating and aging of three different cast aluminum alloys.

A high precision instrument to measure angular and binocular deviation introduced by aircraft windscreens by using a shadow casting technique

NASA Astrophysics Data System (ADS)

Shivananju, B. N.; Yamdagni, S.; Vasu, R. M.; Asokan, S.

2012-12-01

Objects viewed through transparent sheets with residual non-parallelism and irregularity appear shifted and distorted. This distortion is measured in terms of angular and binocular deviation of an object viewed through the transparent sheet. The angular and binocular deviations introduced are particularly important in the context of aircraft windscreens and canopies as they can interfere with decision making of pilots especially while landing, leading to accidents. In this work, we have developed an instrument to measure both the angular and binocular deviations introduced by transparent sheets. This instrument is especially useful in the qualification of aircraft windscreens and canopies. It measures the deviation in the geometrical shadow cast by a periodic dot pattern trans-illuminated by the distorted light beam from the transparent test specimen compared to the reference pattern. Accurate quantification of the shift in the pattern is obtained by cross-correlating the reference shadow pattern with the specimen shadow pattern and measuring the location of the correlation peak. The developed instrument is handy to use and computes both angular and binocular deviation with an accuracy of less than ±0.1 mrad (≈0.036 mrad) and has an excellent repeatability with an error of less than 2%.

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

NASA Astrophysics Data System (ADS)

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

2017-04-01

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

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

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

NASA Astrophysics Data System (ADS)

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

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

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

NASA Astrophysics Data System (ADS)

Combeau, Hervé; Založnik, Miha; Bedel, Marie

2016-08-01

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

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

NASA Astrophysics Data System (ADS)

Perrier, Frédéric; Desrayaud, Christophe; Bouvier, Véronique

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

Design of experiments to optimize an in vitro cast to predict human nasal drug deposition.

PubMed

Shah, Samir A; Dickens, Colin J; Ward, David J; Banaszek, Anna A; George, Chris; Horodnik, Walter

2014-02-01

Previous studies showed nasal spray in vitro tests cannot predict in vivo deposition, pharmacokinetics, or pharmacodynamics. This challenge makes it difficult to assess deposition achieved with new technologies delivering to the therapeutically beneficial posterior nasal cavity. In this study, we determined best parameters for using a regionally divided nasal cast to predict deposition. Our study used a model suspension and a design of experiments to produce repeatable deposition results that mimic nasal deposition patterns of nasal suspensions from the literature. The seven-section (the nozzle locator, nasal vestibule, front turbinate, rear turbinate, olfactory region, nasopharynx, and throat filter) nylon nasal cast was based on computed tomography images of healthy humans. It was coated with a glycerol/Brij-35 solution to mimic mucus. After assembling and orienting, airflow was applied and nasal spray containing a model suspension was sprayed. After disassembling the cast, drug depositing in each section was assayed by HPLC. The success criteria for optimal settings were based on nine in vivo studies in the literature. The design of experiments included exploratory and half factorial screening experiments to identify variables affecting deposition (angles, airflow, and airflow time), optimization experiments, and then repeatability and reproducibility experiments. We found tilt angle and airflow time after actuation affected deposition the most. The optimized settings were flow rate of 16 L/min, postactuation flow time of 12 sec, a tilt angle of 23°, nozzle angles of 0°, and actuation speed of 5 cm/sec. Neither cast nor operator caused significant variation of results. We determined cast parameters to produce results resembling suspension nasal sprays in the literature. The results were repeatable and unaffected by operator or cast. These nasal spray parameters could be used to assess deposition from new devices or formulations. For human deposition studies using radiolabeled formulations, this cast could show that radiolabel deposition represents drug deposition. Our methods could also be used to optimize settings for other casts.

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.

Three-Dimensional Flow Behavior Inside the Submerged Entry Nozzle

NASA Astrophysics Data System (ADS)

Real-Ramirez, Cesar Augusto; Carvajal-Mariscal, Ignacio; Sanchez-Silva, Florencio; Cervantes-de-la-Torre, Francisco; Diaz-Montes, Jesus; Gonzalez-Trejo, Jesus

2018-05-01

According to various authors, the surface quality of steel depends on the dynamic conditions that occur within the continuous casting mold's upper region. The meniscus, found in that upper region, is where the solidification process begins. The liquid steel is distributed into the mold through a submerged entry nozzle (SEN). In this paper, the dynamic behavior inside the SEN is analyzed by means of physical experiments and numerical simulations. The particle imaging velocimetry technique was used to obtain the vector field in different planes and three-dimensional flow patterns inside the SEN volume. Moreover, large eddy simulation was performed, and the turbulence model results were used to understand the nonlinear flow pattern inside the SEN. Using scaled physical and numerical models, quasi-periodic behavior was observed due to the interaction of two three-dimensional vortices that move inside the SEN lower region located between the exit ports of the nozzle.

The development of high strength corrosion resistant precipitation hardening cast steels

NASA Astrophysics Data System (ADS)

Abrahams, Rachel A.

Precipitation Hardened Cast Stainless Steels (PHCSS) are a corrosion resistant class of materials which derive their properties from secondary aging after a normalizing heat treatment step. While PHCSS materials are available in austenitic and semi-austenitic forms, the martensitic PHCSS are most widely used due to a combination of high strength, good toughness, and corrosion resistance. If higher strength levels can be achieved in these alloys, these materials can be used as a lower-cost alternative to titanium for high specific strength applications where corrosion resistance is a factor. Although wrought precipitation hardened materials have been in use and specified for more than half a century, the specification and use of PHCSS has only been recent. The effects of composition and processing on performance have received little attention in the cast steel literature. The work presented in these investigations is concerned with the experimental study and modeling of microstructural development in cast martensitic precipitation hardened steels at high strength levels. Particular attention is focused on improving the performance of the high strength CB7Cu alloy by control of detrimental secondary phases, notably delta ferrite and retained austenite, which is detrimental to strength, but potentially beneficial in terms of fracture and impact toughness. The relationship between age processing and mechanical properties is also investigated, and a new age hardening model based on simultaneous precipitation hardening and tempering has been modified for use with these steels. Because the CB7Cu system has limited strength even with improved processing, a higher strength prototype Fe-Ni-Cr-Mo-Ti system has been designed and adapted for use in casting. This prototype is expected to develop high strengths matching or exceed that of cast Ti-6Al-4V alloys. Traditional multicomponent constitution phase diagrams widely used for phase estimation in conventional stainless steels, give poor estimates of secondary phases in PHCSS. No measureable retained austenite was observed in any of the CB7Cu-1 steels studied, in spite of the fact that austenite is predicted by the constitution diagrams. A designed experiment using computationally derived phase equilibrium diagrams and actual experimental tests on CB7Cu of different compositions suggests that the ferrite phase is less stable than the constitution diagrams for austenitic stainless steels suggest. Delta ferrite was also more stable in slower-cooled sand cast material as compared to thin, fast-cooled investment cast material. High temperature solutionizing treatments were effective in dissolving delta ferrite at temperatures above 1900°F (˜1040°C). Delta ferrite dissolution was found to proceed at high rates during initial dissolution, and then was found to slow after 1 hour. Diffusion during the later stages is well-predicted by classical diffusion models. Repeated solution treatments were found to modestly increase both ductility and strength, likely due to subgrain refinement through austenite regrowth. Multistaged aging provided superior strength and toughness increases over similarly peak-aged and near peak-aged material aged at a single temperature. Peak-aged material fractography suggested that low energy quasi-cleavage fracture was likely due to age precipitate embrittlement along with some nucleation of MnS particulates at prior austenite grain boundaries. Yield strengths approaching 190 ksi (1310MPa) can be achieved in CB7Cu-1 if appropriate best-practices "+" processing techniques are used. This includes hot isostatic processing to reduce solidification segregation and heal microporosity, high temperature homogenization for effective age hardening and ferrite reduction, double-cycle solutionizing for structure refinement, and multistaged age strengthening for finer precipitate control. The experimental prototype 11-11PH (Fe-Ni-Cr-Ti-Mo) casting alloys was cast and was found to be delta-ferrite free in the as-cast condition. In this material, proper quench processing to eliminate excessive retained austenite was found to be most influential in terms of high strengths. It was also found that cooling below 0°C provided the best combination of strength and toughness, with the specific strength of the material exceeding that of cast Ti-6Al-4V material. Fractography studies suggest that titanium carbonitride and titanium carbon-nitride-sulfide inclusions limit the toughness of cast materials due to long exposures to ideal growth conditions during initial cooling. OIM studies also suggest that the retained austenite in properly processed 11-11PH alloy takes on an interlath structure, which likely contributes to toughness of the alloy, even at high-strength, peak aged conditions. Yield strengths approaching 235 ksi (1620 MPa) were achieved during initial heat treatment trials. It is expected that further improvements in properties can be achieved with continued improvement of processing for this new cast alloy system.

Method of casting patterned dielectric structures

DOEpatents

Poco, John F.; Hrubesh, Lawrence W.

2001-01-01

A pattern of dielectric structures are formed directly on a substrate in a single step using sol-gel chemistry and molding procedures. The resulting dielectric structures are useful in vacuum applications for electronic devices. Porous, lightweight structures having a high aspect ratio that are suitable for use as spacers between the faceplate and baseplate of a field emission display can be manufactured using this method.

In Vitro Assessment of Spray Deposition Patterns in a Pediatric (12 Year-Old) Nasal Cavity Model.

PubMed

Sawant, Namita; Donovan, Maureen D

2018-03-26

Nasal sprays available for the treatment of cold and allergy symptoms currently use identical formulations and devices for adults as well as for children. Due to the obvious differences between the nasal airway dimensions of a child and those of an adult, the performance of nasal sprays in children was evaluated. Deposition patterns of nasal sprays administered to children were tested using a nasal cast based on MRI images obtained from a 12 year old child's nasal cavity. Test formulations emitting a range of spray patterns were investigated by actuating the device into the pediatric nasal cast under controlled conditions. The results showed that the nasal sprays impacted in the anterior region of the 12 year old child's nasal cavity, and only limited spray entered the turbinate region - the effect site for most topical drugs and the primary absorptive region for systemically absorbed drugs. Differences in deposition patterns following the administration of nasal sprays to adults and children may lead to differences in efficacy between these populations. Greater anterior deposition in children may result in decreased effectiveness, greater anterior dosage form loss, and the increased potential for patient non-compliance.

Structure and properties of stir-cast zinc alloys

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

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

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

Fabrication of Ti-0.48Al Alloy by Centrifugal Casting.

PubMed

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

2018-09-01

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

Single Crystal Casting with Fluidized Carbon Bed Cooling: A Process Innovation for Quality Improvement and Cost Reduction

NASA Astrophysics Data System (ADS)

Hofmeister, M.; Franke, M. M.; Koerner, C.; Singer, R. F.

2017-12-01

Superalloy gas turbine blades are being produced by investment casting and directional solidification. A new process, Fluidized Carbon Bed Cooling (FCBC), has been developed and is now being optimized in a prototype casting unit with 10 kg pouring weight. In early test runs with still rather simple mold cluster geometries, a reduction of the primary dendrite arm spacing of around 40 pct compared to the standard radiation cooling process (HRS) could be demonstrated. The improvement is mainly attributed to higher temperature gradients driving solidification, made possible by a functioning Dynamic Baffle. Compared to earlier development efforts in the literature, contamination of the melt and damage to the equipment are avoided using carbon-based fluidized bed materials and the so-called "counter pressure concept."

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.

Integrated modeling and heat treatment simulation of austempered ductile iron

NASA Astrophysics Data System (ADS)

Hepp, E.; Hurevich, V.; Schäfer, W.

2012-07-01

The integrated modeling and simulation of the casting and heat treatment processes for producing austempered ductile iron (ADI) castings is presented. The focus is on describing different models to simulate the austenitization, quenching and austempering steps during ADI heat treatment. The starting point for the heat treatment simulation is the simulated microstructure after solidification and cooling. The austenitization model considers the transformation of the initial ferrite-pearlite matrix into austenite as well as the dissolution of graphite in austenite to attain a uniform carbon distribution. The quenching model is based on measured CCT diagrams. Measurements have been carried out to obtain these diagrams for different alloys with varying Cu, Ni and Mo contents. The austempering model includes nucleation and growth kinetics of the ADI matrix. The model of ADI nucleation is based on experimental measurements made for varied Cu, Ni, Mo contents and austempering temperatures. The ADI kinetic model uses a diffusion controlled approach to model the growth. The models have been integrated in a tool for casting process simulation. Results are shown for the optimization of the heat treatment process of a planetary carrier casting.

The analysis of composite properties reinforced with particles from palm oil industry waste produced by casting methods

NASA Astrophysics Data System (ADS)

Tugiman; Ariani, F.; Taher, F.; Hasibuan, M. S.; Suprianto

2017-12-01

Palm oil processing industries are very attractive because they offer plenty products with high economic value. The CPO factory processes not only produces crude palm oil but also generates fly ash (FA) particles waste in its final process. The purpose of this investigation to analyze and increase the benefits of particles as reinforcement materials for fabricating aluminum matrix composites (AMC’s) by different casting route. Stirring, centrifugal and squeeze casting method was conducted in this study. Further, the chemical composition of FA particles, densities and mechanical properties have been analyzed. The characteristics of composite material were investigated using an Optical microscope, scanning electron microscope (SEM), hardness (Brinell), impact strength (Charpy). The pin on disc method was used to measure the wear rate. The results show that SiO2, Fe2O3, and Al2O3 are the main compounds of fly ash particles. These particles enhanced the hardness and reduce wear resistance of aluminum matrix composites. The squeeze method gives better results than stir and centrifugal casting.

Microstructure, Tensile and Creep Properties of Ta20Nb20Hf20Zr20Ti20 High Entropy Alloy

PubMed Central

Larianovsky, Natalya; Katz-Demyanetz, Alexander; Eshed, Eyal; Regev, Michael

2017-01-01

This paper examines the microstructure and mechanical properties of Ta20Nb20Hf20Zr20Ti20. Two casting processes, namely, gravity casting and suction-assisted casting, were applied, both followed by Hot Isostatic Pressing (HIP). The aim of the current study was to investigate the creep and tensile properties of the material, since the literature review revealed no data whatsoever regarding these properties. The main findings are that the HIP process is responsible for the appearance of a Hexagonal Close Packed (HCP) phase that is dispersed differently in these two castings. The HIP process also led to a considerable increase in the mechanical properties of both materials under compression, with values found to be higher than those reported in the literature. Contrary to the compression properties, both materials were found to be highly brittle under tension, either during room temperature tension tests or creep tests conducted at 282 °C. Fractography yielded brittle fracture without any evidence of plastic deformation prior to fracture. PMID:28773245

Palatal rugae pattern: An aid for sex identification

PubMed Central

Gadicherla, Prahlad; Saini, Divya; Bhaskar, Milana

2017-01-01

Background: Palatal rugoscopy, or palatoscopy, is the process by which human identification can be obtained by inspecting the transverse palatal rugae inside the mouth. Aim: The aim of the study is to investigate the potential of using palatal rugae as an aid for sex identification in Bengaluru population. Materials and Methods: One hundred plaster casts equally distributed between males and females belonging to age range of 4–16 years were examined for different rugae patterns. Thomas and Kotze classification was adopted for identification of these rugae patterns. Statistical Analysis: The data obtained were subjected to discriminant function analysis to determine the applicability of palatal rugae pattern as an aid for sex identification. Results: Difference in unification patterns among males and females was found to be statistically significant. No significant difference was found between males and females in terms of number of rugae. Overall, wavy and curvy were the most predominant type of rugae seen. Discriminant function analysis enabled sex identification with an accuracy of 80%. Conclusion: This preliminary study undertaken showed the existence of a distinct pattern of distribution of palatal rugae between males and females of Bengaluru population. This study opens scope for further research with a larger sample size to establish palatal rugae as a valuable tool for sex identification for forensic purposes. PMID:28584485

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

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

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

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

The Isothermal Dendritic Growth Experiment

NASA Technical Reports Server (NTRS)

Glicksman, M. E.; Koss, M. B.; Malarik, D. C.

1998-01-01

The growth of dendrites is one of the commonly observed forms of solidification encountered when metals and alloys freeze under low thermal gradients, as occurs in most casting and welding processes. In engineering alloys, the details of the dendritic morphology directly relates to important material responses and properties. Of more generic interest, dendritic growth is also an archetypical problem in morphogenesis, where a complex pattern evolves from simple starting conditions. Thus, the physical understanding and mathematical description of how dendritic patterns emerge during the growth process are of interest to both scientists and engineers. The Isothermal Dendritic Growth Experiment (IDGE) is a basic science experiment designed to measure, for a fundamental test of theory, the kinetics and morphology of dendritic growth without complications induced by gravity-driven convection. The IDGE, a collaboration between Rensselaer Polytechnic Institute, in Troy NY, and NASA's Lewis Research Center (LeRC) was developed over a ten year period from a ground-based research program into a space flight experiment. Important to the success of this flight experiment was provision of in situ near-real-time teleoperations during the spaceflight experiment.

Secondary Waste Cast Stone Waste Form Qualification Testing Plan

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

Westsik, Joseph H.; Serne, R. Jeffrey

2012-09-26

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

Biodegradable materials based on silk fibroin and keratin.

PubMed

Vasconcelos, Andreia; Freddi, Giuliano; Cavaco-Paulo, Artur

2008-04-01

Wool and silk were dissolved and used for the preparation of blended films. Two systems are proposed: (1) blend films of silk fibroin and keratin aqueous solutions and (2) silk fibroin and keratin dissolved in formic acid. The FTIR spectra of pure films cast from aqueous solutions indicated that the keratin secondary structure mainly consists of alpha-helix and random coil conformations. The IR spectrum of pure SF is characteristic of films with prevalently amorphous structure (random coil conformation). Pure keratin film cast from formic acid shows an increase in the amount of beta-sheet and disordered keratin structures. The FTIR pattern of SF dissolved in formic acid is characteristic of films with prevalently beta-sheet conformations with beta-sheet crystallites embedded in an amorphous matrix. The thermal behavior of the blends confirmed the FTIR results. DSC curve of pure SF is typical of amorphous SF and the curve of pure keratin show the characteristic melting peak of alpha-helices for the aqueous system. These patterns are no longer observed in the films cast from formic acid due to the ability of formic acid to induce crystallization of SF and to increase the amount of beta-sheet structures on keratin. The nonlinear trend of the different parameters obtained from FTIR analysis and DSC curves of both SF/keratin systems indicate that when proteins are mixed they do not follow additives rules but are able to establish intermolecular interactions. Degradable polymeric biomaterials are preferred candidates for medical applications. It was investigated the degradation behavior of both SF/keratin systems by in vitro enzymatic incubation with trypsin. The SF/keratin films cast from water underwent a slower biological degradation than the films cast from formic acid. The weight loss obtained is a function of the amount of keratin in the blend. This study encourages the further investigation of the type of matrices presented here to be applied whether in scaffolds for tissue engineering or as controlled release drug delivery vehicles.

40 CFR Table 1 to Subpart Wwww of... - Equations To Calculate Organic HAP Emissions Factors for Specific Open Molding and Centrifugal...

Code of Federal Regulations, 2010 CFR

2010-07-01

... Emissions Factors for Specific Open Molding and Centrifugal Casting Process Streams 1 Table 1 to Subpart... Standards for Hazardous Air Pollutants: Reinforced Plastic Composites Production Pt. 63, Subpt. WWWW, Table... Specific Open Molding and Centrifugal Casting Process Streams ER25AU05.020 ER25AU05.021 [70 FR 50129, Aug...

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.

Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency

DOE PAGES

Stromme, Eric T.; Henderson, Hunter B.; Sims, Zachary C.; ...

2018-04-25

Strong chemical reactions between Al and Ce lead to the formation of intermetallics with exceptional thermal stability. The rapid formation of intermetallics directly from the liquid phase during solidification of Al-Ce alloys leads to an ultrafine microconstituent structure that effectively strengthens as-cast alloys without further microstructural optimization via thermal processing. Die casting is a high-volume manufacturing technology that accounts for greater than 40% of all cast Al products, whereas Ce is highly overproduced as a waste product of other rare earth element (REE) mining. Reducing heat treatments would stimulate significant improvements in manufacturing energy efficiency, exceeding (megatonnes/year) per large-scale heat-treatmentmore » line. In this study, multiple compositions were evaluated with wedge mold castings to test the sensitivity of alloys to the variable solidification rate inherent in high-pressure die casting. Once a suitable composition was determined, it was successfully demonstrated at 800 lbs/h in a 600-ton die caster, after which the as-die cast parts performed similarly to ubiquitous A380 in the same geometry without requiring heat treatment. Furthermore, this work demonstrates the compatibility of Al REE alloys with high-volume die-casting applications with minimal heat treatments.« less

Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency

NASA Astrophysics Data System (ADS)

Stromme, Eric T.; Henderson, Hunter B.; Sims, Zachary C.; Kesler, Michael S.; Weiss, David; Ott, Ryan T.; Meng, Fanqiang; Kassoumeh, Sam; Evangelista, James; Begley, Gerald; Rios, Orlando

2018-06-01

Strong chemical reactions between Al and Ce lead to the formation of intermetallics with exceptional thermal stability. The rapid formation of intermetallics directly from the liquid phase during solidification of Al-Ce alloys leads to an ultrafine microconstituent structure that effectively strengthens as-cast alloys without further microstructural optimization via thermal processing. Die casting is a high-volume manufacturing technology that accounts for greater than 40% of all cast Al products, whereas Ce is highly overproduced as a waste product of other rare earth element (REE) mining. Reducing heat treatments would stimulate significant improvements in manufacturing energy efficiency, exceeding (megatonnes/year) per large-scale heat-treatment line. In this study, multiple compositions were evaluated with wedge mold castings to test the sensitivity of alloys to the variable solidification rate inherent in high-pressure die casting. Once a suitable composition was determined, it was successfully demonstrated at 800 lbs/h in a 600-ton die caster, after which the as-die cast parts performed similarly to ubiquitous A380 in the same geometry without requiring heat treatment. This work demonstrates the compatibility of Al REE alloys with high-volume die-casting applications with minimal heat treatments.

Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency

NASA Astrophysics Data System (ADS)

Stromme, Eric T.; Henderson, Hunter B.; Sims, Zachary C.; Kesler, Michael S.; Weiss, David; Ott, Ryan T.; Meng, Fanqiang; Kassoumeh, Sam; Evangelista, James; Begley, Gerald; Rios, Orlando

2018-04-01

Strong chemical reactions between Al and Ce lead to the formation of intermetallics with exceptional thermal stability. The rapid formation of intermetallics directly from the liquid phase during solidification of Al-Ce alloys leads to an ultrafine microconstituent structure that effectively strengthens as-cast alloys without further microstructural optimization via thermal processing. Die casting is a high-volume manufacturing technology that accounts for greater than 40% of all cast Al products, whereas Ce is highly overproduced as a waste product of other rare earth element (REE) mining. Reducing heat treatments would stimulate significant improvements in manufacturing energy efficiency, exceeding (megatonnes/year) per large-scale heat-treatment line. In this study, multiple compositions were evaluated with wedge mold castings to test the sensitivity of alloys to the variable solidification rate inherent in high-pressure die casting. Once a suitable composition was determined, it was successfully demonstrated at 800 lbs/h in a 600-ton die caster, after which the as-die cast parts performed similarly to ubiquitous A380 in the same geometry without requiring heat treatment. This work demonstrates the compatibility of Al REE alloys with high-volume die-casting applications with minimal heat treatments.

Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency

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

Stromme, Eric T.; Henderson, Hunter B.; Sims, Zachary C.

Strong chemical reactions between Al and Ce lead to the formation of intermetallics with exceptional thermal stability. The rapid formation of intermetallics directly from the liquid phase during solidification of Al-Ce alloys leads to an ultrafine microconstituent structure that effectively strengthens as-cast alloys without further microstructural optimization via thermal processing. Die casting is a high-volume manufacturing technology that accounts for greater than 40% of all cast Al products, whereas Ce is highly overproduced as a waste product of other rare earth element (REE) mining. Reducing heat treatments would stimulate significant improvements in manufacturing energy efficiency, exceeding (megatonnes/year) per large-scale heat-treatmentmore » line. In this study, multiple compositions were evaluated with wedge mold castings to test the sensitivity of alloys to the variable solidification rate inherent in high-pressure die casting. Once a suitable composition was determined, it was successfully demonstrated at 800 lbs/h in a 600-ton die caster, after which the as-die cast parts performed similarly to ubiquitous A380 in the same geometry without requiring heat treatment. Furthermore, this work demonstrates the compatibility of Al REE alloys with high-volume die-casting applications with minimal heat treatments.« less

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Characterisation and modelling of defect formation in direct-chill cast AZ80 alloy

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

Mackie, D.; Robson, J.D.; Withers, P.J.

2015-06-15

Wrought magnesium alloys for demanding structural applications require high quality defect free cast feedstock. The aim of this study was to first identify and characterise typical defects in direct chill cast magnesium–aluminium–zinc (AZ) alloy billet and then use modelling to understand the origins of these defects so they can be prevented. Defects were first located using ultrasonic inspection and were then characterised using X-ray computed tomography (XCT) and serial sectioning, establishing the presence of oxide films and intermetallic particles Al{sub 8}Mn{sub 5} in all defects. A model was developed to predict the flow patterns and growth kinetics of the intermetallicmore » phases during casting, which influence the formation of defects. Simulation of the growth of the intermetallic particles demonstrated that precipitation from the liquid occurs in the mould. The combination of the entrained oxide films and intermetallic particles recirculates in the liquid metal and continues to grow, until large enough to settle, which is predicted to occur at the centre of the mould where the flow is the slowest. Based on these predictions, strategies to reduce the susceptibility to defect formation are suggested. - Highlights: • Casting defects in magnesium direct chill casting have been imaged and characterised in 3-dimensions. • The occurrences of co-located clusters of particles and oxide films have been characterised and explained. • A coupled model has been developed to help interpret the observed trend for defects located towards the centre of billets.« less

Processing of sintered alpha SiC

NASA Technical Reports Server (NTRS)

Storm, R. S.

1984-01-01

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

CXCL12-CXCR4 signalling plays an essential role in proper patterning of aortic arch and pulmonary arteries.

PubMed

Kim, Bo-Gyeong; Kim, Yong Hwan; Stanley, Edward L; Garrido-Martin, Eva M; Lee, Young Jae; Oh, S Paul

2017-11-01

Chemokine CXCL12 (stromal derived factor 1: SDF1) has been shown to play important roles in various processes of cardiovascular development. In recent avian studies, CXCL12 signalling has been implicated in guidance of cardiac neural crest cells for their participation in the development of outflow tract and cardiac septum. The goal of this study is to investigate the extent to which CXCL12 signalling contribute to the development of aortic arch and pulmonary arteries in mammals. Novel Cxcl12-LacZ reporter and conditional alleles were generated. Using whole mount X-gal staining with the reporter allele and vascular casting techniques, we show that the domain branching pattern of pulmonary arteries in Cxcl12-null mice is completely disrupted and discordant with that of pulmonary veins and airways. Cxcl12-null mice also displayed abnormal and superfluous arterial branches from the aortic arch. The early steps of pharyngeal arch remodelling in Cxcl12-null mice appeared to be unaffected, but vertebral arteries were often missing and prominent aberrant arteries were present parallel to carotid arteries or trachea, similar to aberrant vertebral artery or thyroid ima artery, respectively. Analysis with computed tomography not only confirmed the results from vascular casting studies but also identified abnormal systemic arterial supply to lungs in the Cxcl12-null mice. Tie2-Cre mediated Cxcr4 deletion phenocopied the Cxcl12-null phenotypes, indicating that CXCR4 is the primary receptor for arterial patterning, whereas Cxcl12 or Cxcr4 deletion by Wnt1-Cre did not affect aortic arch patterning. CXCL12-CXCR4 signalling is essential for the correct patterning of aortic arches and pulmonary arteries during development. Superfluous arteries in Cxcl12-null lungs and the aortic arch infer a role of CXCL12 in protecting arteries from uncontrolled sprouting during development of the arterial system. Published on behalf of the European Society of Cardiology. All rights reserved. © The Author 2017. For Permissions, please email: journals.permissions@oup.com.

Bridge Health Monitoring Using a Machine Learning Strategy

DOT National Transportation Integrated Search

2017-01-01

The goal of this project was to cast the SHM problem within a statistical pattern recognition framework. Techniques borrowed from speaker recognition, particularly speaker verification, were used as this discipline deals with problems very similar to...

Gender variation in morphological patterns of lip prints among some north Indian populations.

PubMed

Vats, Yogesh; Dhall, Jasmine Kaur; Kapoor, Ak

2012-01-01

Personal identification is an integral part of forensic investigations. For the same, DNA profiling and fingerprints are the most commonly used tools. But these evidences are not ubiquitous and may not necessarily be obtained from the crime scene. In such a scenario, other physical and trace evidences play a pivotal role and subsequently the branches employed are forensic osteology, odontology, biometrics, etc. A relatively recent field in the branch of forensic odontology is cheiloscopy or the study of lip prints. A comparison of lip prints from the crime scene and those obtained from the suspects may be useful in the identification or narrowing down the investigation. The purpose of the present study is to determine the gender and population variability in the morphological patterns of lip prints among brahmins, Jats, and scheduled castes of Delhi and Haryana, India. Samples were collected from Jats, brahmins, and scheduled castes of Delhi and Haryana. The total sample size consisted of 1399 individuals including 781 males and 618 females in the age group of 8-60 years. Care was taken not to collect samples from genetically related individuals. The technique was standardized by recording lip prints of 20 persons and analyzing them. Lip prints were collected by using a corporate's invisible tape and analyzed using a hand lens. The patterns were studied along the entire length and breadth of both the upper and the lower lip. The data were analyzed by SPSS statistical package version 17 to determine the frequencies and percentages of occurrence of the pattern types in each population group and a comparison between males and females among the groups was carried out by using the z test. The z-test comparison between patterns of males and females shows significant differences with respect to pattern types I', II, III, and IV among brahmins; I', II, III, IV, and Y among Jats; and I, I', II, III, and V among scheduled castes. Thus, it can be concluded that the variability of the lip print pattern can help sex differentiation among groups and that more studies on the lip print pattern should be carried out to bring new dimensions to forensic anthropology and to aid the law enforcement agencies.

Freeze Tape Casting of Functionally Graded Porous Ceramics

NASA Technical Reports Server (NTRS)

Sofie, Stephen W.

2007-01-01

Freeze tape casting is a means of making preforms of ceramic sheets that, upon subsequent completion of fabrication processing, can have anisotropic and/or functionally graded properties that notably include aligned and graded porosity. Freeze tape casting was developed to enable optimization of the microstructures of porous ceramic components for use as solid oxide electrodes in fuel cells: Through alignment and grading of pores, one can tailor surface areas and diffusion channels for flows of gas and liquid species involved in fuel-cell reactions. Freeze tape casting offers similar benefits for fabrication of optimally porous ceramics for use as catalysts, gas sensors, and filters.

Effect of TurboSwirl Structure on an Uphill Teeming Ingot Casting Process

NASA Astrophysics Data System (ADS)

Bai, Haitong; Ersson, Mikael; Jönsson, Pär

2015-12-01

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

On Macrosegregation

NASA Astrophysics Data System (ADS)

Ludwig, Andreas; Wu, Menghuai; Kharicha, Abdellah

2015-11-01

Macrosegregations, namely compositional inhomogeneities at a scale much larger than the microstructure, are typically classified according to their metallurgical appearance. In ingot castings, they are known as `A' and `V' segregation, negative cone segregation, and positive secondary pipe segregation. There exists `inverse' segregation at casting surfaces and `centerline' segregation in continuously cast slabs and blooms. Macrosegregation forms if a relative motion between the solute-enriched or -depleted melt and dendritic solid structures occurs. It is known that there are four basic mechanisms for the occurrence of macrosegregation. In the recent years, the numerical description of the combination of these mechanisms has become possible and so a tool has emerged which can be effectively used to get a deeper understanding into the process details which are responsible for the formation of the above-mentioned different macrosegregation appearances. Based on the most sophisticated numerical models, we consequently associate the four basic formation mechanisms with the physical phenomena happening during (i) DC-casting of copper-based alloys, (ii) DC-casting of aluminum-based alloys, (iii) continuous casting of steel, and (iv) ingot casting of steel.

Laser welding of removable partial denture frameworks.

PubMed

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

2008-01-01

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

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.

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.

"Split Cast Mounting: Review and New Technique".

PubMed

Gundawar, S M; Pande, Neelam A; Jaiswal, Priti; Radke, U M

2014-12-01

For the fabrication of a prosthesis, the Prosthodontist meticulously performs all the steps. The laboratory technician then make every effort/strives to perform the remaining lab procedures. However when the processed dentures are remounted on the articulator, some changes are seen. These changes may be divided into two categories: Pre-insertion and post-insertion changes, which deal with the physical properties of the materials involved (Parker, J Prosthet Dent 31:335-342, 1974). Split cast mounting is the method of mounting casts on the articulator. It is essentially a maxillary cast constructed in two parts with a horizontal division. The procedure allows for the verification of the accuracy of the initial mounting and the ease of removal and replacement of the cast. This provides a precise means of correcting the changes in occlusion occurring as a result of the processing technique (Nogueira et al., J Prosthet Dent 91:386-388, 2004). Instability of the split mounting has always been a problem to the Prosthodontist thereby limiting its use. There are various materials mentioned in the literature. The new technique by using Dowel pins and twill thread is very easy, cheaper and simple way to stabilize the split mounting. It is useful and easy in day to day laboratory procedures. The article presents different methods of split cast mounting and the new procedure using easily available materials in prosthetic laboratory.

Effect of heat treatment on mechanical properties of age-hardenable gold alloy at intraoral temperature.

PubMed

Watanabe, I; Watanabe, E; Cai, Z; Okabe, T; Atsuta, M

2001-09-01

The aim of this study was to investigate the effect of various heat treatments on the mechanical properties of gold alloys capable of age-hardening at intraoral temperature. Dumbbell-shaped patterns (ISO 6871) were cast with three gold alloys (Sofard; NC Type-IV; Aurum Cast, NihombashiTokuriki Co.). The Sofard alloy is age-hardenable at intraoral temperature. The castings underwent various heat treatments [as-cast (AC); solution treatment (ST); high-temperature aging (HA); intraoral aging (IA)]. After these heat treatments, ultimate tensile strength (UTS), 0.2% offset yield strength (YS), and elongation (EL) were measured at a strain rate of 1.7x10(-4)/s. Fracture surfaces of the specimens after tensile testing were observed using SEM. Vickers hardness was also measured after heat treating. After IA, the hardness values of the Sofard alloy increased and reached values similar to the hardness of the Sofard specimens aged at high temperature (HA). The hardness values of the NC Type-IV and Aurum Cast specimens slightly increased after IA, but did not reach the values of the specimens after HA. All the Sofard, NC Type-IV and Aurum Cast specimens showed significantly (P<0.05) greater hardness values after HA, compared with the values after any other heat treatments (AC, ST and IA). The UTS and YS of the specimens indicated a tendency similar to the results obtained for hardness. The Sofard specimens with ST showed the greatest elongation compared to the corresponding NC Type-IV and Aurum Cast specimens. However, the elongation of the Sofard specimens was abruptly reduced after intraoral aging. Intraoral aging significantly improved the mechanical properties and hardness of the Sofard alloy.

Nonocclusal dental microwear analysis of 300,000-year-old Homo heilderbergensis teeth from Sima de los Huesos (Sierra de Atapuerca, Spain).

PubMed

Pérez-Pérez, A; Bermúdez De Castro, J M; Arsuaga, J L

1999-04-01

Casts of nonocclusal enamel surfaces of 190 teeth from the Middle Pleistocene site of Sima de los Huesos have been micrographed by scanning electron microscopy. Microscopic analyses of striation density and length by orientation show distinct patterns of intrapopulation variability. Significant differences in the number and length of the striations by orientation are found between maxillary and mandibular teeth. This probably reflects differences in the mechanical forces involved in the process of chewing food. Significant differences are present between isolated and in situ teeth that could be caused by postdepositional processes differentially affecting the isolated teeth. In addition, a distinct and very unusual striation pattern is observed in a sample of teeth that can be explained only by a strong nondietary, most probably postmortem abrasion of the enamel surfaces. These teeth have a very high density of scratches, shorter in length than those found on other teeth, that are not indicative of dietary habits. No known depositional process may account for the presence of such postmortem wear since heavy transportation of materials within the clayish sediments has been discarded for the site. Despite this, a characteristic dietary striation pattern can be observed in most of the teeth analyzed. Most likely the diet of the Homo heidelbergensis hominids from Sima de los Huesos was highly abrasive, probably with a large dependence on hard, poorly processed plant foods, such as roots, stems, and seeds. A highly significant sex-related difference in the striation pattern can also be observed in the teeth analyzed, suggesting a differential consistency in the foods eaten by females and males.

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

NASA Astrophysics Data System (ADS)

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

2012-02-01

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

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.

Modeling of Quasi-Four-Phase Flow in Continuous Casting Mold Using Hybrid Eulerian and Lagrangian Approach

NASA Astrophysics Data System (ADS)

Liu, Zhongqiu; Sun, Zhenbang; Li, Baokuan

2017-04-01

Lagrangian tracking model combined with Eulerian multi-phase model is employed to predict the time-dependent argon-steel-slag-air quasi-four-phase flow inside a slab continuous casting mold. The Eulerian approach is used for the description of three phases (molten steel, liquid slag, and air at the top of liquid slag layer). The dispersed argon bubble injected from the SEN is treated in the Lagrangian way. The complex interfacial momentum transfers between various phases are considered. Validation is supported by the measurement data of cold model experiments and industrial practice. Close agreements were achieved for the gas volume fraction, liquid flow pattern, level fluctuation, and exposed slag eye phenomena. Many known phenomena and new predictions were successfully reproduced using this model. The vortex slag entrapment phenomenon at the slag-steel interface was obtained using this model, some small slag drops are sucked deep into the liquid pool of molten steel. Varying gas flow rates have a large effect on the steel flow pattern in the upper recirculation zone. Three typical flow patterns inside the mold with different argon gas flow rates have been obtained: double roll, three roll, and single roll. Effects of argon gas flow rate, casting speed, and slag layer thickness on the exposed slag eye and level fluctuation at the slag-steel interface were studied. A dimensionless value of H ave/ h was proposed to describe the time-averaged level fluctuation of slag-steel interface. The exposed slag eye near the SEN would be formed when the value of H ave/ h is larger than 0.4.

SEM corrosion-casts study of the microcirculation of the flat bones in the rat.

PubMed

Pannarale, L; Morini, S; D'Ubaldo, E; Gaudio, E; Marinozzi, G

1997-04-01

Little is known about the organization of microcirculation in flat bones in comparison with long bones. This study, therefore, helps us to determine the design of this vascular system in flat bones in relation to their structure and function. The organization of microvasculature in parietal, scapula, and ileum bones of 15 young sexually mature rats, aged 6-7 weeks, was studied by light and scanning electron microscopy (SEM) from vascular corrosion cast (vcc), a resin-cast obtained material. Our observations show that the pattern of the microcirculation in flat bones is different in the thick and thin parts of such bones. Where the bone is thinner than 0.4 mm, only periosteal and dural network exist. Larger vessels which do not form a real network connect the two tables of the bones in these regions. In thicker areas, the organization of the microvasculature is similar to that in long bones, with distinct periosteal, cortical and bone marrow networks. Moreover, in different bones, outer networks show slightly different characteristics according to the different adjacent structures (dura mater, muscles etc.). Different types of vessels were recognized by comparing their different diameter, course and endothelial imprints. The microvascular patterns of the flat bones are strongly influenced by the bone thickness. The different microvascular systems can interact both with the bone modelling and remodeling and with the variable metabolic needs, modifying the microvascular pattern and the blood flow. This is even more important in view of the reciprocal influence of the different networks within the same bone.

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.

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

NASA Astrophysics Data System (ADS)

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

2017-03-01

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

Novel casting processes for single-crystal turbine blades of superalloys

NASA Astrophysics Data System (ADS)

Ma, Dexin

2018-03-01

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

Micromechanical Characterization and Texture Analysis of Direct Cast Titanium Alloys Strips

NASA Technical Reports Server (NTRS)

2000-01-01

This research was conducted to determine a post-processing technique to optimize mechanical and material properties of a number of Titanium based alloys and aluminides processed via Melt Overflow Solidification Technique (MORST). This technique was developed by NASA for the development of thin sheet titanium and titanium aluminides used in high temperature applications. The materials investigated in this study included conventional titanium alloy strips and foils, Ti-1100, Ti-24Al-11Nb (Alpha-2), and Ti-48Al-2Ta (Gamma). The methodology used included micro-characterization, heat-treatment, mechanical processing and mechanical testing. Characterization techniques included optical, electron microscopy, and x-ray texture analysis. The processing included heat-treatment and mechanical deformation through cold rolling. The initial as-cast materials were evaluated for their microstructure and mechanical properties. Different heat-treatment and rolling steps were chosen to process these materials. The properties were evaluated further and a processing relationship was established in order to obtain an optimum processing condition. The results showed that the as-cast material exhibited a Widmanstatten (fine grain) microstructure that developed into a microstructure with larger grains through processing steps. The texture intensity showed little change for all processing performed in this investigation.

High-throughput preparation of complex multi-scale patterns from block copolymer/homopolymer blend films.

PubMed

Park, Hyungmin; Kim, Jae-Up; Park, Soojin

2012-02-21

A simple, straightforward process for fabricating multi-scale micro- and nanostructured patterns from polystyrene-block-poly(2-vinylpyridine) (PS-b-P2VP)/poly(methyl methacrylate) (PMMA) homopolymer in a preferential solvent for PS and PMMA is demonstrated. When the PS-b-P2VP/PMMA blend films were spin-coated onto a silicon wafer, PS-b-P2VP micellar arrays consisting of a PS corona and a P2VP core were formed, while the PMMA macrodomains were isolated, due to the macrophase separation caused by the incompatibility between block copolymer micelles and PMMA homopolymer during the spin-coating process. With an increase of PMMA composition, the size of PMMA macrodomains increased. Moreover, the P2VP blocks have a strong interaction with a native oxide of the surface of the silicon wafer, so that the P2VP wetting layer was first formed during spin-coating, and PS nanoclusters were observed on the PMMA macrodomains beneath. Whereas when a silicon surface was modified with a PS brush layer, the PS nanoclusters underlying PMMA domains were not formed. The multi-scale patterns prepared from copolymer micelle/homopolymer blend films are used as templates for the fabrication of gold nanoparticle arrays by incorporating the gold precursor into the P2VP chains. The combination of nanostructures prepared from block copolymer micellar arrays and macrostructures induced by incompatibility between the copolymer and the homopolymer leads to the formation of complex, multi-scale surface patterns by a simple casting process. This journal is © The Royal Society of Chemistry 2012

Directed ordering of phase separated domains and dewetting of thin polymer blend films on a topographically patterned substrate.

PubMed

Bhandaru, Nandini; Karim, Alamgir; Mukherjee, Rabibrata

2017-07-21

Substrate pattern guided self-organization of ultrathin and confined polymeric films on a topographically patterned substrate is a useful approach for obtaining ordered meso and nano structures over large areas, particularly if the ordering is achieved during film preparation itself, eliminating any post-processing such as thermal or solvent vapor annealing. By casting a dilute solution of two immiscible polymers, polystyrene (PS) and polymethylmethacrylate (PMMA), from a common solvent (toluene) on a topographically patterned substrate with a grating geometry, we show the formation of self-organized meso patterns with various degrees of ordering. The morphology depends on both the concentration of the dispensed solution (C n ) and the blend composition (R B ). Depending on the extent of dewetting during spin coating, the final morphologies can be classified into three distinct categories. At a very low C n the solution dewets fully, resulting in isolated polymer droplets aligned along substrate grooves (Type 1). Type 2 structures comprising isolated threads with aligned phase separated domains along each substrate groove are observed at intermediate C n . A continuous film (Type 3) is obtained above a critical concentration (C n *) that depends on R B . While the extent of ordering of the domains gradually diminishes with an increase in film thickness for Type 3 patterns, the size of the domains remains much smaller than that on a flat substrate, resulting in significant downsizing of the features due to the lateral confinement imposed on the phase separation process by the topographic patterns. Finally, we show that some of these structures exhibit excellent broadband anti-reflection (AR) properties.

Simple agarose micro-confinement array and machine-learning-based classification for analyzing the patterned differentiation of mesenchymal stem cells

PubMed Central

Sato, Asako; Vogel, Viola; Tanaka, Yo

2017-01-01

The geometrical confinement of small cell colonies gives differential cues to cells sitting at the periphery versus the core. To utilize this effect, for example to create spatially graded differentiation patterns of human mesenchymal stem cells (hMSCs) in vitro or to investigate underpinning mechanisms, the confinement needs to be robust for extended time periods. To create highly repeatable micro-fabricated structures for cellular patterning and high-throughput data mining, we employed here a simple casting method to fabricate more than 800 adhesive patches confined by agarose micro-walls. In addition, a machine learning based image processing software was developed (open code) to detect the differentiation patterns of the population of hMSCs automatically. Utilizing the agarose walls, the circular patterns of hMSCs were successfully maintained throughout 15 days of cell culture. After staining lipid droplets and alkaline phosphatase as the markers of adipogenic and osteogenic differentiation, respectively, the mega-pixels of RGB color images of hMSCs were processed by the software on a laptop PC within several minutes. The image analysis successfully showed that hMSCs sitting on the more central versus peripheral sections of the adhesive circles showed adipogenic versus osteogenic differentiation as reported previously, indicating the compatibility of patterned agarose walls to conventional microcontact printing. In addition, we found a considerable fraction of undifferentiated cells which are preferentially located at the peripheral part of the adhesive circles, even in differentiation-inducing culture media. In this study, we thus successfully demonstrated a simple framework for analyzing the patterned differentiation of hMSCs in confined microenvironments, which has a range of applications in biology, including stem cell biology. PMID:28380036

Validation of tool mark analysis of cut costal cartilage.

PubMed

Love, Jennifer C; Derrick, Sharon M; Wiersema, Jason M; Peters, Charles

2012-03-01

This study was designed to establish the potential error rate associated with the generally accepted method of tool mark analysis of cut marks in costal cartilage. Three knives with different blade types were used to make experimental cut marks in costal cartilage of pigs. Each cut surface was cast, and each cast was examined by three analysts working independently. The presence of striations, regularity of striations, and presence of a primary and secondary striation pattern were recorded for each cast. The distance between each striation was measured. The results showed that striations were not consistently impressed on the cut surface by the blade's cutting edge. Also, blade type classification by the presence or absence of striations led to a 65% misclassification rate. Use of the classification tree and cross-validation methods and inclusion of the mean interstriation distance decreased the error rate to c. 50%. © 2011 American Academy of Forensic Sciences.

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

Determining the Mechanical Properties of Lattice Block Structures

NASA Technical Reports Server (NTRS)

Wilmoth, Nathan

2013-01-01

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

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.

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.

Systematic review of spica casting for the treatment of paediatric diaphyseal femur fractures.

PubMed

Tisherman, R T; Hoellwarth, J S; Mendelson, S A

2018-04-01

Paediatric femur fractures are commonly encountered and often successfully managed with spica casting. Despite spica casting's long history there is little formal guidance for optimal outcomes and no consolidation of existing literature. The purpose of this study is to review the available literature regarding the use of spica casting for the management of paediatric diaphyseal femur fractures. The PubMed database was queried for all research articles including the phrase "spica". A total of 788 abstracts were reviewed for relevance to the current study. Data was extracted from all available research studies which specified tolerance for fracture angulation or shortening in the cast. Additionally, all articles describing alternative materials, methods for spica application, and complications of spica casting were reviewed. In all, 106 articles were found relevant to the management of diaphyseal femur fractures in the paediatric population. The aggregated, accepted fracture shortening decreased from 16 mm to 18 mm before age ten years to 12 mm to 14 mm after puberty. Aggregated, accepted angulation decreased from 14° to 16° varus/valgus and 18° to 22° pro/recurvatum before age two years, to 6° to 8° and 10° to 12° by puberty, respectively. The overall reported complication rate was 19.6%, with the most common complication being skin compromise in 8.2% of patients, followed by unacceptable angulation at the fracture site in 4.2% of patients and excessive limb shortening in 1.9% of patients. This article reviews the available spica casting literature and compiles the available data. Spica casting offers a safe, effective means for definitive management of paediatric diaphyseal femur fractures. Future research identifying the rate and pattern of remodelling as it relates to angulation and shortening at various patient ages, particularly beyond the aforementioned norms, would be valuable to identify true biological tolerances versus accepted expert opinion. Review of level II evidence.

Virtual aluminum castings: An industrial application of ICME

NASA Astrophysics Data System (ADS)

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

2006-11-01

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

Surface-Casting Synthesis of Mesoporous Zirconia with a CMK-5-Like Structure and High Surface Area.

PubMed

Gu, Dong; Schmidt, Wolfgang; Pichler, Christian M; Bongard, Hans-Josef; Spliethoff, Bernd; Asahina, Shunsuke; Cao, Zhengwen; Terasaki, Osamu; Schüth, Ferdi

2017-09-04

About 15 years ago, the Ryoo group described the synthesis of CMK-5, a material consisting of a hexagonal arrangement of carbon nanotubes. Extension of the surface casting synthesis to oxide compositions, however, was not possible so far, in spite of many attempts. Here it is demonstrated, that crystalline mesoporous hollow zirconia materials with very high surface areas up to 400 m 2  g -1 , and in selected cases in the form of CMK-5-like, are indeed accessible via such a surface casting process. The key for the successful synthesis is an increased interaction between the silica hard template surface and the zirconia precursor species by using silanol group-rich mesoporous silica as a hard template. The surface areas of the obtained zirconias exceed those of conventionally hard-templated ones by a factor of two to three. The surface casting process seems to be applicable also to other oxide materials. © 2017 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim.

Electrochemical Synthesis of Core-Shell-Structured NbC-Fe Composite Powder for Enforcement in Low-Carbon Steel.

PubMed

Li, Hongmei; Song, Qiushi; Xu, Qian; Chen, Ying; Xu, Liang; Man, Tiannan

2017-11-01

An NbC-Fe composite powder was synthesized from an Nb₂O₅/Fe/C mixture by electrochemical reduction and subsequent carbonization in molten CaCl₂-NaCl. The composite has a core-shell structure, in which NbC acts as the cores distributing in the Fe matrix. A strong bonding between NbC and Fe is benefit from the core-shell structure. The sintering and electrochemical reduction processes were investigated to probe the mechanism for the reactions. The results show that NbC particles about several nanometers were embraced by the Fe shell to form a composite about 100 nm in size. This featured structure can feasibly improve the wettability and sinterability of NbC as well as the uniform distribution of the carbide in the cast steel. By adding the composite into steel in the casting process, the grain size of the casted steel was markedly deceased from 1 mm to 500 μm on average, favoring the hardening of the casted steel.

A new magnesium alloy system: TEXAS

NASA Astrophysics Data System (ADS)

Wiese, Björn; Mendis, Chamini; Blawert, Carsten; Nyberg, Eric; Kainer, Karl Ulrich; Hort, Norbert

A new TEXAS alloy system (Mg-Sn-Nd-Ca-Al-Si) is presented in order to extend the range of applications for magnesium alloys. The alloy has been produced by permanent mould direct chill casting, a process that provides a homogenous distribution of alloying elements throughout the entire casting. This work presents microstructural features and a new Mg-Sn-Ca phase with the morphology of hexagonal platelets. Additionally mechanical properties and the corrosion behaviour of TEXAS alloys are presented in as cast and heat treated conditions.

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

DOEpatents

Scheffer, Karl D.

1984-07-03

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

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

DOEpatents

Scheffer, K.D.

1984-07-03

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

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

Visualization of nasal airflow patterns in a patient affected with atrophic rhinitis using particle image velocimetry

NASA Astrophysics Data System (ADS)

Garcia, G. J. M.; Mitchell, G.; Bailie, N.; Thornhill, D.; Watterson, J.; Kimbell, J. S.

2007-10-01

The relationship between airflow patterns in the nasal cavity and nasal function is poorly understood. This paper reports an experimental study of the interplay between symptoms and airflow patterns in a patient affected with atrophic rhinitis. This pathology is characterized by mucosal dryness, fetor, progressive atrophy of anatomical structures, a spacious nasal cavity, and a paradoxical sensation of nasal congestion. A physical replica of the patient's nasal geometry was made and particle image velocimetry (PIV) was used to visualize and measure the flow field. The nasal replica was based on computed tomography (CT) scans of the patient and was built in three steps: three-dimensional reconstruction of the CT scans; rapid prototyping of a cast; and sacrificial use of the cast to form a model of the nasal passage in clear silicone. Flow patterns were measured by running a water-glycerol mixture through the replica and evaluating the displacement of particles dispersed in the liquid using PIV. The water-glycerol flow rate used corresponded to an air flow rate representative of a human breathing at rest. The trajectory of the flow observed in the left passage of the nose (more affected by atrophic rhinitis) differed markedly from what is considered normal, and was consistent with patterns of epithelial damage observed in cases of the condition. The data are also useful for validation of computational fluid dynamics predictions.

Stabilization of the Thermal Decomposition of Poly(Propylene Carbonate) Through Copper Ion Incorporation and Use in Self-Patterning

NASA Astrophysics Data System (ADS)

Spencer, Todd J.; Chen, Yu-Chun; Saha, Rajarshi; Kohl, Paul A.

2011-06-01

Incorporation of copper ions into poly(propylene carbonate) (PPC) films cast from γ-butyrolactone (GBL), trichloroethylene (TCE) or methylene chloride (MeCl) solutions containing a photo-acid generator is shown to stabilize the PPC from thermal decomposition. Copper ions were introduced into the PPC mixtures by bringing the polymer mixture into contact with copper metal. The metal was oxidized and dissolved into the PPC mixture. The dissolved copper interferes with the decomposition mechanism of PPC, raising its decomposition temperature. Thermogravimetric analysis shows that copper ions make PPC more stable by up to 50°C. Spectroscopic analysis indicates that copper ions may stabilize terminal carboxylic acid groups, inhibiting PPC decomposition. The change in thermal stability based on PPC exposure to patterned copper substrates was used to provide a self-aligned patterning method for PPC on copper traces without the need for an additional photopatterning registration step. Thermal decomposition of PPC is then used to create air isolation regions around the copper traces. The spatial resolution of the self-patterning PPC process is limited by the lateral diffusion of the copper ions within the PPC. The concentration profiles of copper within the PPC, patterning resolution, and temperature effects on the PPC decomposition have been studied.

Reproducibility of ZrO2-based freeze casting for biomaterials.

PubMed

Naleway, Steven E; Fickas, Kate C; Maker, Yajur N; Meyers, Marc A; McKittrick, Joanna

2016-04-01

The processing technique of freeze casting has been intensely researched for its potential to create porous scaffold and infiltrated composite materials for biomedical implants and structural materials. However, in order for this technique to be employed medically or commercially, it must be able to reliably produce materials in great quantities with similar microstructures and properties. Here we investigate the reproducibility of the freeze casting process by independently fabricating three sets of eight ZrO2-epoxy composite scaffolds with the same processing conditions but varying solid loading (10, 15 and 20 vol.%). Statistical analyses (One-way ANOVA and Tukey's HSD tests) run upon measurements of the microstructural dimensions of these composite scaffold sets show that, while the majority of microstructures are similar, in all cases the composite scaffolds display statistically significant variability. In addition, composite scaffolds where mechanically compressed and statistically analyzed. Similar to the microstructures, almost all of their resultant properties displayed significant variability though most composite scaffolds were similar. These results suggest that additional research to improve control of the freeze casting technique is required before scaffolds and composite scaffolds can reliably be reproduced for commercial or medical applications. Copyright © 2015 Elsevier B.V. All rights reserved.

Development of materials for the rapid manufacture of die cast tooling

NASA Astrophysics Data System (ADS)

Hardro, Peter Jason

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

Characterization of Technetium Speciation in Cast Stone

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

Um, Wooyong; Jung, Hun Bok; Wang, Guohui

2013-11-11

This report describes the results from laboratory tests performed at Pacific Northwest National Laboratory (PNNL) for the U.S. Department of Energy (DOE) EM-31 Support Program (EMSP) subtask, “Production and Long-Term Performance of Low Temperature Waste Forms” to provide additional information on technetium (Tc) speciation characterization in the Cast Stone waste form. To support the use of Cast Stone as an alternative to vitrification for solidifying low-activity waste (LAW) and as the current baseline waste form for secondary waste streams at the Hanford Site, additional understanding of Tc speciation in Cast Stone is needed to predict the long-term Tc leachability frommore » Cast Stone and to meet the regulatory disposal-facility performance requirements for the Integrated Disposal Facility (IDF). Characterizations of the Tc speciation within the Cast Stone after leaching under various conditions provide insights into how the Tc is retained and released. The data generated by the laboratory tests described in this report provide both empirical and more scientific information to increase our understanding of Tc speciation in Cast Stone and its release mechanism under relevant leaching processes for the purpose of filling data gaps and to support the long-term risk and performance assessments of Cast Stone in the IDF at the Hanford Site.« less

Long-Term Resolution of Severe Ankle Contractures Using Botulinum Toxin, Serial Casting, Splinting, and Motor Retraining.

PubMed

Leung, Joan; Stroud, Katarina

2018-01-01

Purpose: Serial casting for ankle contractures is traditionally performed in prone, a position that patients may not easily tolerate. Also, although serial casting is effective in correcting contracture, its effect dissipates quickly. This case report describes a procedure for performing casting for ankle contractures in a supine or sitting position. It also describes a process that enables the effect of serial casting to be maintained long term. Client Description: The client was an adult who had suffered traumatic brain injury and severe bilateral ankle contractures. Intervention: He received botulinum toxin and serial casting for his bilateral ankle contractures, one ankle at 8 months and the other at 13 months after the injury. He then underwent a programme of splinting and motor training. Measures and Outcome: The client gained more than 40° dorsiflexion for both ankles after receiving botulinum toxin injections and serial casting. The improvement in ankle range enabled him to progress to walking practice. Ankle splinting was gradually reduced. On discharge at 25 months post-injury, the ankle joint range was maintained. Implications: The use of botulinum toxin and serial casting, followed by an intensive programme of splinting and motor training, may be an option to consider for effective long-term resolution of severe contractures after acquired brain injury.

Improved quantitative visualization of hypervelocity flow through wavefront estimation based on shadow casting of sinusoidal gratings.

PubMed

Medhi, Biswajit; Hegde, Gopalakrishna M; Gorthi, Sai Siva; Reddy, Kalidevapura Jagannath; Roy, Debasish; Vasu, Ram Mohan

2016-08-01

A simple noninterferometric optical probe is developed to estimate wavefront distortion suffered by a plane wave in its passage through density variations in a hypersonic flow obstructed by a test model in a typical shock tunnel. The probe has a plane light wave trans-illuminating the flow and casting a shadow of a continuous-tone sinusoidal grating. Through a geometrical optics, eikonal approximation to the distorted wavefront, a bilinear approximation to it is related to the location-dependent shift (distortion) suffered by the grating, which can be read out space-continuously from the projected grating image. The processing of the grating shadow is done through an efficient Fourier fringe analysis scheme, either with a windowed or global Fourier transform (WFT and FT). For comparison, wavefront slopes are also estimated from shadows of random-dot patterns, processed through cross correlation. The measured slopes are suitably unwrapped by using a discrete cosine transform (DCT)-based phase unwrapping procedure, and also through iterative procedures. The unwrapped phase information is used in an iterative scheme, for a full quantitative recovery of density distribution in the shock around the model, through refraction tomographic inversion. Hypersonic flow field parameters around a missile-shaped body at a free-stream Mach number of ∼8 measured using this technique are compared with the numerically estimated values. It is shown that, while processing a wavefront with small space-bandwidth product (SBP) the FT inversion gave accurate results with computational efficiency; computation-intensive WFT was needed for similar results when dealing with larger SBP wavefronts.

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.

An experimental AWTS process and comparisons of ONERA T2 and 0.3-m TCT AWTS data for the ONERA CAST-10 aerofoil

NASA Technical Reports Server (NTRS)

Wolf, Stephen; Jenkins, Renaldo

1989-01-01

An experimental Adaptive Wall Test Section (AWTS) process is described. Comparisons of the ONERA T2 and the 0.3-m TCT (transonic cryogenic tunnel) AWTS data for the ONERA CAST-10 airfoil are presented. Most of the 0.3-m TCT data is new and preliminary and no sidewall boundary layer control is involved. No conclusions are given.

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

DOT National Transportation Integrated Search

2016-07-01

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

Amodal processing in human prefrontal cortex.

PubMed

Tamber-Rosenau, Benjamin J; Dux, Paul E; Tombu, Michael N; Asplund, Christopher L; Marois, René

2013-07-10

Information enters the cortex via modality-specific sensory regions, whereas actions are produced by modality-specific motor regions. Intervening central stages of information processing map sensation to behavior. Humans perform this central processing in a flexible, abstract manner such that sensory information in any modality can lead to response via any motor system. Cognitive theories account for such flexible behavior by positing amodal central information processing (e.g., "central executive," Baddeley and Hitch, 1974; "supervisory attentional system," Norman and Shallice, 1986; "response selection bottleneck," Pashler, 1994). However, the extent to which brain regions embodying central mechanisms of information processing are amodal remains unclear. Here we apply multivariate pattern analysis to functional magnetic resonance imaging (fMRI) data to compare response selection, a cognitive process widely believed to recruit an amodal central resource across sensory and motor modalities. We show that most frontal and parietal cortical areas known to activate across a wide variety of tasks code modality, casting doubt on the notion that these regions embody a central processor devoid of modality representation. Importantly, regions of anterior insula and dorsolateral prefrontal cortex consistently failed to code modality across four experiments. However, these areas code at least one other task dimension, process (instantiated as response selection vs response execution), ensuring that failure to find coding of modality is not driven by insensitivity of multivariate pattern analysis in these regions. We conclude that abstract encoding of information modality is primarily a property of subregions of the prefrontal cortex.

Letter Report: LAW Simulant Development for Cast Stone Screening Test

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

Russell, Renee L.; Westsik, Joseph H.; Swanberg, David J.

2013-03-27

More than 56 million gallons of radioactive and hazardous waste are stored in 177 underground storage tanks at the U.S. Department of Energy’s (DOE’s) Hanford Site in southeastern Washington State. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) is being constructed to treat the wastes and immobilize them in a glass waste form. The WTP includes a pretreatment facility to separate the wastes into a small volume of high-level waste (HLW) containing most of the radioactivity and a larger volume of low-activity waste (LAW) containing most of the nonradioactive chemicals. The HLW will be converted to glass in themore » HLW vitrification facility for ultimate disposal at an offsite federal repository. At least a portion (~35%) of the LAW will be converted to glass in the LAW vitrification facility and will be disposed of onsite at the Integrated Disposal Facility (IDF). The pretreatment and HLW vitrification facilities will have the capacity to treat and immobilize the wastes destined for each facility. However, a second facility will be needed for the expected volume of additional LAW requiring immobilization. A cementitious waste form known as Cast Stone is being considered to provide the required additional LAW immobilization capacity. The Cast Stone waste form must be acceptable for disposal in the IDF. The Cast Stone waste form and immobilization process must be tested to demonstrate that the final Cast Stone waste form can comply with waste acceptance criteria for the IDF disposal facility and that the immobilization processes can be controlled to consistently provide an acceptable waste form product. Further, the waste form must be tested to provide the technical basis for understanding the long term performance of the waste form in the IDF disposal environment. These waste form performance data are needed to support risk assessment and performance assessment (PA) analyses of the long-term environmental impact of the waste disposal in the IDF. A testing program was developed in fiscal year (FY) 2012 describing in some detail the work needed to develop and qualify Cast Stone as a waste form for the solidification of Hanford LAW (Westsik et al. 2012). Included within Westsik et al. (2012) is a section on the near-term needs to address Tri-Party Agreement Milestone M-062-40ZZ. The objectives of the testing program to be conducted in FY 2013 and FY 2014 are to: • Determine an acceptable formulation for the LAW Cast Stone waste form. • Evaluate sources of dry materials for preparing the LAW Cast Stone. • Demonstrate the robustness of the Cast Stone waste form for a range of LAW compositions. • Demonstrate the robustness of the formulation for variability in the Cast Stone process. • Provide Cast Stone contaminant release data for PA and risk assessment evaluations. The first step in determining an acceptable formulation for the LAW Cast Stone waste form is to conduct screening tests to examine expected ranges in pretreated LAW composition, waste stream concentrations, dry-materials sources, and mix ratios of waste feed to dry blend. A statistically designed test matrix will be used to evaluate the effects of these key parameters on the properties of the Cast Stone as it is initially prepared and after curing. The second phase of testing will focus on selection of a baseline Cast Stone formulation for LAW and demonstrating that Cast Stone can meet expected waste form requirements for disposal in the IDF. It is expected that this testing will use the results of the screening tests to define a smaller suite of tests to refine the composition of the baseline Cast Stone formulation (e.g. waste concentration, water to dry mix ratio, waste loading).« less

The impact of caste on the growth of male Sikhs in Punjab, India.

PubMed

Singh, L P; Harrison, G A

1997-01-01

This study is based on a cross-sectional sample of 442 Sikh boys and young male adults who were born in and around the town of Phagwara, in the state of Punjab, India, and stayed there all their lives. The sample comprised Sikh boys at three crucial phases of growth, at 5-6, 10-11 and 15-16 years, and young adults around 18 years of age. The sample comprised three distinct caste groups, viz. Jats, Ramgarhias and Ravidassias, belonging respectively to upper, middle and lower socioeconomic strata of the Sikh community. Differences in stature and body weight are particularly marked around early adolescence, and there is some indication of caste differences reappearing in young adults. In the case of body mass index, however, the differences seem most marked in late adolescence. There is no clear directional pattern to the way skinfolds change, but inter-caste differences become more marked with age. There is a suggestion of continuing growth beyond 16 years of age, and indications that the well-off groups grow more, as compared to the poor groups, during this period. Comparisons of young adults with older groups of the same caste indicate an increase in body weight with age, but smaller stature in the older groups. There is thus evidence for a secular stature increase among present-day Punjabi Sikhs.

Socio-environmental and endocrine influences on developmental and caste-regulatory gene expression in the eusocial termite Reticulitermes flavipes

PubMed Central

2010-01-01

Background Strict regulation of caste differentiation, at the molecular level, is thought to be important to maintain social structure in insect societies. Previously, a number of extrinsic and intrinsic factors have been shown to influence caste composition in termite colonies. One important factor is the influence of nestmates; in particular, soldier termites are known to inhibit hormone-dependent worker-to-soldier differentiation. However, soldier influences on nestmates at the molecular level are virtually unknown. Here, to test the hypothesis that soldiers can influence nestmate gene expression, we investigated the impact of four treatments on whole-body gene expression in totipotent Reticulitermes flavipes workers: (i) juvenile hormone III (JHIII; a morphogenetic hormone), (ii) soldier head extracts (SHE), (iii) JHIII+SHE, and (iv) live soldiers. Results Using quantitative-real-time PCR we determined the expression patterns of 49 previously identified candidate genes in response to the four treatments at assay days 1, 5, and 10. Thirty-eight total genes from three categories (chemical production/degradation, hemolymph protein, and developmental) showed significant differential expression among treatments. Most importantly, SHE and live soldier treatments had a significant impact on a number of genes from families known to play roles in insect development, supporting previous findings and hypotheses that soldiers regulate nestmate caste differentiation via terpene primer pheromones contained in their heads. Conclusions This research provides new insights into the impacts that socio-environmental factors (JH, soldiers, primer pheromones) can have on termite gene expression and caste differentiation, and reveals a number of socially-relevant genes for investigation in subsequent caste differentiation research. PMID:20416061

Socio-environmental and endocrine influences on developmental and caste-regulatory gene expression in the eusocial termite Reticulitermes flavipes.

PubMed

Tarver, Matthew R; Zhou, Xuguo; Scharf, Michael E

2010-04-23

Strict regulation of caste differentiation, at the molecular level, is thought to be important to maintain social structure in insect societies. Previously, a number of extrinsic and intrinsic factors have been shown to influence caste composition in termite colonies. One important factor is the influence of nestmates; in particular, soldier termites are known to inhibit hormone-dependent worker-to-soldier differentiation. However, soldier influences on nestmates at the molecular level are virtually unknown. Here, to test the hypothesis that soldiers can influence nestmate gene expression, we investigated the impact of four treatments on whole-body gene expression in totipotent Reticulitermes flavipes workers: (i) juvenile hormone III (JHIII; a morphogenetic hormone), (ii) soldier head extracts (SHE), (iii) JHIII+SHE, and (iv) live soldiers. Using quantitative-real-time PCR we determined the expression patterns of 49 previously identified candidate genes in response to the four treatments at assay days 1, 5, and 10. Thirty-eight total genes from three categories (chemical production/degradation, hemolymph protein, and developmental) showed significant differential expression among treatments. Most importantly, SHE and live soldier treatments had a significant impact on a number of genes from families known to play roles in insect development, supporting previous findings and hypotheses that soldiers regulate nestmate caste differentiation via terpene primer pheromones contained in their heads. This research provides new insights into the impacts that socio-environmental factors (JH, soldiers, primer pheromones) can have on termite gene expression and caste differentiation, and reveals a number of socially-relevant genes for investigation in subsequent caste differentiation research.

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.

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

Effect of molybdenum, vanadium, boron on mechanical properties of high chromium white cast iron in as-cast condition

NASA Astrophysics Data System (ADS)

Nurjaman, F.; Sumardi, S.; Shofi, A.; Aryati, M.; Suharno, B.

2016-02-01

In this experiment, the effect of the addition carbide forming elements on high chromium white cast iron, such as molybdenum, vanadium and boron on its mechanical properties and microstructure was investigated. The high chromium white cast iron was produced by casting process and formed in 50 mm size of grinding balls with several compositions. Characterization of these grinding balls was conducted by using some testing methods, such as: chemical and microstructure analysis, hardness, and impact test. From the results, the addition of molybdenum, vanadium, and boron on high chromium white cast iron provided a significant improvement on its hardness, but reduced its toughness. Molybdenum induced fully austenitic matrix and Mo2C formation among eutectic M7C3 carbide. Vanadium was dissolved in the matrix and carbide. While boron was played a role to form fine eutectic carbide. Grinding balls with 1.89 C-13.1 Cr-1.32 Mo-1.36 V-0.00051 B in as-cast condition had the highest hardness, which was caused by finer structure of eutectic carbide, needle like structure (upper bainite) matrix, and martensite on its carbide boundary.

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.

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

Solvent-Free Manufacturing of Electrodes for Lithium-ion Batteries

NASA Astrophysics Data System (ADS)

Ludwig, Brandon; Zheng, Zhangfeng; Shou, Wan; Wang, Yan; Pan, Heng

2016-03-01

Lithium ion battery electrodes were manufactured using a new, completely dry powder painting process. The solvents used for conventional slurry-cast electrodes have been completely removed. Thermal activation time has been greatly reduced due to the time and resource demanding solvent evaporation process needed with slurry-cast electrode manufacturing being replaced by a hot rolling process. It has been found that thermal activation time to induce mechanical bonding of the thermoplastic polymer to the remaining active electrode particles is only a few seconds. Removing the solvent and drying process allows large-scale Li-ion battery production to be more economically viable in markets such as automotive energy storage systems. By understanding the surface energies of various powders which govern the powder mixing and binder distribution, bonding tests of the dry-deposited particles onto the current collector show that the bonding strength is greater than slurry-cast electrodes, 148.8 kPa as compared to 84.3 kPa. Electrochemical tests show that the new electrodes outperform conventional slurry processed electrodes, which is due to different binder distribution.

Elongated phase separation domains in spin-cast polymer blend thin films characterized using a panoramic image.

PubMed

Zhang, Hong; Okamura, Yosuke

2018-02-14

Polymer thin films with micro/nano-structures can be prepared by a solvent evaporation induced phase separation process via spin-casting a polymer blend, where the elongated phase separation domains are always inevitable. The striation defect, as a thickness nonunifomity in spin-cast films, is generally coexistent with the elongated domains. Herein, the morphologies of polymer blend thin films are recorded from the spin-cast center to the edge in a panoramic view. The elongated domains are inclined to appear at the ridge regions of striations with increasing radial distance and align radially, exhibiting a coupling between the phase separation morphology and the striation defect that may exist. We demonstrate that the formation of elongated domains is not attributed to shape deformation, but is accomplished in situ. A possible model to describe the initiation and evolution of the polymer blend phase separation morphology during spin-casting is proposed.

[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.

Data on the effect of homogenization heat treatments on the cast structure and tensile properties of alloy 718Plus in the presence of grain-boundary elements.

PubMed

Hosseini, Seyed Ali; Madar, Karim Zangeneh; Abbasi, Seyed Mehdi

2017-08-01

The segregation of the elements during solidification and the direct formation of destructive phases such as Laves from the liquid, result in in-homogeneity of the cast structure and degradation of mechanical properties. Homogenization heat treatment is one of the ways to eliminate destructive Laves from the cast structure of superalloys such as 718Plus. The collected data presents the effect of homogenization treatment conditions on the cast structure, hardness, and tensile properties of the alloy 718Plus in the presence of boron and zirconium additives. For this purpose, five alloys with different contents of boron and zirconium were cast by VIM/VAR process and then were homogenized at various conditions. The microstructural investigation by OM and SEM and phase analysis by XRD were done and then hardness and tensile tests were performed on the homogenized alloys.